Danfoss Turbocor TTS Series User guide

®
Applications and Installation Manual - Revision S
Danfoss Turbocor® Twin-Turbine
Centrifugal Compressors
TTS/TGS/TTH/TGH Compressors
http://turbocor.danfoss.com |

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Table of Contents
Table of Contents 3
Chapter 1.0 Introduction 11
1.1 Scope 11
1.2 Document Symbols 11
Chapter 2.0 Compressor Overview 19
2.1 TTS/TGS/TTH/TGH Compressor Nomenclature 19
2.2 Refrigerant Type 21
2.3 Environment 21
2.4 Configurations of the TTS/TGS/TTH/TGH Compressor Models 22
2.5 Compressor Module 23
Chapter 3.0 Functional Description 25
3.1 Main Fluid Path 25
3.2 Motor Cooling 26
3.3 Inlet Guide Vanes 29
3.4 Compressor Control Overview 30
3.4.1 Motor Drive System 30
3.4.2 Soft Start 31
3.4.3 Bearing Motor Compressor Controller 31
3.4.4 Compressor Control 31
3.4.5 Capacity Control 31
3.4.6 Expansion Valve Control 31
3.4.7 Motor/Bearing Control 31
3.4.8 Monitoring Functions 32
3.4.9 Abnormal Conditions 32
3.4.10 Bearing PWM Amplifier 32
3.4.11 Serial Driver 32
3.4.12 Backplane 32
3.4.13 High-Voltage DC-DC Converter 33
3.5 Magnetic Bearing System 33
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3.5.1 Overview 33
3.5.2 Bearing Control System 33
Chapter 4.0 Control Interface Wiring 35
4.1 Control Wiring Connection Guidelines 37
4.2 Interface Cable 38
4.3 Compressor I/O Board Mounting Details 39
4.3.1 Compressor I/O Board Mounting Instructions 39
Chapter 5.0 General Specifications 41
5.1 Construction 41
5.2 Maximum Pressure 41
5.3 Maximum Discharge Temperature 41
5.4 Suction Pressure Limits 42
5.5 Standards Compliance 43
Chapter 6.0 Electrical Specifications 45
6.1 Supply Voltage and Frequency 45
6.2 Voltage Sag Immunity 45
6.3 Compressor Current Limit and Operating Range Settings 45
6.4 Disconnects 47
6.5 Motor Insulation Class 47
6.6 AC Input Line/Power Electronic Component Protection 47
6.7 Power Line Contactor 48
6.8 CE Compliance and EMI/EMC Filtering 48
6.9 Surge Protection 49
6.10 Line Reactor 49
6.11 Harmonic Current Filtering (IEEE 519) 49
6.12 Grounding (Earth) Connection Guidelines 49
6.13 Equipment Panel 50
6.14 Mains Input Cable Specification 51
6.15 Idle Power Consumption 51
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Chapter 7.0 Compressor Performance 53
7.1 Performance Ratings 53
7.2 Tolerance of Performance Ratings 53
Chapter 8.0 Operating Envelopes 55
Chapter 9.0 Minimum Unloading Capacity 67
Chapter 10.0 Control Logic Guidelines for Multiple Compressors 69
Chapter 11.0 Product Certification 71
Chapter 12.0 Guide Specifications 73
12.1 General 73
12.2 Refrigerant 73
12.3 Compressor Bearings 73
12.4 Capacity Control 73
12.5 Compressor Motor 73
12.6 Compressor Electronics 73
12.7 Ancillary Devices 73
Chapter 13.0 System Design Guidelines 75
13.1 General Requirements 75
13.2 Economizer Option 76
13.3 Motor/Electronics Cooling Requirements 76
13.4 Electrical Requirements 77
13.5 Application-Specific Requirements 77
13.5.1 Medium Evaporating Temperature Application (TGS230/TTS300/TGH285/TTH375) 77
13.5.2 High Evaporating Temperature Application (TGS310/TTS350/TGS490/TGS390/TTS400/TGS520/TTS700) 77
13.5.3 Limited Capacity at Low Pressure Ratios 78
13.5.4 Low Lift Application 78
Chapter 14.0 Sample Refrigeration Circuits 81
Chapter 15.0 Sound and Power Specifications 91
15.1 TTS300 and TTS400 Sound Power Measurements 91
15.1.1 Results 91
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Chapter 16.0 Physical Data 95
16.1 Clearance 95
Chapter 17.0 Piping Considerations 109
Chapter 18.0 Environmental Considerations 111
18.1 Humidity 111
18.2 Vibration 111
Chapter 19.0 Shipping Considerations 113
19.1 Vibration 113
Chapter 20.0 Installation 115
20.1 Unpacking and Inspection 115
20.2 Rigging Requirements 115
20.3 Unit Placement 115
20.4 Mounting Base 116
20.5 Piping Connections 117
20.6 Control Wiring 118
20.6.1 Control Wiring Connections 118
20.6.2 Circuit Grounding 119
20.6.3 Voltage-Free Contacts 120
20.7 Power Wiring 121
Appendix A 125
A.1 Line Reactor Installation Instructions 125
Appendix B 127
B.1 EMI/EMC Filter Installation Instructions 127
Appendix C 129
C.1 Pressure Regulating Valve Installation Instructions 129
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List of Changes
Revision Date Page Description of Change
P 06-12-2019 Redevelopment of manual
to include TTH/TGH
compressors
P.1 12-12-2019 Update to include TG490
and Medium Temp
Q 04-06-2020 Major Revision H upgrade
R 02-01-2021 Includes High SST and
general review/update
S 07-29-2021 Complete review/many
small changes made
Includes new TTS 575V
option
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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 [phone]
Fax [phone]
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.
