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twin-turbine centrifugal compressor

1. RS 485 Comm Settings RS 232 Comm Settings f Slave Address 58400 x BaudRate 19200 BaudRate Pay Jl Pei x Parity hoo Stop Bits j2 0 Stop Bits HandShake v HandShake The communication settings will not take effect until the compressor has been completely powered down and powered up again Cancel lt Back Figure 43 Modbus Communications Window Record the comm settings before you close the Service Monitoring Tool since they will be necessary to communicate with the compressor when you restart the Service Monitoring Tool 68 Danfoss Turbocor Compressors Inc CSS IOP D01 L1 V06 0 Installation and Operation Manual 5 6 6 Review and For Download Settings The Review and For Download Settings window allows you to review the settings you have made before downloading and or saving the configuration data Cancel BE Review and For Download Settings Register Description 16bit Value DStatus ig 40057 Units 0 40029 Control Mode 0 40058 Temporary Su 0 S 40059 Temporary Su 0 40249 Run Status vol 9000 42061 IGY Start Step 6000 42039 Starting Speed 0 40226 Suction Pressu 1151 40235 Ex 1 Max Ste 0 40236 EXV1 Initializa 0 40062 EXV1 Control 1 40068 EXV1 Automat 0 v lt B Figure 44 Review and For Download Settings Danfoss Turbocor Compressors Inc CSS IOP D01 L1 V06 0 69 Commissioning 5 6 6 1 Downloading and Saving Configuration Data At the end of the commiss
2. Interface Cable Compressor UO Board Figure 16 Compressor I O Board Connections 26 Danfoss Turbocor Compressors Inc CSS IOP D01 L1 V06 0 Installation and Operation Manual Figure 17 shows the typical control wiring See Table 3 for a description 4 5 4 Erd Phase 1A IEvaparabar or EWY Phase 1B kad balancing EXV Phase 24 valve EXV Phase 28 Ex Phase 14 EXV 1 EX Phase 18 iEcancmizer ar load balancing EXV Phase 2A sabe EXV Phase 36 Level Sensor 4 15 f Sensor Son 1 5Volrs aparator Level Sensor V Level Sensor 154 D Sensor Signal 1 5Valts rae Lowel Sean OW Temperature Sereor Signal 1 SVolts Sanson Vv Sensor 5v Pressure Sensor Signal 1 5 otz OUT OUT OUT OUT Danfoss Turbocor Compressors Inc CSS IOP D01 L1 V06 0 Control Wiring Details Aagi DI a DI Figure 17 Typical Control Wiring Riza Mianitenrsg Connector DES Med Bue Comenpe Shield Madius P85 Not Meis RS Ap Mot Derared 0 108 Demure interlok Contact Safety ME Interlock Contact Safety MAC Compressor Stabus HiO Coni Compressor Stabus MA Con Motor Speed Monitor Motor Speed Monitor Liquid Temgserabune Liquid Temperature Compressor Running BUCO Cc Compressor Running HAT Cr Universal Analog Clutpart Universal Anaket Cutput Entering Chilled Water Temp Sensor Leaving Chilled Water Temp Sessor Universal cutput can be usec Lead balancing vale I
3. A motor that has permanent magnetism as opposed to electromagnetism Programmable Logic Controller See Compression Ratio Sensors that are able to detect the presence of nearby objects without any physical contact A proximity sensor often emits an electromagnetic or electrostatic field or a beam of electromagnetic radiation infrared for instance and looks for changes in the field or return signal Pulse Width Modulation Bearings that control the position of the shaft on the X and Y axis A rectifier is an electrical device that converts AC current to pulsating DC current A resistor is an electrical component that limits or regulates the flow of electrical current in an electronic circuit Return Material Authorization Silicon Controlled Rectifier The SCR is a four layer solid state device that controls current and converts AC to DC A PCB plug in responsible for the operation of the IGV stepper motor and optional expansion valves It contains four relays for the solenoid valves compressor status and compressor run status respectively Saturated Discharge Temperature Seasonal Energy Efficiency Ratio The path travelled by the compressor shaft relative to the bearing magnetic centers An impeller with boxed in or shrouded impeller blades as opposed to an open impeller CSS IOP D01 L1 V06 0 SIE Semi Integrated Electronics version of the compressor Single Stage Type of centrifugal compressor having on
