Danfoss Turbocor TT Series User manual

Danfoss Turbocor® Twin-Turbine
Centrifugal Compressors
TT & TG Series Compressors
Applications and Installation Manual - Revision N
http://turbocor.danfoss.com
®

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Content
1 Introduction........................................................................................................................................9
1.1 Scope ........................................................................................................................................................................................................9
1.2 Organization of this Manual..............................................................................................................................................................9
1.3 Document Symbols ........................................................................................................................................................................... 10
1.4 Denitions............................................................................................................................................................................................. 11
2 Overview of the TT/TG Compressor ................................................................................................15
2.1 TT/TG Compressor Nomenclature................................................................................................................................................ 15
2.2 Refrigerant Type.................................................................................................................................................................................. 15
2.2.1 TG Series ..................................................................................................................................................................................... 15
2.3 Environment........................................................................................................................................................................................ 16
2.4 Congurations of the TT/TG Compressor Models .................................................................................................................. 16
2.5 Compressor Module.......................................................................................................................................................................... 17
3 Functional Description....................................................................................................................19
3.1 Main Fluid Path................................................................................................................................................................................... 19
3.2 Motor Cooling..................................................................................................................................................................................... 20
3.3 Inlet Guide Vanes............................................................................................................................................................................... 22
3.4 Compressor Control Overview ..................................................................................................................................................... 22
3.4.1 Motor Drive System................................................................................................................................................................ 23
3.4.2 Soft-Start Board ....................................................................................................................................................................... 23
3.4.3 Bearing Motor Compressor Controller............................................................................................................................ 23
3.4.4 Compressor Control ................................................................................................................................................................ 23
3.4.5 Capacity Control....................................................................................................................................................................... 23
3.4.6 Expansion Valve Control........................................................................................................................................................ 24
3.4.7 Motor/Bearing Control........................................................................................................................................................... 24
3.4.8 Monitoring Functions............................................................................................................................................................. 24
3.4.9 Abnormal Conditions ............................................................................................................................................................ 24
3.4.10 Bearing PWM Amplier ...................................................................................................................................................... 25
3.4.11 Serial Driver............................................................................................................................................................................. 25
3.4.12 Backplane ................................................................................................................................................................................ 25
3.4.13 High-Voltage DC-DC Converter....................................................................................................................................... 26
3.5 Magnetic Bearing System............................................................................................................................................................... 26
3.5.1 Overview .................................................................................................................................................................................... 26
3.5.2 Bearing Control System ........................................................................................................................................................ 26
4 Control Interface Wiring...................................................................................................................28
4.1 Control Wiring Connection Guidelines...................................................................................................................................... 29
4.2 Interface Cable ................................................................................................................................................................................... 30
4.3 Compressor I/O Board Mounting Details.................................................................................................................................. 31
4.3.1 Compressor I/O Board - Mounting Instructions........................................................................................................... 31
5 General Specications......................................................................................................................33
5.1 Construction........................................................................................................................................................................................ 33
5.2 Maximum Pressure ............................................................................................................................................................................ 33
5.3 Maximum Discharge Temperature............................................................................................................................................... 34
5.4 Suction Pressure Limits ................................................................................................................................................................... 35
5.5 Codes and Standards Compliance .............................................................................................................................................. 35
6 Electrical Specications ...................................................................................................................37
6.1 Supply Voltage and Frequency..................................................................................................................................................... 37
6.2 Compressor Current Limit and Operating Range Settings................................................................................................. 37
6.3 Disconnects ......................................................................................................................................................................................... 38
6.4 Motor Insulation Class ..................................................................................................................................................................... 39
6.5 AC Input Line/Power Electronic Component Protection .................................................................................................... 39
6.6 Power Line Contactor....................................................................................................................................................................... 39
6.7 CE Compliance and EMI/EMC Filtering...................................................................................................................................... 39
6.8 Surge Protection................................................................................................................................................................................ 40
6.9 Harmonic Filtering (IEEE 519)........................................................................................................................................................ 40
6.10 Grounding (Earth) Connection Guidelines............................................................................................................................ 40
6.11 Equipment Panel............................................................................................................................................................................. 41
6.12 Mains Input Cable Specication................................................................................................................................................ 42
6.13 Idle Power Consumption.............................................................................................................................................................. 42
7 Compressor Performance ................................................................................................................43
7.1 Performance Ratings......................................................................................................................................................................... 43
7.2 Tolerance of Performance Ratings................................................................................................................................................ 43