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Chapter 1.0 Introduction
This Applications and Installation Manual is intended to be a guide for application data/installation procedures
specific to Danfoss Turbocor compressors. It is not intended to inform on fundamental safety, refrigeration and
electrical design skills. It is assumed and presumed that persons using this manual are appropriately certified and
have detailed knowledge, experience and skills in respect to designing for and working with high pressure
refrigerants and medium voltage electrical components (to 1 KV high power AC & DC) as well as complex control
systems.
Some potential safety situations may not be foreseen or covered in this guide. Danfoss LLC assumes personnel using
this manual and working on Danfoss LLC compressors are familiar with, and carry out, all safe work practices
necessary to ensure safety for personnel and equipment.
1.1 Scope
This manual is designed for use with Bearing Motor Compressor Controller (BMCC) software, Version 4.0.0 and later.
Table 1-1 Application Manual Applicability
Manual Release Date BMCCFirmware Versions
M-AP-001-XX Rev E September 2013 CC 2.3.1213
M-AP-001-XX Rev L October 2016 CC 3.1.4
M-AP-001-XX Rev M November 2017 CC 4.0 and later
M-AP-001-XX Rev M.1 November 2017 CC 4.1 and later
M-AP-001-XX Rev N May 2018 CC 4.1 and later
M-AP-001-XX Rev P.1 November 2019 CC 4.2 and later
M-AP-001-XX Rev R January 2021 CC 4.3 and later
1.2 Document Symbols
The following symbols are used in this document.
NOTE: Provides additional information such as a tip, comment, or other useful, but not imperative information. A
Note is displayed in the format shown below.
NOTE
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DANGER: Indicates 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 below.
• • • DANGER! • • •
CAUTION: Indicates 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 below.
• • • CAUTION • • •
Table 1-2 Acronyms and Terms
Acronym/Term Definition
Alarms Alarms indicate a condition at the limit of the normal operating envelope. Compressor
alarms will still allow the compressor to run, but speed is reduced to bring the alarm
condition under the alarm limit.
AHRI Air-Conditioning, Heating, and Refrigeration Institute (www.ari.org;www.ahrinet.org).
ANSI American National Standards Institute.
ASHRAE American Society of Heating Refrigeration and Air-Conditioning Engineers
(www.ashrae.org).
Axial Bearing Bearing that controls the horizontal movement (Z axis) of the motor shaft.
Backplane A printed circuit board (PCB) for the purpose of power and control signal transmission.
Many other components connect to this board.
BMCC Bearing Motor Compressor Controller. The BMCC is the central processor board of the
compressor. Based on its sensor inputs, it controls the bearing and motor system and
maintains compressor control within the operating limits.
Bus Bars Heavy-gauge metal conductors used to transfer large electrical currents.
Capacitor A passive component that stores energy in the form of an electrostatic field.
Cavity Sensor Negative Temperature Coefficient (NTC) temperature sensor located behind the
Backplane for the purpose of sensing motor-cooling vapor temperature. Provides
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Acronym/Term Definition
overheat protection to motor windings.
CE Conformance European. The CE marking (also known as CE mark) is a mandatory
conformity mark on many products placed on the single market in the European (EU)
Economic Area. The CE marking certifies that a product has met EU health, safety, and
environmental requirements, which ensure consumer safety.
CEC Canadian Electrical Code.
Choke Definitive point on compressor map where mass flow rate is at maximum for compressor
speed and lift conditions.
CIM Compressor Interface Module; the part of the compressor electronics where the user
connects all field connection wiring such as RS-485, EXV and analog / digital wiring. Also
known as the Input/Output (IO) board.
