Danfoss Turbocor TTS Series User manual

Danfoss Turbocor® Twin-Turbine
Centrifugal Series Compressors
TTS, TGS, TTH, TGH Series Compressors
Service Manual - Revision G
http://turbocor.danfoss.com
®

This manual covers Major Revision "F" and later compressors. If you have a Major Revision "E" or earlier compressor, we suggest
downloading Service Manual Revision E from our website since there are some steps that are unique.

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Table of Contents
Chapter 1.0 Introduction ........................................................................................................................................................................ 15
1.1 Application...................................................................................................................................................................................................................................................................15
1.2 Purpose .........................................................................................................................................................................................................................................................................16
1.3 Organization................................................................................................................................................................................................................................................................17
1.4 Commitment to Quality and the Environment...............................................................................................................................................................................................18
1.5 Safety Summary.........................................................................................................................................................................................................................................................18
1.6 Precautions ..................................................................................................................................................................................................................................................................18
1.7 Refrigerant Type.........................................................................................................................................................................................................................................................18
1.8 Electrical Isolation......................................................................................................................................................................................................................................................19
1.9 Handling Static Sensitive Devices........................................................................................................................................................................................................................20
1.10 DC Bus Test Harness Installation and Removal.............................................................................................................................................................................................22
1.11 Compressor Fasteners ...........................................................................................................................................................................................................................................27
1.12 General O-ring Handling ......................................................................................................................................................................................................................................27
Chapter 2.0 Compressor Fundamentals ................................................................................................................................................ 31
2.1 Main Fluid Path...........................................................................................................................................................................................................................................................31
2.2 Motor and Power Electronics Cooling................................................................................................................................................................................................................31
2.3 Capacity Control.........................................................................................................................................................................................................................................................34
2.4 Compressor Energy and Signal Flow..................................................................................................................................................................................................................34
Chapter 3.0 Compressor Removal and Installation.............................................................................................................................. 41
3.1 Refrigerant Containment........................................................................................................................................................................................................................................41
3.2 Compressor Removal ...............................................................................................................................................................................................................................................41
3.3 Compressor Installation ..........................................................................................................................................................................................................................................42
3.4 Compressor Replacement Considerations for Motor Cooling Adapter.................................................................................................................................................43
3.5 Exterior Connection Torque Specifications......................................................................................................................................................................................................45
Chapter 4.0 Compressor Components................................................................................................................................................... 51
4.1 Component Identification......................................................................................................................................................................................................................................51
4.2 Compressor Covers...................................................................................................................................................................................................................................................56
4.3 Cooling Adapter.........................................................................................................................................................................................................................................................61
4.4 Compressor Interface Module ..............................................................................................................................................................................................................................63
4.5 Compressor Interface Cable ..................................................................................................................................................................................................................................66
4.6 Compressor Controller Cable Harness...............................................................................................................................................................................................................67
4.7 Solenoids and Coils...................................................................................................................................................................................................................................................72
4.8 Interstage Pipe - TTH/TGH......................................................................................................................................................................................................................................77
4.9 Compressor Housing End Cap..............................................................................................................................................................................................................................78
4.10 IGV ................................................................................................................................................................................................................................................................................80
4.11 Mains Plate Bracket ................................................................................................................................................................................................................................................93
4.12 3-Phase Main Voltage Input Terminal Block ..................................................................................................................................................................................................95
4.13 Input Mains Bus Bars (Except TTS300/TGS230) ..........................................................................................................................................................................................103
4.14 Terminal Block Fuse Replacement...................................................................................................................................................................................................................105
4.15 Soft Start...................................................................................................................................................................................................................................................................107
4.16 SCR DC Bus Bar - TTS300/TGS230....................................................................................................................................................................................................................119
4.17 Soft Start SCR Gate Cable...................................................................................................................................................................................................................................121
4.18 Soft Start AC/DC Harness ...................................................................................................................................................................................................................................124
4.19 Silicone-Controlled Rectifier ............................................................................................................................................................................................................................133
4.20 SCR Cooling Manifold..........................................................................................................................................................................................................................................150
4.21 Snubber Capacitors..............................................................................................................................................................................................................................................156
4.22 DC Capacitor Bus Bar Assembly.......................................................................................................................................................................................................................156
4.23 Inverter......................................................................................................................................................................................................................................................................165
4.24 Motor Components..............................................................................................................................................................................................................................................191
4.25 High Voltage DC-DC Converter........................................................................................................................................................................................................................201
4.26 Backplane.................................................................................................................................................................................................................................................................207
4.27 Serial Driver.............................................................................................................................................................................................................................................................212
4.28 BMCC .........................................................................................................................................................................................................................................................................214
4.29 Bearing Pulse Width Modulator Amplifier....................................................................................................................................................................................................218
4.30 Magnetic Bearings................................................................................................................................................................................................................................................223
4.31 Bearing Sensors .....................................................................................................................................................................................................................................................228
4.32 Cavity Temperature Sensor................................................................................................................................................................................................................................231
4.33 Pressure/Temperature Sensor ..........................................................................................................................................................................................................................234
Chapter 5.0 Troubleshooting ............................................................................................................................................................... 241
5.1 Alarm and Fault Indications.................................................................................................................................................................................................................................241
5.2 Troubleshooting with the Service Monitoring Tools Software ...............................................................................................................................................................243
5.3 Bearing Calibration .................................................................................................................................................................................................................................................250
5.4 Compressor Connection Status Indications...................................................................................................................................................................................................255
5.5 System and Compressor Level Troubleshooting..........................................................................................................................................................................................255

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Table of Contents
Chapter 6.0 Maintenance......................................................................................................................................................................263
6.1 Preventative Maintenance Tasks......................................................................................................................................................................................................................263
6.2 Moisture Prevention Measures.........................................................................................................................................................................................................................264
Appendix A – Acronyms/Terms ........................................................................................................................................................... 269
Appendix B – Compressor Troubleshooting Flowcharts................................................................................................................... 271
Appendix C – Compressor Test Sheet .................................................................................................................................................277