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Content
8 Operating Envelopes........................................................................................................................45
9 Minimum Unloading Capacity.........................................................................................................51
10 Control Logic Guidelines for Multiple Compressors....................................................................53
11 Product Certication......................................................................................................................55
12 Guide Specications.......................................................................................................................57
12.1 General................................................................................................................................................................................................ 57
12.2 Refrigerant......................................................................................................................................................................................... 57
12.3 Compressor Bearings..................................................................................................................................................................... 57
12.4 Capacity Control.............................................................................................................................................................................. 57
12.5 Compressor Motor.......................................................................................................................................................................... 57
12.6 Compressor Electronics ................................................................................................................................................................ 57
12.6.1 Ancillary Devices................................................................................................................................................................... 57
13 System Design Guidelines .............................................................................................................59
13.1 General Requirements .................................................................................................................................................................. 59
13.2 Economizer Option ........................................................................................................................................................................ 60
13.3 Motor/Electronics Cooling Requirements ............................................................................................................................. 60
13.4 Electrical Requirements................................................................................................................................................................ 61
13.5 Application-Specic Requirements.......................................................................................................................................... 61
13.5.1 Medium Evaporating Temperature Application (TT300) ....................................................................................... 61
13.5.2 Low Lift Application............................................................................................................................................................. 61
13.5.3 Limited Capacity at Low pressure Ratios ..................................................................................................................... 62
14 Sample Refrigeration Circuits .......................................................................................................63
15 Sound and Power Specications...................................................................................................71
15.1 TT300 and TT400 Sound Power Measurements ................................................................................................................... 71
15.1.1 Results....................................................................................................................................................................................... 71
16 Physical Data...................................................................................................................................75
16.1 Clearance ........................................................................................................................................................................................... 75
16.2 Center of Gravity ............................................................................................................................................................................. 77
16.3 Torque Specications..................................................................................................................................................................... 86
17 Piping Considerations....................................................................................................................87
18 Environmental Considerations......................................................................................................89
18.1 Humidity ............................................................................................................................................................................................ 89
18.2 Vibration............................................................................................................................................................................................. 89
19 Shipping Considerations...............................................................................................................91
19.1 Vibration............................................................................................................................................................................................. 91
20 Installation......................................................................................................................................93
20.1 Unpacking and Inspection .......................................................................................................................................................... 93
20.2 Rigging Requirements .................................................................................................................................................................. 93
20.3 Unit Placement ................................................................................................................................................................................ 93
20.4 Mounting Base................................................................................................................................................................................. 94
20.5 Piping Connections........................................................................................................................................................................ 95
20.6 Control Wiring .................................................................................................................................................................................. 96
20.6.1 Control Wiring Connections ............................................................................................................................................. 96
20.6.2 Circuit Grounding................................................................................................................................................................. 98
20.6.3 Voltage-Free Contacts......................................................................................................................................................... 99
20.7 Power Wiring...................................................................................................................................................................................100
Appendix A: Power Line Accessories Installation .......................................................................... 103
A.1 Line Reactor Installation Instructions.......................................................................................................................................103
A.1.1 AC Line Cable Connection (From External Disconnect) ..........................................................................................103
A.1.2 AC Line Cable Connection (to Compressor Terminal) ..............................................................................................103
Appendix B: Power Line Accessories Installation .......................................................................... 105
B.1 EMI/EMC Filter Installation Instructions...................................................................................................................................105
B.1.1 Line Side Connection............................................................................................................................................................105
B.1.2 Load Side Connection ..........................................................................................................................................................105
B.1.3 Harmonic Filter........................................................................................................................................................................105