4. Bearing PWM Amplifier e Backplane Serial Driver HV DC DC Converter Danfoss Turbocor Compressors Inc 79 CSS IOP D01 L1 V06 0 Functional Description Surge Suppressor Line Motor Drive Reactor i i 460 750 VDC eee EMI EMC Half Controlled 1 DC Link Ki 380 480VAC Filter Rectifier Capacitors eme Inverter H m mmm 460 750 VDC Soft Start HV DC DC Controller Converter 24VDC 250VDC Power supplies to Backplane Harmonic Filter To Motor Cooling Solenoids Serial Bearing Motor rie pcs To IGV Stepper Motor Module BMCC Lee 2 haft Position Oud ts esi ak a e LI LI LI H LI H Compressor Front Rear Inputs Chiller Radial Radial Axial Interface Beart Le Bearing 1 Bearing 1 Bearing Compressor Module i 1 L Outputs a L al RS 485 Comms to Chiller or Building ort ici sie Customer m Chiller Control Sensor Ring Communications _ _ Interface agnostic d ae Bearing PWM Terminal Amplifier Figure 52 Compressor Control System Functional Block Diagram Bd Sensor Ring Soft Start Board IGBT DC DC Converter Backplane Serial Driver Bearing Motor Compressor Controller BMCC PWM Amplifier Figure 53 Component Locations 80 Danfoss Turbocor Compressors Inc CSS IOP DO01 L 1 V06 0 Installation and Operation Manual 6 2 1 6 2 2 6 2 3 Motor Drive System Normally AC power to the compressor re
5. PV NI FW D WA L 7 Oe Ss NZ TWIN TURBINE CENTRIFUGAL COMPRESSOR INSTALLATION AND OPERATION MANUAL Danfoss Turbocor Compressors Inc CSS IOP D01 L 1 V06 0 July 2010 This Page Left Intentionally Blank Installation and Operation Manual Table of Contents Proprietary iim 5 Listof Changes EE 6 UI WOM e E E E E E 9 e Le 9 Safety SUITITIBE V sgrios dees ge csdcisdi ecu D PED O Oee eaea iea aec E Odd eodd e erp reped CodE 10 Safety Eegenheeten nd ten erent eee ee 10 Voltage Checks Using DC Bus Test Harness Safety Cable 12 Voltage Checks Using DC Bus Test Harness sonoeeeeeeeeeeeeeereeeeeesesererrrrrreee 12 Installation e TE A NN 19 Unpacking and Inspection icuussassacs aci HORN DEPepSE ER ke RU MG RE CHER RR Iq Eae EE seared 19 Rigging Se tu 19 Unit Placement MR 19 Piping Connections REPRE RTL 21 equus 24 Compressor I O Board Mounting Instructions esesses 24 Control Wiring Connections c Dp 24 Control Wiring Connection Guidelines AA 25 Control Wiring DetallS ce sS 27 Circuit Grounding ME EE NICE 29 Vo lt ge Free MONA CUS Me 32 mild omm 33 amp vnn sme c m 35 UO Jumper Setup and Initial Checks AANEREN 35 U
6. When a demand 22V is applied to the compressor the shaft will levitate and the compressor will automatically speed up to the minimum startup speed This takes about 90 seconds When the compressor has reached this point it will adjust its speed and the IGV position in order to attain the desired kW setpoint If the demand drops below 2V the compressor will ramp down to 0 RPMs and will de levitate the shaft For proper operation various control strategy rules are implemented in the compressor controller They can mainly be divided into efficiency rules unloading rules and safety rules see Figure 62 SO qc Se aci un uisa eee D cU uii M de 4 Setpoint in of max kW 6 Fault Z 0 2 10 reset point Demand in Volts Shaft levitates Figure 62 Demand kW Relationship Danfoss Turbocor Compressors Inc CSS IOP DO01 L 1 V06 0 Installation and Operation Manual 6 5 2 6 5 3 6 6 Chiller Mode When a chiller is equipped with a single compressor a separate chiller controller is not needed the compressor can be set to control the leaving entering chilled water temperature by connecting an NTC temperature sensor to the I O Board refer to the Application Manual for sensor characteristics The chilled water setpoint can be set through the Service Monitoring Tool Modbus Mode The demand to the compressor motor kW can be either directly set using the Service Monitoring Tool or can be provided by the chiller controller