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List of Tables
Table 2-1 Compressor Fluid Paths...............................................................................................................................................................................................................................31
Table 3-1 Exterior Connection Torque Specifications ......................................................................................................................................................................................45
Table 4-1 Compressor Components (Covers On)..................................................................................................................................................................................................51
Table 4-2 Compressor Components Service Side (Excludes TTH/TGH Compressors) .............................................................................................................................52
Table 4-3 Compressor Components Service Side (TTH/TGH Only) ................................................................................................................................................................53
Table 4-4 Compressor Components Capacitor Side (Excludes TTH/TGH)....................................................................................................................................................54
Table 4-5 Compressor Components Capacitor Side (TTH/TGH Only)............................................................................................................................................................55
Table 4-6 Compressor Cover Torque Specifications.............................................................................................................................................................................................60
Table 4-7 Cooling Adapter Torque Specifications.................................................................................................................................................................................................62
Table 4-8 CIM Ports and Jumpers................................................................................................................................................................................................................................63
Table 4-9 Compressor Controller Cable Harness Torque Specifications.......................................................................................................................................................72
Table 4-10 Solenoid Coil Resistance Ranges...........................................................................................................................................................................................................73
Table 4-11 Solenoid Torque Specifications..............................................................................................................................................................................................................76
Table 4-12 Interstage Pipe Torque Specifications .................................................................................................................................................................................................78
Table 4-13 Compressor Housing End Cap Torque Specifications....................................................................................................................................................................79
Table 4-14 IGV Components.........................................................................................................................................................................................................................................80
Table 4-15 IGV Feedthrough Wiring Order ..............................................................................................................................................................................................................84
Table 4-16 IGV Feedthrough Pin to Wire Reference .............................................................................................................................................................................................90
Table 4-17 IGV Torque Specifications.........................................................................................................................................................................................................................92
Table 4-18 Mains Plate Torque Specifications.........................................................................................................................................................................................................95
Table 4-19 Expected AC Voltage Range....................................................................................................................................................................................................................98
Table 4-20 Terminal Block Torque Specifications ................................................................................................................................................................................................103
Table 4-21 AC Bus Bar Torque Specifications........................................................................................................................................................................................................105
Table 4-22 Terminal Block Fuse Torque Specifications ......................................................................................................................................................................................107
Table 4-23 Closed-Top Soft Start Connection Identification...........................................................................................................................................................................108
Table 4-24 Open-Top Soft Start Connection Identification .............................................................................................................................................................................109
Table 4-25 Soft Start Fuse Details .............................................................................................................................................................................................................................112
Table 4-26 Soft Start Torque Specifications...........................................................................................................................................................................................................119
Table 4-27 SCR DC Bus Bar Torque Specifications...............................................................................................................................................................................................121
Table 4-28 Soft Start AC/DC Harness Torque Specifications ...........................................................................................................................................................................133
Table 4-29 SCR Diode Values ......................................................................................................................................................................................................................................137
Table 4-30 SCR Gate Resistance Ranges.................................................................................................................................................................................................................137
Table 4-31 SCR Temperature Sensor Torque Specifications ............................................................................................................................................................................141
Table 4-32 SCR Torque Specifications......................................................................................................................................................................................................................149
Table 4-33 SCR Cooling Manifold Torque Specifications..................................................................................................................................................................................155
Table 4-34 DC Capacitor Bus Bar Assembly Torque Specifications...............................................................................................................................................................164
Table 4-35 Inverter Cable Harness Torque Specifications ................................................................................................................................................................................168
Table 4-36 Spring Identification Table.....................................................................................................................................................................................................................189
Table 4-37 Inverter Torque Specifications..............................................................................................................................................................................................................190
Table 4-38 Motor Assembly Torque Specifications.............................................................................................................................................................................................200
Table 4-39 DC-DC Torque Specifications................................................................................................................................................................................................................206
Table 4-40 Backplane Connections..........................................................................................................................................................................................................................208
Table 4-41 Backplane Test Points..............................................................................................................................................................................................................................209
Table 4-42 Backplane LED Locations.......................................................................................................................................................................................................................210
Table 4-43 Backplane Test Point Values..................................................................................................................................................................................................................211
Table 4-44 Backplane Torque Specifications.........................................................................................................................................................................................................212
Table 4-45 PWM Torque Specifications...................................................................................................................................................................................................................222
Table 4-46 Magnetic Bearing Coil Resistance Values.........................................................................................................................................................................................224
Table 4-47 Bearing Amperage Nominal Ranges..................................................................................................................................................................................................225
Table 4-48 Magnetic Bearing Torque Specifications..........................................................................................................................................................................................228
Table 4-49 Bearing Sensor Coil Resistance............................................................................................................................................................................................................229
Table 4-50 Bearing Sensor Torque Specifications ...............................................................................................................................................................................................231
Table 4-51 Cavity Sensor Torque Specifications ..................................................................................................................................................................................................233
Table 4-52 Pressure/Temperature Sensor Torque Specifications...................................................................................................................................................................237
Table 5-1 Alarm Types ...................................................................................................................................................................................................................................................241
Table 5-2 Compressor Fault Types............................................................................................................................................................................................................................241
Table 5-3 Compressor Status 2 Faults......................................................................................................................................................................................................................242
Table 5-4 Motor Fault Types........................................................................................................................................................................................................................................243
Table 5-5 Bearing Fault Types.....................................................................................................................................................................................................................................243
Table 5-6 Compressor Status......................................................................................................................................................................................................................................245
Table 5-7 Compressor Status 2 Faults......................................................................................................................................................................................................................247
Table 5-8 Motor Status..................................................................................................................................................................................................................................................248
Table 5-9 Bearing Status...............................................................................................................................................................................................................................................250
Table 6-1 Preventative Maintenance Tasks............................................................................................................................................................................................................263
Table 6-2 SCR Fastener Torque Specifications......................................................................................................................................................................................................267
Table A-1 Acronyms/Terms .........................................................................................................................................................................................................................................269

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List of Figures
Figure 2-1 Compressor Fluid Paths.............................................................................................................................................................................................................................31
Figure 2-2 Cooling Inlet Adapter.................................................................................................................................................................................................................................32
Figure 2-3 Split Cooling Path - TTH375/TGH285 ...................................................................................................................................................................................................33
Figure 2-4 Split Cooling Path - (TTS/TGS (Except TTS300/TGS230 Serial Cooling)....................................................................................................................................33
Figure 2-5 Serial Cooling Path - TTS300/TGS230...................................................................................................................................................................................................34
Figure 2-6 Compressor Energy and Signal Flow Connections .........................................................................................................................................................................36
Figure 2-7 Compressor Energy and Control Flow Block Diagram - TTS/TGS Compressors....................................................................................................................37
Figure 3-1 Compressor Power Cable Removal.......................................................................................................................................................................................................41
Figure 3-2 Compressor Mounting Fasteners...........................................................................................................................................................................................................42
Figure 3-3 Motor Cooling Fitting.................................................................................................................................................................................................................................43
Figure 4-1 Compressor Components Identification (Covers On) ....................................................................................................................................................................51
Figure 4-2 Compressor Component Identification - Service Side (Excludes TTH/TGH Compressors)...............................................................................................52
Figure 4-3 Compressor Component Identification - Service Side (TTH/TGH Only)..................................................................................................................................53
Figure 4-4 Compressor Component Identification - Capacitor Side (Excludes TTH/TGH)......................................................................................................................54
Figure 4-5 Compressor Component Identification - Capacitor Side (TTH/TGH Only).............................................................................................................................55
Figure 4-6 Top Covers Removal ...................................................................................................................................................................................................................................56
Figure 4-7 Mains Input Cover Torque Sequence ...................................................................................................................................................................................................57
Figure 4-8 Top Cover........................................................................................................................................................................................................................................................57
Figure 4-9 Service Side Cover.......................................................................................................................................................................................................................................58
Figure 4-10 Service Side Cover ....................................................................................................................................................................................................................................58
Figure 4-11 Capacitor Cover .........................................................................................................................................................................................................................................59
Figure 4-12 Capacitor Nylon Nuts...............................................................................................................................................................................................................................59
Figure 4-13 Relief Membrane Position......................................................................................................................................................................................................................60
Figure 4-14 Recessed Holes ..........................................................................................................................................................................................................................................60
Figure 4-15 Capacitor Cover Torque Sequence......................................................................................................................................................................................................60
Figure 4-16 Cooling Adapter - Excludes TTH375/TGH285.................................................................................................................................................................................61
Figure 4-17 Cooling Adapter - TTH375/TGH285) ..................................................................................................................................................................................................61
Figure 4-18 Compressor Interface Module Ports & Jumpers ............................................................................................................................................................................63
Figure 4-19 Removing the Compressor Interface Module from the DIN Rail.............................................................................................................................................66
Figure 4-20 Compressor Interface Cable..................................................................................................................................................................................................................67
Figure 4-21 Compressor Controller Cable Harness Variants..............................................................................................................................................................................68
Figure 4-22 Backplane Connections..........................................................................................................................................................................................................................69
Figure 4-23 Pressure/Temperature and SCR Temperature Sensor Locations - TTS300/TGS230...........................................................................................................69
Figure 4-24 Pressure/Temp and SCR Temp Sensor Locations - TTS/TGS.......................................................................................................................................................70
Figure 4-25 Pressure/Temperature Sensors - TTH375/TGH285........................................................................................................................................................................70
Figure 4-26 IGV Connector Clamp..............................................................................................................................................................................................................................70
Figure 4-27 Cable Passage.............................................................................................................................................................................................................................................71
Figure 4-28 Cooling Valve Bodies ...............................................................................................................................................................................................................................72
Figure 4-29 Compressor Cooling Solenoid Coils...................................................................................................................................................................................................72
Figure 4-30 Solenoid Coil Harness..............................................................................................................................................................................................................................73
Figure 4-31 Backplane - J16 Connector....................................................................................................................................................................................................................73
Figure 4-32 Compressor Cooling Solenoid Coil Cable Connector..................................................................................................................................................................74
Figure 4-33 Backplane - Cool LEDs and +24V Test Points ..................................................................................................................................................................................74
Figure 4-34 Solenoid Cooling Path - TTS300/TGS230..........................................................................................................................................................................................74
Figure 4-35 Solenoid Component Removal............................................................................................................................................................................................................75
Figure 4-36 Solenoid Actuator Coil Position...........................................................................................................................................................................................................76
Figure 4-37 Interstage Pipe...........................................................................................................................................................................................................................................77
Figure 4-38 Interstage Pipe Removal.........................................................................................................................................................................................................................77
Figure 4-39 Compressor Housing End Cap - TTS/TGS .........................................................................................................................................................................................78
Figure 4-40 Compressor Housing End Cap - TTH/TGH........................................................................................................................................................................................78
Figure 4-41 IGV Assembly..............................................................................................................................................................................................................................................80
Figure 4-42 IGV Connections........................................................................................................................................................................................................................................80
Figure 4-43 IGV Motor Feedthrough..........................................................................................................................................................................................................................81
Figure 4-44 SMT Icon.......................................................................................................................................................................................................................................................81
Figure 4-45 Compressor Configuration Tool...........................................................................................................................................................................................................81
Figure 4-46 Control Mode..............................................................................................................................................................................................................................................82
Figure 4-47 Compressor Monitor Tool.......................................................................................................................................................................................................................82
Figure 4-48 IGV Open Percentage - 100%................................................................................................................................................................................................................82
Figure 4-49 IGV Open Percentage - 0%.....................................................................................................................................................................................................................82
Figure 4-50 Backplane Cool LEDs ...............................................................................................................................................................................................................................83
Figure 4-51 Backplane +15V Test Point.....................................................................................................................................................................................................................83
Figure 4-52 IGV Harness Removal...............................................................................................................................................................................................................................83
Figure 4-53 IGV Housing Removal..............................................................................................................................................................................................................................84
Figure 4-54 IGV Feedthrough Removal.....................................................................................................................................................................................................................84
Figure 4-55 Set Screw Removal ...................................................................................................................................................................................................................................85
Figure 4-56 IGV Motor Assembly Removal..............................................................................................................................................................................................................85
Figure 4-57 Locking Collar Tool ...................................................................................................................................................................................................................................85