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Table 1-1 - Application Manual Applicability .....................................................................................................................................9
Table 1-2 - Denitions.............................................................................................................................................................................. 11
Table 2-1 - Refrigerant Used with Turbocor Compressors .......................................................................................................... 15
Table 3-1 - Backplane LEDs .................................................................................................................................................................... 25
Table 4-1 - Control Wiring Details ........................................................................................................................................................ 29
Table 5-1 - Discharge Pressure Alarm and Trip Settings .............................................................................................................. 33
Table 5-2 - Discharge Temperature Trip Settings ........................................................................................................................... 34
Table 5-3 - Maximum Pressure Ratio Limits ..................................................................................................................................... 34
Table 5-4 - Maximum Allowable Pressure [PS]................................................................................................................................ 34
Table 5-5 - Suction Pressure Alarm and Trip Settings................................................................................................................... 35
Table 6-1 - Acceptable AC Voltage Range......................................................................................................................................... 37
Table 6-2 - Acceptable Frequency Range ......................................................................................................................................... 37
Table 6-3 - FLA and LRA Value Range................................................................................................................................................. 38
Table 6-4 - Main Cable Connector Plate Hole Sizes....................................................................................................................... 42
Table 13-1 - Recommended Minimum Copper Tube Size .......................................................................................................... 60
Table 13-2 - Low Lift Pump Sizing........................................................................................................................................................ 61
Table 15-1 - Sound Power Measurements for TT300.................................................................................................................... 71
Table 15-2 - Sound Pressure Calculation for TT300....................................................................................................................... 71
Table 15-3 - Sound Power at Third Octave Band, TT300 Compressor..................................................................................... 72
Table 15-4 - Sound Power Measurements........................................................................................................................................ 72
Table 15-5 - Sound Pressure Calculation........................................................................................................................................... 72
Table 15-6 - Sound Power at Third Octave Band of TT400 Compressor ................................................................................ 73
Table 16-1 - Physical Dimensions......................................................................................................................................................... 75
Table 16-2 - Center of Gravity X-Y Coordinates............................................................................................................................... 78
Table 16-3 - Screw Hole Specications.............................................................................................................................................. 85
Table 16-4 - Torque Specications....................................................................................................................................................... 86
List of Tables