Compression Ratio The absolute discharge pressure divided by the absolute suction pressure.
CPR Compressor Performance Rating.
CSA Canadian Standards Association (www.csa.ca).
dB Logarithmic scale that measures sound and loudness.
dBA Sound level measurement that has been adjusted based on how the human ear perceives
sounds in the air.
DCBus High DC voltage simultaneously connected to multiple compressor components via
metallic bus bars, including the capacitors.
DC-DC Converter DC-DC converters supply and electrically isolate the high and low DC voltages that are
required by the control circuits. When the compressor is switched on, the High-Voltage
(HV) DC-DC Converter receives its 15VAC supply from the Soft-Start Board. Once the DC
DC-DC Converter bus voltage has risen to a pre-determined level, the HV DC-DC
Converter’s onboard circuits are powered by the DC bus (460-900VDC). The HV DC-DC
Converter delivers +24VDC (with respect to 0V) to the Backplane, and HV+ (+250VDC
with respect to HV-) to the magnetic Bearing Pulse Width Modulation (PWM) Amplifier via
the Backplane.
Diffuser Part of a centrifugal compressor in the fluid module that transforms the high-velocity,
low- pressure gas exiting the impeller into higher-pressure, low-velocity gas discharged
into the condenser.
EMC Electromagnetic Compatibility.
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Acronym/Term Definition
EMF Electromotive Force.
EMI Electromagnetic Interference.
EMI Filter A circuit or device that provides electromagnetic noise suppression for an electronic
device.
EPDM Ethylene propylene diene monomer – type of synthetic rubber.
ETL ETL Testing Laboratories, now a mark of Intertek Testing Services.
EXV Electronic Expansion Valve. Pressure-independent refrigerant metering device driven by
electrical input.
Feedthrough An insulated conductor connecting two circuits on opposite sides of a barrier such as a
compressor housing or PCB.
FLA Full Load Ampere.
Generator Mode A function of the compressor where the stator becomes a generator, creating sufficient
power to allow for the shaft to graduate slowly and drop onto the touchdown bearings
safely. This occurs when the inverter has insufficient power to sustain safe and normal
operation and is typically due to a loss of power.
Harmonics Harmonics are multiples of the fundamental frequency distortions found in electrical
power, subjected to continuous disturbances.
HFC Hydrofluorocarbon.
HFC-134a A positive-pressure, chlorine-free refrigerant having zero ozone depletion potential.
HV High Voltage.
Hz Hertz.
IEEE Institute of Electrical and Electronic Engineers (www.ieee.org).
IGV Inlet Guide Vanes. The IGV assembly is a variable-angle guiding device that pre-rotates
refrigerant flow at the compressor intake and is also used for capacity control. The IGV
assembly consists of movable vanes and a motor. The vane angle, and hence, the degree
of pre-rotation to the refrigerant flow, is determined by the BMCC and controlled by the
Serial Driver. The IGV position can vary between approximately 0-percent and 110-
percent open.
Impeller Rotating part of a centrifugal compressor that increases the pressure of refrigerant vapor
from the lower evaporator pressure to the higher condenser pressure.
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Acronym/Term Definition
ISO International Organization for Standardization.
I/OBoard Input/Output Board facilitating a connection between the compressor controller and/ or
PC and the compressor. It allows the user to control the compressor and allows the
compressor to return status and sensor information to the user. Also known as the CIM.
Inverter The Inverter converts the DC bus voltage into an adjustable frequency and adjustable
amplitude, three-phase simulated AC voltage.
kPa Kilopascal.
kPag Kilopascal Gauge.
kW Kilowatt.
kV Kilovolt.
LBV Load Balance Valve. A modulating valve that can be installed to bypass discharge gas to
the inlet of the evaporator to provide gas flow at certain conditions such as startup,
surge, and further unloading of the compressor.
LED Light-Emitting Diode.
Levitation The elevation or suspension of the compressor shaft by the magnetic field created by the
magnetic bearings.
Line Reactor A transformer-like device designed to introduce a specific amount of inductive reactance
into a circuit. When this occurs, it limits the change in current in the line, which in turn
filters the waveform and attenuates electrical noise and harmonics associated with an
inverter/drive output.
LLC Limited Liability Company.
LRA Locked Rotor Ampere.
LVD Low voltage directive.
Modbus A serial communications protocol published by Modicon in 1979 for use with its
programmable logic controllers (PLCs). It has become a de facto standard
communications protocol in industry, and is now the most commonly available means of
connecting industrial electronic devices. Modbus allows for communication between
many devices connected to the same network, for example a system that measures
temperature and humidity and communicates the results to a computer.