7. 5 5 Monitor w o Connection The Monitor w o Connection feature allows you to operate the Service Monitoring Tool without being connected to a compressor Since there is no connection many of the features will not be able to function correctly To monitor without a connection 1 Click File gt Monitor w o Connection The Select User Level to Simulate window 19 is displayed 19 Select User Level to Simulate D Read Only Basic Low OEM O High Engineering Figure 36 Select User Level to Simulate Dialog Box 2 Select a user level to simulate 3 Click OK You can begin using the Service Monitoring Tool 56 Danfoss Turbocor Compressors Inc CSS IOP D01 L1 V06 0 Installation and Operation Manual 5 6 Using the Compressor Commissioning Wizard The Service Monitoring Tool features a Turbocor Compressor Commissioning wizard to guide you through the complete compressor configuration process The following section describes how to use the wizard Use the Turbocor Compressor Commissioning wizard only if compress or is not running Never attempta download while the comp ressor is running as it can lead to a loss of comp ressor control If loss of co ntrol occurs then open the interlock co ntacts to stop e compressor Ensure thatthe inter lock con tacts are o pen before downloading configuration data To use the Turbocor Compressor Commissioning Wizard complete the following steps 1 Selec
8. 86 87 88 89 Compressor I O Board mounting instructions 24 configuration magnetic bearing 91 connections control wiring 24 control wiring 24 connections 24 details 28 crcuit grounding 29 D data general for compressor 42 Danfoss Turbocor Compressors Inc CSS IOP D01 L1 V06 0 E EMI Filter 93 End Commissioning 73 Expansion Valve Control 82 95 F fundamentals compressor 75 G grounding circuit 29 H Harmonic Filter 93 High voltage DC DC Converter 90 l T O jumper settings 35 setup 35 initial checks compressor off 38 system 35 inittial checks compressor on 39 Inlet Guide Vanes 79 J jumper details 36 L LEDs Backplane 90 Line Reactor 93 M magnetic bearing configuration 91 Magnetic Bearing System 91 Main Fluid Path 75 main supply voltage checking 99 maintenance inspections 96 frequency 96 operational maintenance checks 96 Modbus Network Mode 95 Monitor Program downloading and saving configuration data 70 minimum requirements 43 RS232 connection 52 Monitoring Functions 82 119 Motor Cooling 77 Motor Drive System 81 Motor Bearing Control 82 mounting instructions Compressor I O Board 24 O operating modes analog mode 94 chiller mode 95 compressor 94 Modbus network mode 95 operational maintenance checks 96 owner s responsibilities 96 P piping connections 21 power line contactor 93 control and filtering 93 filters
9. 93 power wiring 33 ground connection 34 R owner s 96 rigging requirements 19 120 S safety precautions 10 safety summary 10 Serial Driver 83 settings IO jumper 35 system checks 35 38 T tools 9 service 9 TT300 Compressor Fluid Path 76 U unit placement 19 unpacking and inspection 19 V voltage checking main supply 99 W wiring control 24 power 33 Danfoss Turbocor Compressors Inc CSS IOP D01 L1 V06 0 GTURBOCOR Danfoss Turbocor Compressors Inc 1769 East Paul Dirac Drive Tallahassee Florida 32310 Phone 1 850 504 4800 Fax 1 850 575 2126 www turbocor com Copyright 2010 Printed in USA
10. Vanes ee Eeer 79 Compressor Control Overview EEN 79 Motor KE E EN Soft Start Board EE 81 Bearing Motor Compressor Controller sssseeseseeeeeeeee 81 ADnormal Conditions EE 83 Bearing PWM Amplifier m P 83 sac Sege Ae deeg dene ee EAEE e E 83 Backplane IP 89 High Voltage DC DC Converter 2 22 2 ccccccccccceeeeeseeeeeenesesscneseceeeeeeenee 90 Magnetic Bearing System torte niet nest GEES 91 ciu Mec 91 Bearing GCoritrol SySlelmi E 91 Power Line Control and Filtering uineis ranae ttr natans an EEN 93 Power Line Contactor Zedtegegeheegeeie inescht Eeer dcad iusd 93 Power Line Filters and Line Reactor AAA 93 Compressor Operating MOGOGS aiuaosr pres ned wen ape REFER RAO dU e ISR sess secannsnndiacaVecnnpeneds 94 jute eM DE 94 Sal ce 95 Modbus Mode M 95 Expansion Valve GOonlrol 2 aoi rcaasse ater tnu ptmaepe sooo sad rd nad p t nl Se d Dncita dun ndESE aoc d gine 95 Operational Maintenance Checks AAA 96 Owner s e le 96 Frequency of Inspections E 96 Checking the Main Supply Voltage eec cerent 99 Mounting Instructions e 107 AC Line Cable Connection From External Disconnect 109 AC Line Cable Connection to Compressor Terminal 109 Line Side Connection c seein 111 Load Si