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Figure 2-1 - Compressor Nomenclature............................................................................................................................................ 15
Figure 2-2 - Major Components ........................................................................................................................................................... 16
Figure 3-1 - Compressor Fluid Path TG230 / TT300 ....................................................................................................................... 19
Figure 3-2 - Compressor Fluid Path (TG310, TT350, TG390, TT400, TG520, and TT700)................................................... 20
Figure 3-3 - Compressor Cooling Circuit (TG230 / TT300) .......................................................................................................... 21
Figure 3-4 - Compressor Cooling Circuit (TT300 Split-Cooling, TG310, TT350, TG390, TT400, and TG520) .............. 21
Figure 3-5 - Compressor Control System Functional Block Diagram...................................................................................... 22
Figure 3-6 - Magnetic Bearing Conguration.................................................................................................................................. 26
Figure 3-7 - Magnetic Bearing Control System............................................................................................................................... 27
Figure 4-1 - Typical Control Wiring...................................................................................................................................................... 28
Figure 4-2 - ModBus Grounding Diagram ........................................................................................................................................ 28
Figure 4-3 - I/O Wiring Specications................................................................................................................................................. 30
Figure 4-4 - Compressor I/O Board...................................................................................................................................................... 31
Figure 4-5 - Compressor I/O Board Installation .............................................................................................................................. 31
Figure 6-1 - Typical Ground Connections ......................................................................................................................................... 41
Figure 8-1 - Operating Envelope, TT300 and TG230 ..................................................................................................................... 45
Figure 8-2 - Operating Envelope, TT300 and TG230 (Medium Temperature Compressor)............................................. 46
Figure 8-3 - Operating Envelope, TT350 and TG310 ..................................................................................................................... 47
Figure 8-4 - Operating Envelope, TT400 and TG390 ..................................................................................................................... 48
Figure 8-5 - Operating Envelope, TT700 and TG520 ..................................................................................................................... 49
Figure 13-1 - Centrifugal Performance Dynamics.......................................................................................................................... 62
Figure 14-1 - Typical Refrigeration Piping Schematic................................................................................................................... 63
Figure 14-2 - Typical Refrigeration Piping Schematic With Staging and Load Balancing Valve.................................... 64
Figure 14-3 - Typical Refrigeration Piping Schematic With Flash Tank Economizer .......................................................... 65
Figure 14-4 - Typical Refrigeration Piping Schematic With Sub-Cooler Circuit Economizer.......................................... 66
Figure 14-5 - Typical Refrigeration Piping Schematic Using Motor-Cooling Pressure Regulating Valve
(Medium Temperature Compressors Only) ............................................................................................................ 67
Figure 14-6 - Typical Refrigeration Piping Schematic With Multiple DX Evaporators....................................................... 68
Figure 14-7 - Typical Refrigeration Piping Schematic Using Multiple Compressors on a Common Circuit
With a Flooded Evaporator........................................................................................................................................... 69
Figure 16-1 - Suction/Front View All Models ................................................................................................................................... 75
Figure 16-2 - Service Side View All Models....................................................................................................................................... 76
Figure 16-3 - Discharge Side View ....................................................................................................................................................... 76
Figure 16-4a - Center of Gravity ........................................................................................................................................................... 77
Figure 16-4b - Center of Gravity........................................................................................................................................................... 78
Figure 16-5 - Discharge Port Details (TT300 and TG230) ............................................................................................................ 79
Figure 16-6 - Discharge Port Details (TT350 and TG310) ............................................................................................................ 80
Figure 16-7 - Discharge Port Detail (TT400 and TG390) .............................................................................................................. 80
Figure 16-8 - Discharge Port Detail (TT700 and TG520) .............................................................................................................. 81
Figure 16-9 - Suction Port (All Models) .............................................................................................................................................. 82
Figure 16-10 - Suction Port Detail DD (All Models) ....................................................................................................................... 83
Figure 16-11 - Suction Port Detail DD (TT700 and TG520)......................................................................................................... 83
Figure 16-12 - TT300 Flange Footprint Details................................................................................................................................ 84
Figure 16-13 - TT350, TG310, TG390, and TT400 Flange Footprint Details ........................................................................... 84
Figure 16-14 - TT700 and TG520 Flange Footprint Details ......................................................................................................... 85
Figure 16-15 - Motor Cooling Fitting.................................................................................................................................................. 86
Figure 19-1 - Anti-Vibration Bracket ................................................................................................................................................... 91
Figure 20-1 - Rigging Set-up.................................................................................................................................................................. 93
Figure 20-2 - Mounting Base (TT and TG series)............................................................................................................................. 94
Figure 20-3 - Incorrect Compressor Mounting Pad Installation ............................................................................................... 94
Figure 20-4 - Correct Compressor Mounting Pad Installation................................................................................................... 95
Figure 20-5 - Motor-Cooling Connection and Access Port......................................................................................................... 96
Figure 20-6 - Compressor I/O Board Connections......................................................................................................................... 97
Figure 20-7 - Interlock and Motor Speed Connections................................................................................................................ 98
Figure 20-8 - Interlock Circuit Tests..................................................................................................................................................... 99
Figure 20-9 - Typical Electrical Connections ..................................................................................................................................100
Figure 20-10 - Ground Post Nuts........................................................................................................................................................101
Figure 20-11 - Compressor AC Input Terminals ............................................................................................................................101
Figure A-1 - Line Reactor Connections ............................................................................................................................................104
Figure B-1 - Interconnection Layout.................................................................................................................................................106
Figure B-2 - Grounding Diagram........................................................................................................................................................106
List of Figures

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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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This Applications and Installation Manual 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:
1. Overview of the TT/TG series compressors - provides an overview of the Twin-Turbo
and Total-Green (TT and TG) series compressors, including an introduction to the
compressor.
2. Compressor Module - provides details on the Compressor Module of the compressor,
including product capacity and application range, maximum pressure alarm and fault
limits.
3. System Design Guidelines - provides basic guidelines and requirements for the design
and manufacture of R134a, R513a, and R1234ze(E) systems equipped with DTC TT/TG
series compressors.
4. Installation Guidelines - describes application/installation procedures specic to
Danfoss Turbocor TT/TG compressors.
1.2 Organization of
this Manual
1 Introduction
Table 1-1 - Application
Manual Applicability
This manual is designed for use with BMCC
software, Version 4.0.0 and later.
1.1 Scope
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
Introduction