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List of Figures
Figure 4-58 Locking Collar Removal ..........................................................................................................................................................................................................................86
Figure 4-59 Worm Gear Removal................................................................................................................................................................................................................................86
Figure 4-60 Large Worm Gear Bearing Removal ...................................................................................................................................................................................................86
Figure 4-61 IGV Throat Removal..................................................................................................................................................................................................................................87
Figure 4-62 Small Worm Gear Bearing Removal....................................................................................................................................................................................................87
Figure 4-63 Small Worm Gear Bearing Installation...............................................................................................................................................................................................87
Figure 4-64 IGV Position Indicator Magnet .............................................................................................................................................................................................................88
Figure 4-65 Large Worm Gear Bearing Installation...............................................................................................................................................................................................88
Figure 4-66 Locking Collar Installation .....................................................................................................................................................................................................................89
Figure 4-67 IGV Worm Gear Alignment ....................................................................................................................................................................................................................89
Figure 4-68 Shaft Position..............................................................................................................................................................................................................................................89
Figure 4-69 IGV Motor Alignment...............................................................................................................................................................................................................................90
Figure 4-70 Motor Wire Position..................................................................................................................................................................................................................................90
Figure 4-71 IGV Motor Wires Connected..................................................................................................................................................................................................................91
Figure 4-72 Feedthrough Orientation.......................................................................................................................................................................................................................91
Figure 4-73 IGV Housing Installation.........................................................................................................................................................................................................................91
Figure 4-74 IGV Position Indicator..............................................................................................................................................................................................................................92
Figure 4-75 Mains Plate Bracket ..................................................................................................................................................................................................................................93
Figure 4-76 Ground Post Nuts......................................................................................................................................................................................................................................94
Figure 4-77 Mains Input Nut Installation - TTS300/TGS230 Compressors ...................................................................................................................................................94
Figure 4-78 Mains Input Nut Installation - TTS/TGS/TTH/TGH Rev. H and Earlier (Except TTS300/TGS230)...................................................................................94
Figure 4-79 Input Terminal Block - TTS300/TGS230.............................................................................................................................................................................................95
Figure 4-80 Input Terminal Block - TTS/TGS/TTH/TGH Rev. H (Except TTS300/TGS230).........................................................................................................................96
Figure 4-81 Input Terminal Block - TTS/TGS/TTH/TGH Rev. F and Earlier (Except TTS300/TGS230)....................................................................................................96
Figure 4-82 Measuring the 3-Phase AC Input Voltage on the AC Input Terminals - TTS300/TGS230.................................................................................................97
Figure 4-83 Measuring 3-Phase AC Input Voltage on AC Input Terminals (TTS/TGS/TTH/TGH (Except TTS300/TGS230)..........................................................97
Figure 4-84 Terminal Block Removal - TTS300/TGS230.......................................................................................................................................................................................98
Figure 4-85 Input Terminal Block Removal - TTS/TGS/TTH/TGH Rev. F and Earlier (Except TTS300/TGS230) ................................................................................99
Figure 4-86 Input Terminal Block Removal - TTS/TGS/TTH/TGH Rev. H (Except TTS300/TGS230) ....................................................................................................100
Figure 4-87 Input Terminal Block Installation - TTS300/TGS230....................................................................................................................................................................100
Figure 4-88 Terminal Block - Input Pressure Screws - TTS300/TGS230........................................................................................................................................................101
Figure 4-89 Input Terminal Block Installation - TTS/TGS/TTH/TGH Rev. F and Earlier (Except TTS300/TGS230)..........................................................................101
Figure 4-90 Input Terminal Block Installation - TTS/TGS/TTH/TGH Rev. H (Except TTS300/TGS230) ..............................................................................................102
Figure 4-91 Input Mains Bus Bar Examples ...........................................................................................................................................................................................................103
Figure 4-92 AC/DC Bus Bus Bar Connectors - TTS/TGS/TTH/TGS Rev. F and earlier (Except TTS300/TGH230).............................................................................104
Figure 4-93 AC/DC Bus Bus Bar Connectors - TTS/TGS/TTH/TGS Rev. H (Except TTS300/TGH230)...................................................................................................104
Figure 4-94 Terminal Block Fuse................................................................................................................................................................................................................................105
Figure 4-95 Terminal Block Fuse Test.......................................................................................................................................................................................................................106
Figure 4-96 Terminal Block Fuse Removal..............................................................................................................................................................................................................106
Figure 4-97 Soft Start Variants....................................................................................................................................................................................................................................107
Figure 4-98 Closed-Top Soft Start Connections...................................................................................................................................................................................................108
Figure 4-99 Open-Top Soft Start Connections.....................................................................................................................................................................................................109
Figure 4-100 Soft Start Label Location....................................................................................................................................................................................................................110
Figure 4-101 Soft Start Fuse Locations ...................................................................................................................................................................................................................111
Figure 4-102 Closed-Top Soft Start J9 Connector...............................................................................................................................................................................................112
Figure 4-103 Ground Location...................................................................................................................................................................................................................................113
Figure 4-104 Closed-Top Soft Start...........................................................................................................................................................................................................................113
Figure 4-105 Soft Start Lift...........................................................................................................................................................................................................................................113
Figure 4-106 Closed-Top Soft Start Connector Removal..................................................................................................................................................................................114
Figure 4-107 Open-Top Soft Start J7 Connector..................................................................................................................................................................................................114
Figure 4-108 Ground Location...................................................................................................................................................................................................................................114
Figure 4-109 Open-Top Soft Start Connector Removal ....................................................................................................................................................................................115
Figure 4-110 Open-Top Soft Start Removal...........................................................................................................................................................................................................115
Figure 4-111 Closed-Top-Soft Start Installation...................................................................................................................................................................................................116
Figure 4-112 Ground Stud Location.........................................................................................................................................................................................................................116
Figure 4-113 Open-Top-Soft Start Installation .....................................................................................................................................................................................................117
Figure 4-114 Soft Start without Adapter................................................................................................................................................................................................................118
Figure 4-115 Soft Start Fan Orientation..................................................................................................................................................................................................................118
Figure 4-116 Soft Start Fan Installation ..................................................................................................................................................................................................................118
Figure 4-117 Soft Start Fan Connector....................................................................................................................................................................................................................119
Figure 4-118 SCR DC Bus Bars ....................................................................................................................................................................................................................................119
Figure 4-119 SCR DC Bus Bar Removal - TTS300/TGS230.................................................................................................................................................................................120
Figure 4-120 SCR DC Bus Bar to SCR Alignment..................................................................................................................................................................................................120
Figure 4-121 Soft Start SCR Gate Cable (Closed-Top Soft Starts)...................................................................................................................................................................121
Figure 4-122 Soft Start SCR Gate Cable (Open-Top Soft Starts).....................................................................................................................................................................121
Figure 4-123 Soft Start SCR Gate Cable Removal - TTS300/TGS230.............................................................................................................................................................122
Figure 4-124 Soft Start SCR Gate Cable Removal at SCR - TTS/TGS/TTH/TGH Models Rev. F and Earlier (Except TTS300/TGS230)......................................122