Monitor Program A software program provided by Danfoss LLC that can be downloaded to a PC or laptop
computer to monitor, regulate, control or verify the operation of a compressor.
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Acronym/Term Definition
Motor Back EMF Back electromotive force is a voltage that occurs in electric motors where there is relative
motion between the armature of the motor and the external magnetic field and is also a
parameter used to evaluate the strength of the permanent magnets of the shaft. One
practical application is to use this phenomenon to indirectly measure motor speed as
well as estimate position.
MSDS Material Safety Data Sheet.
NEC National Electric Code (www.necplus.org).
NEMA National Electrical Manufacturers Association.
Nm Newton meter. A unit of torque. 1 Nm = 0.738 pound-force foot (lbf/f ).
NTC Negative Temperature Coefficient. Refers to thermistor characteristic. Decrease in
temperature results in a rise in resistance (ohms).
ODF Outside Diameter Flare.
OEM Original Equipment Manufacturer.
PCB Printed Circuit Board.
PLC Programmable Logic Controller.
Pressure Ratio See “Compression Ratio”.
PE Protective Earth.
PSIG Pounds per square in gauge.
PWM Pulse Width Modulation.
Radial Bearing Bearings that control the position of the shaft on the X and Y axis.
Rectifier A rectifier is an electrical device that converts AC current to pulsating DC current.
Resistor A resistor is an electrical component that limits or regulates the flow of electrical current
in an electronic circuit.
RPM Revolutions per minute.
SCR Silicon-Controlled Rectifier. The SCR is a four-layer, solid-state device that controls current
and converts AC to DC.
Serial Driver A PCB plug-in responsible for the operation of the IGV stepper motor and optional
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Acronym/Term Definition
expansion valves. It contains four relays for the solenoid valves, compressor status and
compressor run status respectively.
SDT Saturated Discharge Temperature.
SMT Service Monitor Tools a PC program provided byDanfoss LLC. A user friendly way of
displaying compressor data to the user and offer adjustment of predetermined
parameters. The user interface adjusts itself according to the active access level at the
compressor.
Soft-Start Board / Soft-
Starter
The Soft-Start Board limits in-rush current by progressively increasing the conduction
angle of the SCRs. This technique is used at compressor startup while the DC capacitors
are charging up. The Soft-Start Board takes as input a 3-phase voltage source at 50/60Hz
from the input terminal and a DC voltage signal from the SCR output. In turn, it outputs
pulses to the SCR and provides power to the High-Voltage (HV) DC-DC Converter. All
voltages from the Soft-Start Board are with respect to the positive DC bus and not the
compressor ground.
SST Saturated Suction Temperature.
Surge The condition at which the compressor cannot sustain the discharge pressure, allowing
refrigerant to temporarily and rapidly re-enter the compressor fluid path, creating a
cavitating effect. This is an undesirable situation that should be avoided.
Ton The basic unit for measuring the rate of heat transfer (12,000 BTU/H; 3.516 kw/H).
Touchdown Bearings Carbon races or ball bearing for the purpose of preventing mechanical interference
between the shaft and the magnetic bearings should they lose power or fail.
TT Twin Turbine.
Two-Stage Centrifugal
compressor
Type of centrifugal compressor having two impellers. The first-stage impeller raises the
pressure of the refrigerant vapor approximately halfway from the cooler pressure to the
condenser pressure, and the second-stage impeller raises the pressure the rest of the
way. With a two-stage compressor, an interstage economizer may be used to improve the
refrigeration cycle efficiency.
UL Underwriters Laboratories (www.ul.com).
VAC Volts Alternating Current.
Vaned Diffuser An assembly of plates with curved vanes that serve to slow, compress, and reduce
refrigerant rotation as it enters the second-stage impeller.
Vaneless Diffuser Similar to a Vaned Diffuser, except that it does not possess any de-swirl vanes.
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Acronym/Term Definition
VDC Volts Direct Current.
VFD Variable Frequency Drive.
W Watt.
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Chapter 2.0 Compressor Overview
The TTS/TGS/TTH/TGH Centrifugal series of compressors is a group of compressors that covers the nominal capacity
range from 90 to 200 Tons (TTS/TTH) and 70 to 150 Tons (TGS/TGH). This series of compressors are an oil free
centrifugal design based on magnetic bearing technology.
As of May 6, 2019, the product nomenclature changed. Figure 2-1 Old Type Code to New Type Code Rev D 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 2-2 Compressor Nomenclature for a complete
description for the new Type Code.
2.1 TTS/TGS/TTH/TGH Compressor Nomenclature
Figure 2-1 Old Type Code to New Type Code Rev D
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Figure 2-2 Compressor Nomenclature
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