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1.3 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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1.4 Denitions
Table 1-2 - Denitions
Introduction
Acronym / Term Denition
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)
ASHRAE American Society of Heating Refrigeration and Air-Conditioning Engineers (www.ashrae.
org)
ASIC Application-Specic Integrated Circuit
ASTM American Society for Testing and Materials (www.astm.org)
Axial Bearing Bearing that controls the horizontal movement (Z axis) of the motor shaft
Backplane A PCB for the purpose of power and control signal transmission. Many other components
connect to this board.
Balance Piston Component within the compressor that provides primary counter to impeller thrust.
Impeller thrust is trimmed by the axial bearing.
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 eld
Cavity Sensor NTC temperature sensor located behind the Backplane for the purpose of sensing motor-
cooling vapor temperature. Provides 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 Economic
Area. The CE marking certies that a product has met EU health, safety, and environmental
requirements, which ensure consumer safety.
Choke Denitive point on compressor map where mass ow rate is at maximum for compressor
speed and lift conditions.
Compression
Ratio The absolute discharge pressure divided by the absolute suction pressure
CSA Canadian Standards Association (www.csa.ca)
DC Bus High DC voltage simultaneously connected to multiple compressor components via
metallic bus bars, including the capacitors
DC Capacitor
Assembly
An assembly of four DC capacitors, four bleeder resistors, and positive and negative bus
bars
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
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) Amplier via the Backplane.
Dielectric
A dielectric is a nonconducting substance. Although “dielectric” and “insulator” are
generally considered synonymous, the term “dielectric” is more often used when
considering the eect of alternating electric elds on the substance while “insulator” is
more often used when the material is being used to withstand a high electric eld.
Diuser
Part of a centrifugal compressor in the uid module that transforms the high-velocity, low-
pressure gas exiting the impeller into higher-pressure, low-velocity gas discharged into the
condenser.
Diode A two-terminal device between which current may ow in one direction only
Down-Trip Voltage A voltage threshold where, if the incoming AC voltage drops below it, the SCRs will shut
down
D-Sub A type of connector/plug (male and female) for control wiring. The RS-232 and large
connectors on either side of the I/O cable are both types of D-Sub connectors.
DTC Danfoss Turbocor compressors Inc.
EEPROM
Electrically Erasable Programmable Read Only Memory. A small chip holds bits of data code
that can be rewritten and erased by an electrical charge, one byte at a time. EEPROM data
cannot be selectively rewritten; the entire chip must be erased and rewritten to update its
contents.
EER Energy Eciency Ratio

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Introduction
Acronym / Term Denition
EMC Electromagnetic Compatibility
EMF Electromotive Force
EMI Electromagnetic Interference
EMI Filter A circuit or device that provides electromagnetic noise suppression for an electronic device
EPC Extended Performance Compressor
ETL ETL Testing Laboratories, now a mark of Intertek Testing Services
EXV Electronic Expansion Valve. Pressure-independent refrigerant metering device driven by
electrical input
Event Log A record of events occurring during the compressor’s lifecycle, indicating when events and
faults occur and in what order. The event log is held in the BMCC.
Faults (Critical)
Critical faults indicate an intolerable or unsafe condition that will result in equipment
failure if unchecked. They will cause the compressor controller to reduce speed and shut
down the system within 60 seconds. This type of fault requires a manual reset. Critical faults
include: Discharge Pressure Fault, 3-Phase Over-Current Fault, and Lock Out Fault. If any
of the following faults occur three times within a 30-minute period, they also will require
a manual reset: Inverter Temperature Fault, Cavity Temperature, SCR Temperature Fault,
Motor High Current Fault, and Motor back EMF is low.
Faults (Non-Critical)
Faults indicate an intolerable or unsafe condition that will result in equipment failure if
unchecked. They will cause the compressor controller to reduce speed and shut down the
system within 60 seconds. This type of fault has an automatic reset.
Feedthrough An insulated conductor connecting two circuits on opposite sides of a barrier such as a
compressor housing or PCB.
FIE Fully Integrated Electronics version of the compressor.
FLA Full Load Amps
Generator Mode
A function of the compressor where the stator becomes a generator, creating sucient
power to allow for the shaft to graduate slowly and drop onto the touchdown bearings
safely. This occurs when the inverter has insucient power to sustain safe and normal
operation and is typically due to a loss of power.
Genlanolin
A type of grease. In certain climates where the dew point falls below the operating
temperature of some of the electronic components, it is necessary to apply Genlanolin to
certain parts of the compressor to prevent moisture accumulation.
Harmonics Harmonics are multiples of the fundamental frequency distortions found in electrical
power, subjected to continuous disturbances.
HFC Hydrouorocarbon
HFC-134a A positive-pressure, chlorine-free refrigerant having zero ozone depletion potential.
Hermetic Motor A motor that is sealed within the refrigerant atmosphere inside the compressor.
ICD Integrated compressor Design
IEEE Institute of Electrical and Electronic Engineers (www.ieee.org)
IGBT Insulated Gate Bipolar Transistor. See Inverter.
IGV
Inlet Guide Vanes. The IGV assembly is a variable-angle guiding device that pre-rotates
refrigerant ow 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 ow, 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.
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
Compressor Interface Module (CIM).
Inverter The Inverter converts the DC bus voltage into an adjustable frequency and adjustable
amplitude, three-phase simulated AC voltage.
IPLV Integrated Part Load Value
LBV
Load Balance Valve. A modulating valve that can be installed to bypass discharge gas to the
inlet of the evaporator to provide gas ow at certain conditions such as startup, surge, and
further unloading of the compressor.