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List of Figures
Figure 4-125 Soft Start SCR Gate Cable Removal at SCR - TTS/TGS/TTH/TGH Models Rev. H (Except TTS300/TGS230)...........................................................122
Figure 4-126 Closed-Top Soft Start J8 Connector Top.......................................................................................................................................................................................123
Figure 4-127 Open-Top Soft Start J2 Connector..................................................................................................................................................................................................123
Figure 4-128 SCR Gate Connector Alignment......................................................................................................................................................................................................124
Figure 4-129 Soft Start AC/DC Harness Connections - TTS300/TGS230 .....................................................................................................................................................125
Figure 4-130 Soft Start AC/DC Harness Connections - TTS/TGS/TTH/TGH (Except TTS300/TGS230) .............................................................................................126
Figure 4-131 AC Input Ring Terminal Removal - TTS300/TGS230 .................................................................................................................................................................127
Figure 4-132 DC Ring Terminal Removal - TTS300/TGS230.............................................................................................................................................................................127
Figure 4-133 DC-DC Connectors (Open Frame)...................................................................................................................................................................................................127
Figure 4-134 DC-DC Connectors (Potted)..............................................................................................................................................................................................................128
Figure 4-135 Closed-Top Soft Start J1 and J7 Removal.....................................................................................................................................................................................128
Figure 4-136 Open-Top Soft Start J1 and J8 Removal .......................................................................................................................................................................................129
Figure 4-137 AC Input Spade and DC Spade Connector Removal - TTS/TGS/TTH/TGH Rev. F and Earlier (Except TTS300/TGS230)...................................129
Figure 4-138 AC Input Ring and DC Spade Connector Removal - TTS/TGS/TTH/TGH Rev. H (Except TTS300/TGS230)............................................................130
Figure 4-139 Soft Start AC/DC Harness Position - TTS300/TGS230 ..............................................................................................................................................................131
Figure 4-140 AC Input and Spade Connector Installation - TTS/TGS/TTH/TGH Rev. F and Earlier (Except TTS300/TGS230) ..................................................132
Figure 4-141 AC Input and Spade Connector Installation - TTS/TGS/TTH/TGH Rev. H (Except TTS300/TGS230)........................................................................133
Figure 4-142 SCR Styles ................................................................................................................................................................................................................................................134
Figure 4-143 SCR Connections - TTS300/TGS230................................................................................................................................................................................................134
Figure 4-144 SCR Connections - TTS/TGS/TTH/TGH Rev. F and Earlier (Except TTS300/TGS230).....................................................................................................135
Figure 4-145 SCR Connections - TTS/TGS/TTH/TGH Rev. H (Except TTS300/TGS230) ...........................................................................................................................135
Figure 4-146 SCR Terminals - Two Hole Mount ....................................................................................................................................................................................................136
Figure 4-147 SCR Terminals - Four Hole Mount ...................................................................................................................................................................................................136
Figure 4-148 SCR Temperature Sensor Assembly ...............................................................................................................................................................................................137
Figure 4-149 J17 Connector........................................................................................................................................................................................................................................137
Figure 4-150 Discharge Pressure/Temperature Sensor Connector Removal - TTS300/TGS230.........................................................................................................138
Figure 4-151 SCR Temperature Sensor Connector - TTS300/TGS230 .........................................................................................................................................................138
Figure 4-152 SCR Temperature Sensor Removal -TTS300/TGS230 ..............................................................................................................................................................139
Figure 4-153 SCR Temperature Sensor Connector - TTS/TGS/TTH/TGH Rev. F and Earlier (Except TTS300/TGS230).................................................................139
Figure 4-154 Discharge Pressure/Temperature Sensor Connector Removal - TTS/TGS/TTH/TGH (Except TTS300/TGS230)..................................................139
Figure 4-155 SCR Temperature Sensor Removal - TTS/TGS/TTH/TGH Rev. F and Earlier (Except TTS300/TGS230).....................................................................140
Figure 4-156 Fuse Block Assemblies - Two Hole Mount - TTS300/TGS230.................................................................................................................................................142
Figure 4-157 DC Bus Bar Removal - TTS300/TGS230..........................................................................................................................................................................................142
Figure 4-158 SCR Removal - TTS300/TGS230........................................................................................................................................................................................................143
Figure 4-159 SCR Gate Cable and AC/DC Harness Connections - TTS/TGS/TTH/TGH Rev. F and Earlier (Except TTS300/TGS230).......................................143
Figure 4-160 SCR Gate Cable and AC/DC Harness Connections - TTS/TGS/TTH/TGH Rev. H (Except TTS300/TGS230) ..........................................................144
Figure 4-161 SCR Bus Fastener Removal - TTS/TGS/TTH/TGH Rev. F and Earlier (Except TTS300/TGS230)....................................................................................144
Figure 4-162 SCR Bus Fastener Removal - TTS/TGS/TTH/TGH Rev. H (Except TTS300/TGS230) ........................................................................................................145
Figure 4-163 SCR Removal - TTS/TGS/TTH/TGH Rev. F and Earlier (Except TTS300/TGS230).............................................................................................................145
Figure 4-164 SCR Removal - TTS/TGS/TTH/TGH Rev. H (Except TTS300/TGS230)..................................................................................................................................145
Figure 4-165 SCR Heat Sink Paste Application - TTS300/TGS230..................................................................................................................................................................146
Figure 4-166 SCR Orientation - TTS300/TGS230..................................................................................................................................................................................................146
Figure 4-167 Bus Bar Installation - TTS300/TGS230............................................................................................................................................................................................147
Figure 4-168 Bus Bar Locations - TTS300/TGS230...............................................................................................................................................................................................147
Figure 4-169 SCR Thermal Paste Application - TTS/TGS/TTH/TGH (Except TTS300/TGS230).............................................................................................................148
Figure 4-170 SCR Torque Sequence - TTS/TGS/TTH/TGH Rev. F and Earlier (Except TTS300/TGS230)............................................................................................148
Figure 4-171 SCR Cooling Manifold .........................................................................................................................................................................................................................150
Figure 4-172 Inverter Assembly Removal - TTS300/TGS230...........................................................................................................................................................................150
Figure 4-173 SCR Cooling Manifold Removal - TTS300/TGS230....................................................................................................................................................................151
Figure 4-174 SCR Cooling Manifold Removal.......................................................................................................................................................................................................152
Figure 4-175 SCR Cooling Plate O-ring Installation - TTS300/TGS230.........................................................................................................................................................152
Figure 4-176 Inverter Heat Sink Plate O-ring Installation - TTS/TGS/TTH/TGH (Except TTS300/TGS230).......................................................................................153
Figure 4-177 SCR Manifold Return Brass Fitting O-ring Installation - TTS/TGS/TTH/TGH (Except TTS300/TGS230)...................................................................153
Figure 4-178 SCR Cooling Plate Installation - TTS/TGS/TTH/TGH (Except TTS300/TGS230)................................................................................................................154
Figure 4-179 DC Bus Components Identification TTS/TGS/TTH/TGH Rev. F and Earlier (Except TTS300/TGS230) .....................................................................156
Figure 4-180 DC Bus Components Identification TTS/TGS/TTH/TGH Rev. H (Except TTS300/TGS230)...........................................................................................157
Figure 4-181 Soft Start Cable Harness to DC Bus................................................................................................................................................................................................157
Figure 4-182 DC Bus Bar and Soft Start Harness Removal - TTS300/TGS230............................................................................................................................................159
Figure 4-183 Snubber Capacitor Removal - TTS300/TGS230..........................................................................................................................................................................159
Figure 4-184 Capacitor Nut Removal - TTS300/TGS230....................................................................................................................................................................................159
Figure 4-185 Capacitor Assembly Removal - TTS300/TGS230........................................................................................................................................................................160
Figure 4-186 SCR Bus Bar Removal - TTS/TGS/TTH/TGH Rev. F and Earlier (Except TTS300/TGS230)..............................................................................................160
Figure 4-187 SCR Bus Bar Removal - TTS/TGS/TTH/TGH Rev. H (Except TTS300/TGS230)....................................................................................................................161
Figure 4-188 Snubber Capacitor Removal - TTS/TGS/TTH/TGH (Except TTS300/TGS230)...................................................................................................................161
Figure 4-189 Capacitor Nut Removal - TTS/TGS/TTH/TGH (Except TTS300/TGS230).............................................................................................................................161
Figure 4-190 Capacitor Assembly Removal - TTS/TGS/TTH/TGH Rev. F and Earlier (Except TTS300/TGS230)..............................................................................162
Figure 4-191 Capacitor Assembly Removal - TTS/TGS/TTH/TGH Rev. H (Except TTS300/TGS230) ...................................................................................................162

