Danfoss VTT Series User guide

Variable Twin Turbo Centrifugal
Compressors VTT Series
VTT880, VTT1000, VTT1200
Applications and Installation Manual
http://turbocor.danfoss.com

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Contents
Introduction...........................................................................................................................................7
Organization of this Manual.....................................................................................................................................................................7
Document Symbols .....................................................................................................................................................................................8
Denitions.......................................................................................................................................................................................................9
Overview of the VTT Compressor.......................................................................................................11
VTT Product Nomenclature................................................................................................................................................................... 11
Features of the VTT Compressor.......................................................................................................................................................... 13
Congurations of the VTT Compressor Models ............................................................................................................................. 13
Compressor Module................................................................................................................................................................................. 13
Capacity Control using IntraFlow™ .............................................................................................................................................. 14
Economizer Option............................................................................................................................................................................ 14
Motor Cable Type ............................................................................................................................................................................... 14
Magnetic Bearings.............................................................................................................................................................................. 14
DC-DC Converter ...................................................................................................................................................................................... 15
Drive Module .............................................................................................................................................................................................. 16
Drive Module External Components........................................................................................................................................... 17
Drive Module Internal Components............................................................................................................................................ 17
Safety Precautions.............................................................................................................................................................................. 18
Thermal Memory Retention Compliance .................................................................................................................................. 18
Drive Module Logic to Power Interface .................................................................................................................................... 19
Power Section .................................................................................................................................................................................. 19
Drive Module Control Input and Output Signals.................................................................................................................... 20
Drive Module Electromagnetic Compatibility (EMC) Considerations ............................................................................. 20
Electrical and Fire Hazard Protection........................................................................................................................................... 20
Drive Module Cooling....................................................................................................................................................................... 20
Cooling Fans...................................................................................................................................................................................... 20
Drive Module Technical Specications ....................................................................................................................................... 21
Motor Cable Sizing............................................................................................................................................................................. 21
Electronic Control System ............................................................................................................................................................... 21
System Interface Connections....................................................................................................................................................... 22
Compressor Control Module (CCM) Board................................................................................................................................ 25
Pulse Width Modulator Amplier (PWM) Board ...................................................................................................................... 25
Compressor Interface Module (CIM) Board............................................................................................................................... 26
Sensor Monitoring.......................................................................................................................................................................... 27
Step Motor Control......................................................................................................................................................................... 27
Relay Output..................................................................................................................................................................................... 27
Compressor Communication Methods ...................................................................................................................................... 27
CAN Communications .................................................................................................................................................................. 27
RS-485 Communication ............................................................................................................................................................... 27
RS-485 Cable Specications......................................................................................................................................................... 29
CIM Circuit Grounding ..................................................................................................................................................................... 29
Environment and Application Boundaries........................................................................................30
Environment Conditions, Storage and Operation......................................................................................................................... 30
Compressor Pressure Limits.................................................................................................................................................................. 30
Maximum Design Pressure.............................................................................................................................................................. 30
Maximum Operating Pressure ....................................................................................................................................................... 30
Mains AC Input Supply Voltage and Frequency ........................................................................................................................... 30
Refrigerant Type......................................................................................................................................................................................... 31
Drive Module Vibration .......................................................................................................................................................................... 33
Industry Approvals and Certications ............................................................................................................................................... 33
Content

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Content
Refrigerant Piping Design ..................................................................................................................33
Refrigerant Piping Connections........................................................................................................................................................... 33
Motor Cooling Connections .................................................................................................................................................................. 33
Motor Cooling Port Specications ............................................................................................................................................... 34
Economizer Port Types..................................................................................................................................................................... 34
Drive Module Piping ................................................................................................................................................................................ 35
Refrigerant Cooling............................................................................................................................................................................ 36
Cold Plate Tube.................................................................................................................................................................................... 36
Piping Design Guidelines ...................................................................................................................................................................... 36
General Requirements...................................................................................................................................................................... 36
Motor and Drive Module Cooling Requirements.................................................................................................................... 37
System Piping and Design............................................................................................................................................................... 37
Refrigeration Schematics ....................................................................................................................................................................... 38
Options and Accessories .....................................................................................................................41
Drive Module Cooling.............................................................................................................................................................................. 41
Ancillary Devices ....................................................................................................................................................................................... 41
Physical Data of the VTT Compressor ................................................................................................42
Compressor Module................................................................................................................................................................................. 42
Drive Module .............................................................................................................................................................................................. 46
DC-DC Converter Dimensions ............................................................................................................50
Installations Guidelines ......................................................................................................................51
Safety Summary......................................................................................................................................................................................... 51
Unpacking and Inspection..................................................................................................................................................................... 51
Required Tools ............................................................................................................................................................................................ 52
Compressor Module Installation........................................................................................................53
Rigging Requirements............................................................................................................................................................................. 53
Clearance...................................................................................................................................................................................................... 54
Compressor Installation Instructions ................................................................................................................................................. 54
Drive Module Installation ...................................................................................................................56
Safety ............................................................................................................................................................................................................. 56
Planning the Installation......................................................................................................................................................................... 56
Pre-Installation Checks............................................................................................................................................................................ 56
Cooling Fans................................................................................................................................................................................................ 56
Airow........................................................................................................................................................................................................... 57
Lifting............................................................................................................................................................................................................. 57
Controls Installation............................................................................................................................58
Control Wiring Guidelines ...................................................................................................................................................................... 58
CIM Board Jumpers................................................................................................................................................................................... 58
CIM Board Wiring Details........................................................................................................................................................................ 58
CIM Board Mounting and Dimensions .............................................................................................................................................. 61
CIM Board RS-485 Cable Connections .............................................................................................................................................. 62
CIM Board RS-485 Cable Termination ................................................................................................................................................ 62
RS-485 Installation and Set-up ........................................................................................................................................................... 62