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Introduction
Acronym / Term Denition
LED Light-Emitting Diode
Levitation The elevation or suspension of the compressor shaft by the magnetic eld created by the
magnetic bearings.
Line Reactor
A transformer-like device designed to introduce a specic amount of inductive reactance
into a circuit. When this occurs, it limits the change in current in the line, which in turn
lters the waveform and attenuates electrical noise and harmonics associated with an
inverter/drive output.
LLSV Liquid Line Solenoid Valve
LR Line Reactor
LRA Locked Rotor Amps
Mid Bus
A connection between the capacitors allowing them to be connected in series and in
parallel simultaneously. Two capacitors in a series make up the DC- and two in a series
make up the DC+, and those two sets of two are connected in parallel.
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 DTC that can be downloaded to a PC or laptop computer
to monitor, regulate, control or verify the operation of a compressor.
MOP Maximum Operating Pressure
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 eld 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.
NEC National Electric Code (www.necplus.org)
Nm Newton meter. A unit of torque. 1 Nm = 0.738 pound-force foot (lbf/f).
NTC Negative Temperature Coecient. Refers to thermistor characteristic. Decrease in
temperature results in a rise in resistance (ohms).
OEM Original Equipment Manufacturer
Open Impeller A compressor impeller with exposed vanes similar to a boat propeller or turbocharger.
PCB Printed Circuit Board
Permanent Magnet
Motor A motor that has permanent magnetism as opposed to electromagnetism
PLC Programmable Logic Controller
Pressure Ratio See “Compression Ratio”
Proximity Sensor
Sensors that are able to detect the presence of nearby objects without any physical
contact. A proximity sensor often emits an electromagnetic or electrostatic eld, or a beam
of electromagnetic radiation (infrared, for instance), and looks for changes in the eld or
return signal.
PWM Pulse Width Modulation
Radial Bearing Bearings that control the position of the shaft on the X and Y axis.
Rectier A rectier is an electrical device that converts AC current to pulsating DC current.
Resistor A resistor is an electrical component that limits or regulates the ow of electrical current in
an electronic circuit.
RMA Return Material Authorization
SCR Silicon-Controlled Rectier. 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
expansion valves. It contains four relays for the solenoid valves, compressor status and
compressor run status respectively.
SDT Saturated Discharge Temperature
SEER Seasonal Energy Eciency Ratio

Page 14 of 108 M-AP-001-EN Rev. N M-AP-001-EN Rev. N
* Danfoss Turbocor’s commitment to excellence ensures continuous product improvements.
* Subject to change without notice.
Introduction
Acronym / Term Denition
Shaft Orbit The path travelled by the compressor shaft relative to the bearing magnetic centers
Shrouded Impeller An impeller with boxed in, or “shrouded,” impeller blades, as opposed to an open impeller.
SIE Semi-Integrated Electronics version of the compressor.
Single-Stage
Centrifugal
compressor
Type of centrifugal compressor having one impeller.
Snubbers Capacitors responsible for eliminating electrical noise/harmonics from the DC Bus before it
reaches the IGBT
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 uid path, creating a
cavitating eect. This is an undesirable situation that should be avoided.
Thrust Bearing A bearing that absorbs the axial forces produced in a centrifugal compressor by the
refrigerant pressure dierential across the impeller.
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 rst-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 eciency
TXV Thermal Expansion Valve. A pressure-dependent refrigerant metering device that operates
independently and is controlled by temperature.
UL Underwriters Laboratories (www.ul.com)
Up-Trip Voltage When the DC- bus reaches the up-trip voltage, the SCRs will be gated open continuously
VAC Volts Alternating Current
Vaned Diuser An assembly of plates with curved vanes that serve to slow, compress, and reduce
refrigerant rotation as it enters the second-stage impeller
Vaneless Diuser Similar to a Vaned Diuser, except that it does not possess any de-swirl vanes
VDC Volts Direct Current
VFD Variable Frequency Drive