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List of Figures
Figure 4-192 Inverter Connections...........................................................................................................................................................................................................................165
Figure 4-193 Inverter Diode Measurements (Skiip 613 Shown)....................................................................................................................................................................166
Figure 4-194 Inverter Cable Harness .......................................................................................................................................................................................................................166
Figure 4-195 Harness Removal from Inverter.......................................................................................................................................................................................................167
Figure 4-196 Harness Removal from Backplane..................................................................................................................................................................................................167
Figure 4-197 Inverter Connector Alignment .......................................................................................................................................................................................................168
Figure 4-198 Fuse Block Assemblies - TTS300/TGS230.....................................................................................................................................................................................169
Figure 4-199 Terminal Block Removal - TTS300/TGS230..................................................................................................................................................................................169
Figure 4-200 Soft Start Harness Removal...............................................................................................................................................................................................................170
Figure 4-201 DC Bus Bar Removal.............................................................................................................................................................................................................................170
Figure 4-202 DC Bus Bar Mylar Removal - TTS300/TGS230.............................................................................................................................................................................171
Figure 4-203 Inverter Copper Tube Removal........................................................................................................................................................................................................171
Figure 4-204 Inverter Cable Harness Removal - TTS300/TGS230..................................................................................................................................................................172
Figure 4-205 Open-Frame DC-DC.............................................................................................................................................................................................................................172
Figure 4-206 Potted DC-DC.........................................................................................................................................................................................................................................172
Figure 4-207 DC-DC Removal (Potted DC-DC Shown)......................................................................................................................................................................................173
Figure 4-208 Motor Winding Sensor Connector Removal...............................................................................................................................................................................173
Figure 4-209 Retainer Clip Rotation.........................................................................................................................................................................................................................173
Figure 4-210 Compressor Cable Harness Removal - TTS300/TGS230..........................................................................................................................................................174
Figure 4-211 Inverter Assembly Removal - TTS300/TGS230...........................................................................................................................................................................174
Figure 4-212 SCR Cooling Manifold Removal - TTS300/TGS230 ...................................................................................................................................................................175
Figure 4-213 SCR Connections - TTS/TGS/TTH/TGH Rev. F and Earlier (Except TTS300/TGS230)......................................................................................................175
Figure 4-214 SCR Connections - TTS/TGS/TTH/TGH Rev. H (Except TTS300/TGS230) ...........................................................................................................................176
Figure 4-215 Terminal Block and AC Mains Input Bus Bar Removal - TTS/TGS/TTH/TGH Rev. F and Earlier (Except TTS300/TGS230) ................................176
Figure 4-216 Input Terminal Block Removal - TTS/TGS/TTH/TGH Rev. H (Except TTS300/TGS230) ...............................................................................................177
Figure 4-217 Inverter Copper Tube Removal - TTS/TGS/TTH/TGH (Except TTS300/TGS230)..............................................................................................................177
Figure 4-218 Retainer Clip Rotation........................................................................................................................................................................................................................178
Figure 4-219 Compressor Cable Harness Removal - TTS/TGS/TTH/TGH (Except TTS300/TGS230)...................................................................................................178
Figure 4-220 Compressor Cable Harness Removal - TTH/TGH Only.............................................................................................................................................................178
Figure 4-221 SCR Manifold Removal - TTS/TGS/TTH/TGH (Except TTS300/TGS230)..............................................................................................................................179
Figure 4-222 Inverter Harness Removal - TTS/TGS/TTH/TGH (Except TTS300/TGS230)........................................................................................................................179
Figure 4-223 DC-DC Removal - TTS/TGS/TTH/TGH Rev. F and Earlier (Except TTS300/TGS230)........................................................................................................180
Figure 4-224 Motor Winding Sensor Removal .....................................................................................................................................................................................................180
Figure 4-225 Inverter Removal - TTS/TGS/TTH/TGH (Except TTS300/TGS230).........................................................................................................................................180
Figure 4-226 Inverter O-ring Removal - TTS/TGS/TTH/TGH (Except TTS300/TGS230) .........................................................................................................................181
Figure 4-227 SCR Manifold Return Brass Fitting Removal - TTS/TGS/TTH/TGH (Except TTS300/TGS230)......................................................................................181
Figure 4-228 SCR Cooling Plate O-ring Installation - TTS300/TGS230.........................................................................................................................................................182
Figure 4-229 Inverter Fastener Locations - TTS300/TGS230 ...........................................................................................................................................................................182
Figure 4-230 DC Bus Installation - TTS300/TGS230 ...........................................................................................................................................................................................183
Figure 4-231 Terminal Block Installation - TTS300/TGS230 ............................................................................................................................................................................184
Figure 4-232 Inverter Fastener Locations - TTS/TGS/TGH (Except TTS300/TGS230)...............................................................................................................................184
Figure 4-233 Inverter Heat Sink Plate O-ring Installation - TTS/TGS (Except TTS300/TGS230)...........................................................................................................185
Figure 4-234 SCR Manifold Return Brass Fitting O-ring Installation - TTS/TGS (Except TTS300/TGS230).......................................................................................185
Figure 4-235 SCR Cooling Plate Installation - TTS/TGS/TTH/TGH (Except TTS300/TGS230)................................................................................................................185
Figure 4-236 DC Bus Capacitor Assembly Installation - TTS/TGS/TTH/TGH (Except TTS300/TGS230).............................................................................................186
Figure 4-237 Driver Board Fasteners........................................................................................................................................................................................................................187
Figure 4-238 Driver Board Removal.........................................................................................................................................................................................................................188
Figure 4-239 Seated Spring Pins ...............................................................................................................................................................................................................................188
Figure 4-240 Spring Locations...................................................................................................................................................................................................................................188
Figure 4-241 Spring Pin Identification ....................................................................................................................................................................................................................189
Figure 4-242 Driver Board Placement .....................................................................................................................................................................................................................189
Figure 4-243 Initial Tightening Pass Sequence....................................................................................................................................................................................................190
Figure 4-244 Connection to Stator...........................................................................................................................................................................................................................192
Figure 4-245 Stator Thermistor R/T Curve 1..........................................................................................................................................................................................................193
Figure 4-246 Motor Bus Bar Removal - PPS Feedthroughs..............................................................................................................................................................................194
Figure 4-247 Motor Bus Bar Removal - Stainless-Steel Feedthroughs ........................................................................................................................................................194
Figure 4-248 Copper Tube Removal.........................................................................................................................................................................................................................195
Figure 4-249 Motor Cover Plate Removal ..............................................................................................................................................................................................................196
Figure 4-250 Thermistor Connector Removal ......................................................................................................................................................................................................196
Figure 4-251 Cover Plate Torque Sequence ..........................................................................................................................................................................................................197
Figure 4-252 High-Power Feedthrough (PPS) ......................................................................................................................................................................................................198
Figure 4-253 High-Power Feedthrough Removal (stainless steel)................................................................................................................................................................198
Figure 4-254 Connection to Stator...........................................................................................................................................................................................................................200
Figure 4-255 J3 - 24VDC Output Connector .........................................................................................................................................................................................................202
Figure 4-256 DC-DC Harness ......................................................................................................................................................................................................................................202
Figure 4-257 DC-DC Harness Routing .....................................................................................................................................................................................................................203
Figure 4-258 Potted DC-DC.........................................................................................................................................................................................................................................204