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Content
Circuit Grounding...................................................................................................................................................................................... 62
Drive Module Controls Connections .................................................................................................................................................. 62
Drive Module Control Terminal Types................................................................................................................................................ 63
Drive Module ModBus and Interlock Connections ...................................................................................................................... 64
Drive Module Installing Control Terminals....................................................................................................................................... 65
Drive Module Basic Wiring ..................................................................................................................................................................... 65
Default Settings................................................................................................................................................................................... 65
Interlock ................................................................................................................................................................................................. 65
Drive Module Serial Communications............................................................................................................................................... 66
Drive Module Installing Control Cables ............................................................................................................................................ 66
Drive Module RS-485 Bus Termination .............................................................................................................................................. 67
LED Cover Description ............................................................................................................................................................................ 68
Access to Control Terminals................................................................................................................................................................... 68
Fieldbus Connection ......................................................................................................................................................................... 68
Electrical Power Wiring .......................................................................................................................69
Drive Module Power Connections ..................................................................................................................................................... 69
Mains AC Input Line Connection ........................................................................................................................................................ 70
Grounding Connection Guidelines ................................................................................................................................................... 70
Safety Grounding Connection....................................................................................................................................................... 71
Motor Cable Connections ..................................................................................................................................................................... 71
Motor Rotation Check ............................................................................................................................................................................. 72
DC-DC Converter Supply Connection ............................................................................................................................................... 72
Connection Tightening Torques .......................................................................................................................................................... 73

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Proprietary Notice
Copyright, Limitations of Liability and Revision
Rights.
This publication contains proprietary information
to Danfoss Turbocor Compressors (DTC). By
accepting and using this manual, the user agrees
that the information contained herein is utilized
solely for operating DTC equipment or third party
vendor equipment intended for communication
with DTC equipment over a serial communication
link. This publication is protected under the
Copyright laws of the United States of America
(USA) and most other countries. The publication
of this Guide is owned by DTC and is published
as the most recent revision as indicated on the
Title page of this document. This document is for
use by DTC customers only; any use beyond the
intended usage of this document is prohibited.
Tests have demonstrated that equipment
will function as designed if the installation if
performed in accordance with the guidelines
provided in this guide. However, DTC does not
guarantee the equipment performance will
work in every physical, hardware or software
environment.
The guidelines provided in this manual are
“AS-IS”, with no warranty of any kind, either
express or implied including; without limitation,
any implied warranties of condition,
uninterrupted use, merchantability or tness
for a particular purpose.
In no event shall DTC 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, DTC is
not responsible for any costs, including but not
limited to those incurred as a result of lost prots
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, DTC’s total aggregate liability for
all damages of any kind and type (regardless
of whether based in contract or tort) shall not
exceed the purchase price of this product.
DTC reserves the right to revise this 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

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M-AI-VT-001-EN Rev.C.1
This Applications and Installation Guide is
intended to be a guide for application data/
installation procedures specic 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 certied 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
Turbocor Compressors (DTC) assumes personnel
using this manual and working on DTC
compressors are familiar with, and carry out all
safe work practices necessary to ensure safety for
personnel and equipment.
This Applications and Installation Manual is
divided into the following sections:
• Overview of the VTT - provides an overview
of the Variable Twin-Turbo (VTT) series
compressors, including an introduction to the
compressor and drive modules and a brief
explanation of IntraFlowTM, a new technology
used in the VTT compressor.
• Compressor Module - provides details on
the Compressor Module of the compressor,
including product capacity and application
range, an in-depth description of IntraFlowTM
technology, maximum pressure alarm and
fault limits.
• Drive Module - provides details on the drive
module, an electronic motor controller that
converts AC line power input into a variable AC
waveform output.
• System Design Guidelines - provides basic
guidelines and requirements for the design and
manufacture of R134a systems equipped with
DTC VTT series compressors.
• Installation Guidelines - describes application/
installation procedures specic to Danfoss
Turbocor VTT compressors.
Organization of
this Manual
Introduction