Page 15 of 108
M-AP-001-EN Rev. N
The TT/TG Centrifugal series of compressors is a group of compressors that covers the
nominal capacity range from 90 to 200 Tons (TT) and 70 to 150 Tons (TG) tons.
The TT/TG series of compressors are an oil free centrifugal design based on magnetic
bearing technology.
2.1 TT/TG Compressor
Nomenclature
2 Overview of the
TT/TG Compressor
TT300 - G - 1 - ST - E - CE
Unit Classication
CE: With CE Mark
NC: Non-conductive Coating
CH: China
Major Revision
N, P, C, A, D, E, F, G...etc.
Options
ST: Standard
MT: Medium Temp
HL: High Lift
Series
TT300
TT350
TT400
TT700
TG230
TG310
TG390
TG520
Voltage**
D: 380V / 3Ph / 60Hz
E: 380V / 3Ph / 50Hz
F: 575V / 3Ph / 60Hz
G: 460V / 3Ph / 60Hz
H: 400V / 3Ph / 50Hz
J: 400V / 3Ph / 60Hz
Refrigerant
1: R-134a
2: R-22
3: R-1234ze (E)
4: R513A
Overview of the TT/TG Compressor
Figure 2-1 - Compressor
Nomenclature
The TT series compressors are totally oil-free and optimized for use with refrigerant R134a.
The TG series compressor is for use with R1234ze(E) refrigerant only.
ASHRAE standard 34 has classied this refrigerant as“R1234ze(E) with safety classication of
A2L”. ASHRAE Standard 34, 2010 Addendum 1 contains the change to the standard.
ASHRAE Standard 15 (Safety Standard) has sent out an initial public review document
outlining proposed changes to this standard to address 2L refrigerants.
2.2 Refrigerant Type
2.2.1 TG Series
NOTE
Do not use recycled refrigerant as it may contain oil, which can aect system reliability. The refrigerant should be pure
and stored in virgin containers.
Table 2-1 - Refrigerant Used
with Turbocor Compressors Compressor Refrigerant
TT series R134a/R513A
TG series R1234ze(E)
NOTE
To ensure a reliable chiller system, all system components, most notably expansion valves, solenoid valves, and sensors, be
appropriate for application in oil free systems as determined by the component manufacturer. In addition, all chiller system
components exposed to refrigerant should be approved by their manufacturer for use with that refrigerant.

Page 16 of 108 M-AP-001-EN Rev. N M-AP-001-EN Rev. N
Overview of the TT/TG Compressor
NOTE
• Contact Danfoss Turbocor for lower ambient temperature operations. Refer to“Operating Envelopes,” for details of the
operating conditions. These conditions are in line with the AHRI 540 Standard.
• All compressors/components should be protected from environments that could cause corrosion to exposed metals. For
outdoor installations, a weather-proof enclosure with vents is recommended to house the compressor.
• TT/TG compressors can operate below -1°C ambient if refrigerant circuit is maintained at a minimum of -1°C Saturated
temperature.
The compressor should not be operated at an altitude higher than 3000m.
The compressor should be stored and operated within the following ambient temperature
ranges:
• Storage: -30°C to 70°C (-22°F to 158°F)
• Operation: -1°C to 52°C (30°F to 125°F).
• Mains Power Applied Non Operating Limit: -25°C (-13°F)
• Humidity: 0-95% Non Condensing
2.3 Environment
PWM Amplifier
Inverter
The TT/TG compressor, motor and power assemblies are packaged in design.2.4 Configurations of the
TT/TG Compressor Models
Figure 2-2 - Major
Components
SCRs
Soft Start Board
DC-DC
Converter
Backplane
Serial Driver
Bearing Motor Compressor
Controller (BMCC)