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Figure 4-259 Open Frame DC-DC .............................................................................................................................................................................................................................204
Figure 4-260 DC-DC Converter Removal................................................................................................................................................................................................................205
Figure 4-261 DC-DC Rear Fastener Install ..............................................................................................................................................................................................................205
Figure 4-262 Potted DC-DC - Top View ...................................................................................................................................................................................................................206
Figure 4-263 Open Frame DC-DC - Top View........................................................................................................................................................................................................206
Figure 4-264 Backplane................................................................................................................................................................................................................................................207
Figure 4-265 Backplane Connections......................................................................................................................................................................................................................208
Figure 4-266 Backplane Test Points..........................................................................................................................................................................................................................209
Figure 4-267 Backplane LED Locations - Left Side..............................................................................................................................................................................................209
Figure 4-268 Backplane LED Locations - Right Side...........................................................................................................................................................................................210
Figure 4-269 Removing the Backplane...................................................................................................................................................................................................................211
Figure 4-270 Serial Driver.............................................................................................................................................................................................................................................212
Figure 4-271 Serial Driver Removal..........................................................................................................................................................................................................................214
Figure 4-272 Insertion Guides....................................................................................................................................................................................................................................214
Figure 4-273 BMCC.........................................................................................................................................................................................................................................................215
Figure 4-274 BMCC Case Separation .......................................................................................................................................................................................................................216
Figure 4-275 BMCC Battery Measurement ............................................................................................................................................................................................................217
Figure 4-276 BMCC Removal......................................................................................................................................................................................................................................217
Figure 4-277 BMCC Insertion Guides.......................................................................................................................................................................................................................218
Figure 4-278 PWM ..........................................................................................................................................................................................................................................................218
Figure 4-279 Bearing Control Signal Flow .............................................................................................................................................................................................................219
Figure 4-280 Bearing Power Feed Throughs and PWM Connection Port...................................................................................................................................................219
Figure 4-281 Connecting Leads to PWM Connector and HV- and HV+ Test Points................................................................................................................................221
Figure 4-282 Removing the PWM Amplifier .........................................................................................................................................................................................................222
Figure 4-283 PWM Amplifier Installation ...............................................................................................................................................................................................................222
Figure 4-284 Bearing Connections...........................................................................................................................................................................................................................223
Figure 4-285 Front and Rear Bearing Feed Through Connectors..................................................................................................................................................................224
Figure 4-286 Compressor Monitor Tool..................................................................................................................................................................................................................225
Figure 4-287 Bearing Power Feedthrough Assembly........................................................................................................................................................................................226
Figure 4-288 Bearing Power Feedthrough Alignment Pin...............................................................................................................................................................................227
Figure 4-289 Bearing Power Feedthrough Torque Sequence.........................................................................................................................................................................227
Figure 4-290 Bearing Sensor Feedthroughs .........................................................................................................................................................................................................228
Figure 4-291 Bearing Sensor Pin Locations...........................................................................................................................................................................................................229
Figure 4-292 Bearing Sensor Feed Through Removal .......................................................................................................................................................................................230
Figure 4-293 Bearing Sensor 9-Pin Feedthrough Connector Torque Sequence......................................................................................................................................230
Figure 4-294 BMCC Insertion Guides.......................................................................................................................................................................................................................231
Figure 4-295 Cavity Sensor..........................................................................................................................................................................................................................................231
Figure 4-296 Cavity Temperature Sensor Terminal.............................................................................................................................................................................................232
Figure 4-297 Temperature vs. Resistance...............................................................................................................................................................................................................232
Figure 4-298 Cavity Temperature Sensor Removal.............................................................................................................................................................................................233
Figure 4-299 Pressure/Temperature Sensor..........................................................................................................................................................................................................234
Figure 4-300 Pressure/Temperature Sensor Connections (All TTS/TGS Compressors)..........................................................................................................................234
Figure 4-301 Pressure/Temperature Sensor Locations (TTH/TGH)...............................................................................................................................................................234
Figure 4-302 Temperature vs. Resistance...............................................................................................................................................................................................................235
Figure 4-303 Pressure/Temperature Cable Terminals........................................................................................................................................................................................235
Figure 4-304 Pressure/Temperature Sensor Pin Locations..............................................................................................................................................................................235
Figure 4-305 Suction Pressure/Temperature Sensor Removal.......................................................................................................................................................................236
Figure 4-306 Discharge Pressure/Temperature Sensor.....................................................................................................................................................................................236
Figure 4-307 Interstage Pressure/Temperature Sensor Removal..................................................................................................................................................................237
Figure 5-1 Fault Trigger Methods..............................................................................................................................................................................................................................244
Figure 5-2 Bearing Calibration Tool..........................................................................................................................................................................................................................251
Figure 5-3 Bearing Calibration Flow.........................................................................................................................................................................................................................254
Figure 6-1 Module Removal........................................................................................................................................................................................................................................264
Figure 6-2 Motor Cooling Valve Solenoids ............................................................................................................................................................................................................265
Figure 6-3 Motor Component Dielectric Grease Application.........................................................................................................................................................................266
Figure 6-4 Accessing Inside SCR to Cooling Manifold Fastener (TTS & TGS Compressors only)........................................................................................................266
Figure 6-5 SCR Fastener Dielectric Grease Application.....................................................................................................................................................................................267

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Proprietary Notice
Copyright, Limitations of Liability and Revision Rights.
This publication contains proprietary information to Danfoss LLC. This publication is protected under
the Copyright laws of the United States of America (USA) and most other countries. This work is owned
by Danfoss LLC, and was published as of the most recent revision of this publication, as indicated on
the Title page of this document. This document is for the use Danfoss LLC customers and prospective
customers only. Any use beyond that is prohibited.
Tests have demonstrated that equipment produced according to the guidelines provided in this
manual will function properly, however Danfoss LLC cannot guarantee the equipment to work in every
physical, hardware or software environment.
The guidelines provided in this manual are provided“AS-IS”without any warranty of any kind, either
express or implied, including, without limitation, any implied warranties of condition, uninterrupted
use, merchantability, fitness for a particular purpose.
In no event shall Danfoss LLC be liable for direct, indirect, special, incidental or consequential damages
arising out of the manufacture, use, or the inability to manufacture or use information contained
in this manual, even if advised of the possibility of such damages. In particular, Danfoss LLC is not
responsible for any costs, including but not limited to those incurred as a result of lost profits or
revenue, loss of damage or equipment, loss of computer programs, loss of data, the costs to substitute
these, or any claims by third parties. In any event, the total aggregate liability for all damages of any
kind and type (regardless of whether based in contract or tort) of Danfoss LLC, shall not exceed the
purchase price of this product.
Danfoss LLC reserves the right to revise the publication at any time and to make changes to its
contents without prior notice or any obligation to notify former or present users of such revisions or
changes.
Danfoss Turbocor Compressors Inc.
1769 East Paul Dirac Drive Tallahassee,
Florida 32310
USA
Phone [phone]
Fax [phone]
http://turbocor.danfoss.com
Encounter an error or see opportunity for improvements while reading
this manual? Email us at [e-mail] with a brief
description.
* Subject to change without notice.
* Danfoss Turbocor’s commitment to excellence ensures continuous product improvements.

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List of Changes
Table 1-1 List of Changes
Revision Date Page Description of Change
F 05-30-2019 Redevelopment of manual to include TTH/TGH and support Revision F and
later compressors
F.1 6-10-2019 15/16 Upodated Typecode figures 1-1 and 1-2.
F.2 11-10-2019 18-19
& 28 Updated TGS490 compressor with R515B refrigerant.
F2 11-10-2019 36 Removed helium and changed the inert gas pressure to 15 psi.
F2 11-10-2019 98 Updated F4 and F5 fuse description.
G 5-27-2020 all Manual updated to include all Major Revision H changes.