11. 55 Compressor Controller Operational Flow Chart 2 of 6 85 Danfoss Turbocor Compressors Inc CSS IOP D01 L1 V06 0 Functional Description Active Control GOTO Wait for demand to Process Analog run fault to clear or Inputs Startup Control Interlock to close Calculate Maximum Power Available Calculate Desired Power MaxPwr demand Shut down Compressor Desired Power 07 Or Fault Present or Interlock Open Yes Reset IGV amp EXV s Figure 56 Compressor Controller Operational Flow Chart 3 of 6 86 Danfoss Turbocor Compressors Inc CSS IOP DO01 L 1 V06 0 Actual Power Desired Power oad Balance Valve Installed oad Balance Valve Not fully Closed Decrement load balance valve Yes position No No RPM Increase Yes CHOKE RPM Compressor Spd No Set Spd Choke Spd Installation and Operation Manual RPM gt SURGE RPM T No Set Spd Surge Spd Yes Decrement IGV position Increment load balance valve position Yes Decrease Compressor Spd Hold IGV position Valve Installed T Yes oad Balance Valve Not fully Open Figure 57 Compressor Controller Operational Flow Chart 4 of 6 Danfoss Turbocor Compressors Inc CSS IOP D01 L1 V06 0 Functional Description Alarm Handler Lower compressor Speed Yes Is fault
12. 7 Perform a leak test evacuation and charge according to industry standards Danfoss Turbocor Compressors Inc CSS IOP DO01 L 1 V06 0 Installation and Operation Manual Service valve is not required if a discharge service valve is installed Economizer Discharge Port Port Suction Motor Cooling 8 X Port Strainer Filter Drier Evaporator Condenser Expansion NOTE Valve The motor cooling liquid line must be connected to the downward leg of a tee fitting after the liquid line dryer and before the solenoid valve and then continue upward this is to ensure that the motor cooling line is fed with liquid refrigerant at all times Solenoid Typical Refrigerant Piping Schematic Figure 12 Typical Refrigeration Schematic Motor Cooling Connection Access Port Schrader Valve Figure 13 Motor Cooling Connection and Access Port Danfoss Turbocor Compressors Inc 23 CSS IOP D01 L1 V06 0 Installation 4 5 Control Wiring The compressor UO Board enables communication of control and status signals between the compressor controller and external equipment These signals include among others cooling demand input EXV control inputs and outputs alarm and interlock contacts and Modbus protocol communications 4 5 1 Compressor I O Board Mounting Instructions The compressor I O Board is designed to be installed on DIN EN 50022 50035 or 50045 mounting rails The board should be mounted in a dry area f
13. Bus Test Harness by using a multimeter set to resistance Check each cable individually see Figure 1 Resistance should be approximately 100kQ Remove the top cover by releasing the nine screws that secure the cover taking particular care not to touch ANY components underneath Using an appropriately rated voltmeter check the DC bus bars for voltage level If the voltage is above 5VDC wait five minutes and recheck until 5VDC or below is achieved Remove the service side cover by releasing the six screws that secure the cover Disconnect the J1 and J7 connectors on the Soft Start Board see Figure 2 Danfoss Turbocor Compressors Inc CSS IOP D01 L 1 V06 0 Installation and Operation Manual FULLY INTEGRATED ELECTRONICS FIE 62mA 250V 100kQ 3W FUSES RESISTOR 100kQ 3W 62mA 250V RESISTOR FUSES SEMI INTEGRATED ELECTRONICS SIE 100kQ 3W ec RESISTOR Figure 1 DC Bus Test Harness Figure 2 Soft Start Board 10 Connect the two plugs of the compressor cable harness into corresponding sockets of the DC Bus Test Harness see Figure 3 Danfoss Turbocor Compressors Inc 13 CSS IOP D01 L1 V06 0 Safety Summary Figure 3 Connect Test Harness to Compressor 11 Connect the two plugs of the DC Bus Test Harness into the Soft Start Board see Figure 4 Figure 4 Connect Test Harness to Soft Start Board As Seen From Top Side of Board 12 Carefully push the plugs away so that the covers can fit into