Page 17 of 108
M-AP-001-EN Rev. N
This section provides a brief overview of the Compressor Module.
The Compressor Module is comprised of three (3) portions:
• Aerodynamics - The aerodynamics portion manages the compression of refrigerant
through the compressor from suction to discharge comprising centrifugal and IGV
technologies.
• Motor - The motor portion contains a direct-drive, high-efficiency, permanent-magnet
synchronous motor powered by pulse-width-modulating (PWM) voltage supply.
The high-speed variable-frequency operation that affords high-speed efficiency,
compactness and soft start capability. Motor cooling is by liquid refrigerant
injection.
• Electronics - The electronics is divided into two (2) sections: Power electronics
located on the top of the compressor including soft-start, DC-DC, SCR, capacitors
and inverter. Control electronics located on the side of the compressor including:
backplane, BMCC, serial driver and PWM.
2.5 Compressor Module
Overview of the TT/TG Compressor

Page 18 of 108 M-AP-001-EN Rev. N M-AP-001-EN Rev. N
THIS PAGE INTENTIONALLY LEFT BLANK

Page 19 of 108
M-AP-001-EN Rev. N
Functional Description
Figure 3-1 - Compressor
Fluid Path TG230 / TT300
3 Functional Description
3.1 Main Fluid Path
Compressor operation begins with a call for cooling from a chiller controller. The compressor
controller then begins compressor ramp-up.
The following paragraphs describe the ow of refrigerant from the intake to the discharge
port of the compressor (see Figure 3-1 and Figure 3-2).
The refrigerant enters the suction side of the compressor as a low-pressure, low-
temperature, super-heated gas. The refrigerant gas passes through a set of adjustable Inlet
Guide Vanes (IGVs) that are used to control the compressor capacity at low-load conditions.
The rst compression element the gas encounters is the rst-stage impeller. The centrifugal
force produced by the rotating impeller results in an increase in both gas velocity and
pressure. The high-velocity gas discharging from the impeller is directed to the second-
stage impeller through de-swirl vanes. The gas is further compressed by the second-stage
impeller and then discharged through a volute via a diuser (a volute is a curved funnel
increasing in area to the discharge port. As the area of the cross-section increases, the volute
reduces the speed of the gas and increases its pressure). From there, the high-pressure/
high-temperature gas exits the compressor at the discharge port.
Discharge Port
Volute
Assembly
1st Stage
Impeller
Low - Pressure / Low -
Temperature Gas
Inlet Guide Vanes
(IGV)
Vaned
Diffuser
2nd Stage Impeller
High - Pressure / High -
Temperature Gas

Page 20 of 108 M-AP-001-EN Rev. N M-AP-001-EN Rev. N
Functional Description
Figure 3-2 - Compressor
Fluid Path (TG310, TT350,
TG390, TT400, TG520, and
TT700)
3.2 Motor Cooling Liquid refrigerant is channelled at full condenser pressure from the main liquid line to the
compressor to cool the electronic, mechanical, and electromechanical components (see
Figure 3-3 and Figure 3-4).
The sub-cooled refrigerant enters the compressor through two solenoid valves and
associated xed orices located behind the service access cover. The orices cause the
refrigerant to expand, thereby lowering its temperature. Both valves operate relative to the
temperature at the sensors that are located at the Insulated Gate Bipolar Transistor (IGBT)
Inverter and motor cavity. When the temperature at either sensor reaches a pre-determined
threshold, one solenoid valve opens. If the temperature increases to the point where it
equals a higher temperature threshold, the second solenoid valve opens.
From the outlet of the orices, the refrigerant is directed to the heatsink plate of the inverter
and then to the underside of the SCR heatsink. From there, the refrigerant passes through
grooves surrounding the motor stator. As the refrigerant ows through the grooves, it
vaporizes into a gas. At the coil outlet, the refrigerant gas is channeled back to the suction
inlet via the motor cavity, thereby cooling the rotor. All models with the exception of the
TT300 and TG230 use a split-cooling method where the motor and electronics portions are
cooled separately by refrigerant liquid.
• • • CAUTION • • •
A minimum operating pressure ratio of 1.5 is required to maintain adequate cooling of the compressor.
Inlet Guide Vanes (IGV)
1st Stage Impeller
De-swirl Vanes
Vaneless Diffuser
2nd Stage Impeller
Discharge Port
Volute
Assembly
Low - Pressure / Low -
Temperature Gas
High - Pressure /
High - Temperature
Gas