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Chapter 1: Compressor Introduction
1.1 Application ........................................................................................................................................................................................ 15
1.2 Purpose .............................................................................................................................................................................................. 16
1.3 Organization...................................................................................................................................................................................... 17
1.4 Commitment to Quality and the Environment ............................................................................................................................... 18
1.5 Safety Summary ................................................................................................................................................................................ 18
1.5.1 Danger Notification...............................................................................................................................................................................................................................................18
1.5.2 Caution Notification..............................................................................................................................................................................................................................................18
1.5.3 Note.............................................................................................................................................................................................................................................................................18
1.6 Precautions ........................................................................................................................................................................................ 18
1.7 Refrigerant Type................................................................................................................................................................................ 18
1.7.1 R134a/513A..............................................................................................................................................................................................................................................................18
1.7.2 R1234ze .....................................................................................................................................................................................................................................................................19
1.7.3 R515B..........................................................................................................................................................................................................................................................................19
1.8 Electrical Isolation............................................................................................................................................................................. 19
1.9 Handling Static Sensitive Devices.................................................................................................................................................... 20
1.9.1 ESD Protection/Grounding.................................................................................................................................................................................................................................21
1.10 DC Bus Test Harness Installation and Removal............................................................................................................................. 22
1.10.1 General Verification and Installation of the DC Bus Test Harness ......................................................................................................................................................22
1.10.2 DC Bus Test Harness Installation for Closed-Top Soft Start...................................................................................................................................................................23
1.10.3 General DC Bus Test Harness Removal.........................................................................................................................................................................................................27
1.10.4 DC Bus Test Harness Removal for Closed-Top Soft Starts......................................................................................................................................................................27
1.10.5 DC Bus Test Harness Removal for Open-Top Soft Starts........................................................................................................................................................................27
1.11 Compressor Fasteners .................................................................................................................................................................... 27
1.12 General O-ring Handling ................................................................................................................................................................ 27

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Chapter 1.0 Introduction
This section provides a brief introduction to the Service Manual including the Application, Purpose,
Organization, Document Conventions used, Safety Information, and the Danfoss LLC Quality Policy.
1.1 Application
As of May 6, 2019, the product nomenclature changed. "Figure 1-1 Old to New Type Code" maps the
old structure of the Type code to the new structure. Additionally, the“Series” indicators not have an
additional character in order to differentiate the standard compressors from high-lift compressors.
Unless the compressor is a high-lift design, an“S” will be added (e.g., TTS350). A high lift compressor
will have an “H” in the Series designation (e.g., TTH375). Throughout this manual, it shall be assumed
that if a series designation contains neither an "S" or "H" (e.g., TT350) that it is not a high-lift design.
Refer to "Figure 1-2 New Type Code" on page 16 for a complete description in the new design.
Figure 1-1 Old to New Type Code
TT300‐E‐1‐ST‐G‐O‐CE
TTS300GES1S010X0XXS123
Mains Plate Size
I/O Board Options
Factory Type
Customer
Specific Accessories
Reserved for
Future Options
Software
Options
Conversion From Old Code to New Code
Product Series and Capacity
Note: The new code adds an “S” for
standard or “H” for High Lift
Voltage Code
Application
Note: “T” is dropped
Major Revision
Build
Note: This would change
from an “O” to a “0”
Existing
New
**
Removed*
Type Code Definition
Product Series and Capacity
TTS300: TT Series 300 Aero Config
TTS350: TT Series 350 Aero Config
TTS400: TT Series 400 Aero Config
TTS500: TT Series 500 Aero Config
TTS700: TT Series 700 Aero Config
TGS230: TG Series 230 Aero Config
TGS310: TG Series 310 Aero Config
TGS390: TG Series 390 Aero Config
TGS520: TG Series 520 Aero Config
TTH375: TT High Lift Series 375 Aero
Config
TGH285: TG High Lift Series 285 Aero
Config
Major Revision
E: Major Revision E
F: Major Revision F
G: Major Revision G
Voltage Code
E: 380V/50Hz
D: 380V/60Hz
H: 400V/50Hz
J: 400V/60Hz
G: 460V/60Hz
F: 575V/60Hz
Application
S: Standard Application
M: Medium Temperature
Application
J: Standard Temp KHK Listed
K: Medium Temp KHK Listed
Mains Plate Size
1: Mains Plate 2.00”
2: Mains Plate 2.48”
3: Mains Plate 3.00”
4: Mains Plate 3.50”
I/O Board Option
S: I/O Board included with 5m
cable
M: No I/O Board, 5m cable
Included
Build
0: New Compressor
C: Rebuilt Certified Compressor
Factory Type
1: TLH Factory (CE Rated)
2: HYN Factory (CH Rated)
3: TLH Factory (NC Rated)
Customer Specific Configuration
0: Gen Covers/Plate, EN/FR/CH
Customer Engraved Nameplate
X: No CPN (Standard)
Y: CPN on Nameplate
Accessories Configuration
0: No accessories
Future Option
X: Reserved
X: Reserved
Software
S123: Software
Revision

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Figure 1-2 New Type Code
1.2 Purpose
This Service Manual is intended to provide service procedures specific to the Danfoss Turbocor
compressors. It is not intended to teach basic fundamental safety, refrigeration, electrical, or fitting
skills. It is assumed persons using this manual will be appropriately certified and have detailed
knowledge, experience, and skills in respect to working with high-pressure refrigerants and medium
voltage electrical components to 1 Kilovolt (kV) high-power alternating current (AC) and direct current
(DC).
Some potential safety situations may not be foreseen or covered in this manual. Danfoss LLC expects
personnel using this manual and working on Danfoss Turbocor compressors to be familiar with, and
carry out, all safe work practices necessary to ensure safety for personnel and equipment.
The purpose of this manual is to provide:
• A general description of the compressor design
• A functional description of the various components of the compressor
• Information regarding procedures necessary to detect the source of a problem within the
compressor
TTS300 G E S 1 S 0 1 0 X 0 X X S123
Major Revision (character 7)
E: Major Revision E
F : Major Revision F
G : Major Revision G
H : Major Revision H
Voltage Code (character 8)
E : 380V/50Hz
D : 380V/60Hz
H : 400V/50Hz
J : 400V/60Hz
G : 460V/60Hz
F : 575V/60Hz
Application (character 9)
S : Standard Application
M : Medium Temperature Application
J : Standard Temp KHK Listed
K : Medium Temp KHK Listed
Mains Plate Size (character 10)
1 : Mains Plate 2.00”
2 : Mains Plate 2.48”
3 : Mains Plate 3.00”
4 : Mains Plate 3.50”
I/O Board Option (character 11)
S : I/O Board included with 5m cable
M : No I/O Board, 5m cable included
Software (character 19-22)
S123 : Software Revision
Future Option (character 18)
X : Reserved
Future Option (character 17)
X : Reserved
Accessories Configuration (character 16)
0 : No accessories
Customer Engraved Nameplate (character 15)
X : No CPN (Standard)
Y : CPN on Nameplate
Customer Specific Configuration (character 14)
0 : Gen Covers/Plate, EN/FR/CH
Factory Type (character 13)
1 : TLH Factory (CE Rated)
2 : HYN Factory (CH Rated)
3 : TLH Factory (NC Rated)
Build (character 12)
0 : New Compressor
C : Rebuilt Certified Compressor
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
Turbocor TTS/TGS Series
Type Code
Product Series and Capacity (characters 1-6)
TTS300 : TT Series 300 Aero Config
TTS350 : TT Series 350 Aero Config
TTS400 : TT Series 400 Aero Config
TTS500 : TT Series 500 Aero Config
TTS700 : TT Series 700 Aero Config
TGS280 : TG Series 280 Aero Config
TGS310 : TG Series 310 Aero Config
TGS390 : TG Series 390 Aero Config
TGS520 : TG Series 520 Aero Config
TTH375 : TT High Lift Series 375 Aero Config
TGH285 : TG High Lift Series 285 Aero Config