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Document Symbols
Introduction
The following symbols are used in this document.
CAUTION: Indicates an essential operating or maintenance procedure, practice, or condition which, if
not strictly observed, could result in damage to equipment or potential problems in the outcome of
the procedure being performed.
NOTE: Indicates something to be noted by the reader.
NOTE
DANGER: Indicates an essential operating or maintenance procedure, practice, or condition,
which, if not strictly observed, could result in serious injury to or death of personnel or long-term
health hazards.
WARNING: Indicates an essential operating or maintenance procedure, practice, or condition
which, if not strictly observed, could result in serious damage or destruction of equipment.
• • • WARNING • • •
• • • DANGER • • •
• • • CAUTION • • •

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M-AI-VT-001-EN Rev.C.1
Term Denition
ADC Analog Digital Converter
AFT Ascending Fault Triggering
ANSI American National Standards Institute
AVC Automatic Vibration Control; a part of the compressor magnetic bearing control system.
AWG American Wire Gauge
Choke Denitive points on the compressor map where the mass ow rate is at maximum for
the compressor speed and lift conditions.
CIM
Compressor Interface Module; the part of the compressor electronics where the user
connects all eld connection wiring such as RS-485, EXV and analog / digital wiring.
Also known as the Input/Output (IO) board.
Conguration A DTC predetermined set of parameters necessary to congure a compressor for a
general or particular customer. It is also known as the parameter revision.
DC-DC Converter DC-DC converter supplies and electrically isolates high and low DC voltages that are
required by the control circuits.
DTC Danfoss Turbocor Compressors
Fault
An intolerable or unsafe condition that can result in equipment failure. Faults will cause
the compressor controller to reduce shaft speed and shut down the system. A fault
requires a manual or auto reset from the chiller controller.
IFV
IntraFlowTM valve directs a small fraction of the ow from the volute exit to the inlet of
the rst stage diuser through a series of nozzles. This injection of ow into the rst stage
diuser provides aerodynamic incidence control pushing the surge line and resulting in a
much larger stable operating range.
Impeller Rotating part of a centrifugal compressor that increases the pressure of refrigerant vapor
from the evaporator pressure to the condenser pressure.
IP Protection
International Protection Marking (IP) code classies and rates the degree of protection
provided against the intrusion (including body parts such as hands and ngers), dust,
accidental contact, and water by mechanical casings and electrical enclosures. It is
published by the International Electrotechnical Commission (IEC).
Modbus
www.modbus.org, Modbus is 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 a commonly available means of
connecting industrial electronic devices.
OEM
Original Equipment Manufacturer. An OEM manufactures products or components that
are purchased by another company and retailed under that purchasing company’s
brand name.
PCB Printed Circuit Board
PLC Programmable Logic Controller
Denitions
Table 1
Denitions
Introduction

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Term Denition
PM Permanent Magnet
Power Cycle Switch o the 3-phase mains until the compressor capacitor bank is discharged – then
turn the 3-phase mains on again.
Pressure Ratio Is the ratio of discharge pressure/suction pressure in absolute terms.
PWM Pulse Width Modulation
REGEN Terminal A type of terminal that takes advantage of its resistance features to transform and absorb
electrical power.
RMS
Root-Mean-Square, RMS is a statistical measure of the magnitude of a varying quantity.
The eective RMS value of a periodic current is equal to the DC current that delivers the
same average power to a resistor as the periodic current.
SH Superheat: The sensible heat added to a refrigerant thus increasing its temperature
following evaporation of all liquid vapor.
SI System International, the International System of Units, http://www.bipm.org.
SMT
Service Monitor Tools, a PC program provided by DTC. A user friendly way of displaying
compressor data to the user and oer adjustment of predetermined parameters. The user
interface adjusts itself according to the active access level at the compressor.
Surge
The condition at which the compressor cannot sustain refrigerant ow through the
impeller. This will result in increased noise level, rapid temperature increase of the impeller
and decrease of absorbed power. This is an undesirable situation that should be avoided.
Turndown Ratio
Turndown ratio refers to the width of the operational range of a device, and is dened
as the ratio of the maximum capacity to minimum capacity. For example, a device with a
maximum output of 10 units and a minimum output of 2 units has a turndown ratio of 5.
User The user is dened as integrator, operator, service, and maintenance sta.
Introduction