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• The procedures for disassembling and assembling various components of the compressor
• Fault and calibration interpretations
• System troubleshooting suggestions
• Maintenance tasks that should be followed
This manual gives only general procedures for servicing and does not provide part numbers of single
products or single components. If this information is required, please contact a recognized Danfoss
Turbocor original equipment manufacturer (OEM) customer.
Additionally, this manual is written for Major revision F and later compressors. When necessary,
particular revision compressors are specified, but the majority of the content remains the same,
regarless of the compressor revision. Danfoss LLC does sell various upgrade kits (e.g., Soft Start
Upgrade Kit) and and those kits may include retrofit cabling or other hardware that are not specifically
installed on production compressors. This manual only illustrates components that were installed on
production compressors. Always refer to the specific spare part kit instructions during installation.
1.3 Organization
This manual is organized in the following manner:
• Section 1: Introduction – this section describes the purpose of the manual, its organization,
conventions used in the manual, and a safety summary which describes the use of Danger,
Caution, and Notes symbols
• Section 2: Compressor Fundamentals – this section identifies the parts of the compressor
and provides fundamental knowledge of the role each component plays in the main fluid path,
motor-cooling system, and in the energy and signal flow
• Section 3: Compressor Removal and Installation – this section describes the safe practices of
removing and installing the compressor
• Section 4: Compressor Components – this section describes in depth component information,
the steps necessary to obtain measurements that verify a component is functional and the steps
necessary to replace a compressor component
• Section 5: Troubleshooting – this section describes troubleshooting using signals from the
compressor to determine the specific source of faults at the system and compressor level
• Section 6: Maintenance – this section contains a table containing a list of tasks that should be
performed on a regular basis to maintain optimal performance of the system
• Appendix A: Acronyms/Terms – this section provides definitions of terms and acronyms used
in this manual
• Appendix B: Compressor Troubleshooting Flowcharts – this section contains flowcharts to
assist you with compressor troubleshooting
• Appendix C: Compressor Test Sheet – this section contains a sheet with test points, expected
values, and the section in the manual associated with a particular test
The following conventions are used in this manual:
• Procedures – all user procedures are listed in numerical steps, unless it is a one-step procedure.
A one-step procedure is shown as a bullet.
• User Action Required (software) – if a user is required to take action in a software procedure, the
action will be shown in bold. Example; When the Login window opens, type in your name and
password.
• Monitoring Program Window Names – all window names will be in italic. Example Compressor
Controller window.
• Internal References – references to sections within this manual are encapsulated in quotes.
Example, Isolate the compressor power as described in the“Electrical Isolation of the
Compressor" section of this manual.
• External References – references to items not within this manual are underlined. Example; Refer
to the Installation and Operation Manual for installation procedures.

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1.4 Commitment to Quality and the Environment
Danfoss Turbocor Compressors is dedicated to leading through innovation and to satisfying our
customers with the best quality, value, and on-time delivery of high-efficiency oil-free centrifugal
compressors.
We are committed to controlling our impact on the environment demonstrated through setting goals
focused on continual improvement and complying with all relevant legislation, regulation, and other
requirements to protect the environment.
1.5 Safety Summary
Safety precautions must be observed during installation, start-up, and service of the compressor due
to the presence of pressure and voltage hazards. Only qualified and trained personnel should install,
start up, and service Danfoss Turbocor compressors. Safety information is located throughout the
manual to alert service personnel of potential hazards and is identified by the headings DANGER and
CAUTION.
1.5.1 Danger Notification
A DANGER notification signifies an essential operation or maintenance procedure, practice, or
condition which, if not strictly observed, could result in injury to or death of personnel or long-
term health hazards. A Danger notification is displayed in the format shown in "Figure 1-3 Danger
Notification Example".
Figure 1-3 Danger Notification Example
1.5.2 Caution Notification
A CAUTION notification signifies an essential operation or maintenance procedure, practice, or
condition which, if not strictly observed, could result in damage to or destruction of equipment
or potential problems in the outcome of the procedure being performed. A Caution notification is
displayed in the format shown in "Figure 1-4 Caution Notification Example".
Figure 1-4 Caution Notification Example
1.5.3 Note
A NOTE provides additional information such as a tip, comment, or other useful, but not imperative
information. A Note is displayed in the format shown in "Figure 1-5 Note Example".
Figure 1-5 Note Example
1.6 Precautions
Consideration for personal safety and equipment safety is very important. This chapter contains
various sections that cover safety precautions and methods that must be followed when servicing the
compressor. Prior to servicing the compressor, carefully read this chapter to ensure familiarity of both
personal and equipment safety.
1.7 Refrigerant Type
1.7.1 R134a/513A
TTS and TTH series compressors are totally oil-free and optimized for use with refrigerants R134a. The
TTS and TTH are also compatible with R513A.
• • • DANGER • • •
• • • CAUTION • • •
NOTE

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M-SV-001-EN Rev. G
1.7.2 R1234ze
TGS and TGH series compressors are totally oil-free and optimized for use with refrigerant R1234ze
only.
ASHRAE standard 34 has classified this refrigerant as“R1234ze(E) with safety classification of A2L.”
ASHRAE Standard 34, 2010 Addendum 1 contains the change to the standard.
1.7.3 R515B
TGS490 compressors can be used with refrigerant R515B which has an ASHRAE Standard 34 safety
classification of A1.
Table 1-2 Refrigerant Used with Danfoss Turbocor
Compressor Refrigerant
TTS Series R134a/R513A
TGS Series R1234ze, R515B (TGS490 only)
TTH Series R134a/R513A
TGH Series R1234ze
1.8 Electrical Isolation
Before servicing the Compressor, isolate the compressor power by completing the following steps:
1. Turn off the Mains Input power to the compressor.
2. Lock Out/Tag Out (LOTO) the mains disconnect to ensure no accidental or unauthorized re-
application of the Mains Input power can occur.
NOTE
The Mains Input fast-acting fuses are installed in the power panel for all compressor models except the TT300/TG230.
3. Remove the Mains Cover only. Refer to "4.2.1 Mains Input Cover" on page 56.
4. Using an appropriately-rated voltage meter, confirm the absence of AC voltage.
• • • DANGER • • •
Do not touch any components when removing the Mains Input Cover.
5. If AC voltage is not present, reinstall the Mains Input cover and wait at least 20 minutes before
removing either the Mains Input or Top Side Cover. If AC voltage still exists, go back to Step 2 to
determine why the compressor voltage is not isolated.
6. Remove the Top Cover, taking particular care not to touch ANY components underneath. Refer
to "4.2.2 Top Cover" on page 57.
7. Using an appropriately-rated voltage meter, check the DC Bus Bars for DC voltage level. If the
NOTE
Do not use recycled refrigerant as it may contain oil, which can affect system reliability. The refrigerant should be pure and stored
in virgin containers.
• • • DANGER • • •
• This equipment contains hazardous voltages that can cause serious injury or death. Only
qualified and trained personnel should work on Danfoss LLC equipment.
• Always wear appropriately-rated safety equipment when working around equipment and/or components energized with
high voltage.
• Removing the Mains Input Cover will expose the technician to a high voltage hazard of up to 632 VAC. Ensure the Mains
Input power is turned off and locked out before removing the Mains Input Cover.

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voltage is above 5 volts direct current (VDC), wait five (5) minutes and recheck until voltage is
below 5 VDC. Refer to "Figure 1-6 DC Bus Voltage Test Points".
Figure 1-6 DC Bus Voltage Test Points
1.9 Handling Static Sensitive Devices
Figure 1-7 ESD Susceptible Caution Label
Active electronic components are susceptible to damage when exposed to static electrical charges.
Damage to such components may lead to outright failure or reduction in service life. Since the
presence of static charges is not always evident, it is essential that service personnel follow static
control procedures at all times when handling sensitive electronic components.
This section outlines static control precautions that must be followed when providing service support
in the field. Service support personnel should create a safe, static-free environment.
Service personnel must use a commercially available service kit for handling static-sensitive devices.
The kit typically includes:
• Ground cord assembly
• Alligator clip
• Grounding wrist strap
• Wrist strap tester
If a safe, static control environment cannot be created for a specific reason, the operator will ensure
that electrostatic discharge (ESD) items and personnel are at the same electrical potential as the
equipment.
The electronic modules should only be removed from the ESD protective bag at the last moment, just
before installation when the operator is ready to do the replacement.
Place Positive
(+) Meter
Lead Here
Place
Negative (-)
Meter Lead
Here
Place
Negative (-)
Meter Lead
Here
TTS350 Revision H Shown
TTS300 Revision G Shown
Place Positive
(+) Meter
Lead Here