14. Inc 59 CSS IOP D01 L1 V06 0 Commissioning e If you selected Analog Input or Modbus Network as your control mode jump to Section 5 6 2 Startup Settings e If you selected Chiller Control Mode proceed to Section 5 6 1 Chiller Control Mode 5 6 1 Chiller Control Mode If you selected Chiller Control Mode the following window displays za Setup Wizard CHILLER CONTROL MODE Determines how the compressor will control the system Choose the sensor that you would like to control the chiller from Leaving Chiller AAA ater Temperature Entering Chiller A Aw ster Temperature Iw Saturated Suction Temperature 30 8 Setpoint Temperature F Chiller Control Loop Tuning Parameters 30 Chiller Proportional Gain 3 Chiller Integral Gain V Chiller Enable Should the compressor start automatically Cancel lt Back Figure 39 Chiller Control Mode To set the Chiller Control Mode settings perform the following steps 1 Select the type of sensor that will control the chiller If selecting Entering or Leaving Chiller Air Water Temperature connect an NTC temperature sensor as specified in the Application Manual to either the Entering or Leaving Chilled Water Temperature input on the compressor I O Board 2 Set the Chiller Control Set Point to the desired value 3 Set the Proportional and Integral Gain values to obtain stable control the Proportional and Integral Gain values will vary depending
15. Next to go to Analog Output setup See Section 5 6 4 Analog Output Setup Danfoss Turbocor Compressors Inc CSS IOP D01 L1 V06 0 Installation and Operation Manual Table 8 Expansion Valve Control Modes Control Mode Description Superheat The calculation of superheat can be based on the temperature and pressure measurements from one of the following sources e Superheat control using the compressor flange temperature and pressure this mode is not recommended as the temperature at the compressor flange is influenced by external factors Superheat control using the compressor flange pressure and a 10K thermistor that is connected to the terminals labeled ENTRY on the Compressor UO Board NOTE Thermistor must be an NTC type 10k 25 C curve type F Superheat control using an external temperature and pressure sensor connected to the terminals on the I O pcb labeled SPARE T amp SPARE P NOTE When this mode is selected the display labeled External Pressure in the Compressor Control window will use a 9 149 PSIA 62 1027 KPa range Any other EXV control mode will result in the display labeled External Pressure in the Compressor Control window to use a 9 510 PSIA 62 3516 KPa range when a sensor is connected Liquid Level Liquid level can be measured from one of the following sources Liquid Level 1 control using a level sensor connected to the terminals on the compressor I O Board labele
16. O board Liquid Temp temperature measured by the sensor connected to the LIQDT terminals of I O board 2 Enter the Starting Output This value equals the percentage of maximum voltage sent to the Analog terminals JP 1 onthe compressor I O Board The Analog output will hold at this position until the start delay timer has expired 3 Enter Starting Output Delay Time This parameter represents the time in seconds that the starting output is in effect The timer starts to count down when the drive is enabled 4 Check the Control Action check box for reverse acting Leaving the check box unchecked will enable direct acting 5 Enter the Proportional Integral and Derivative gains to provide stable control These gain values may require some trial and error to achieve optimum result 6 Enter the minimum Analog output 96 This parameter can be used to maintain a minimum valve open This value is a percentage of the total VDC This parameter can be used for example to maintain a minimum valve open position during operation Danfoss Turbocor Compressors Inc 67 CSS IOP D01 L1 V06 0 Commissioning 5 6 5 Modbus Communications Set up the RS 485 and RS 232 ports as required on the compressor I O Board to enable communication with an external PLC computer or building management system see Figure 43 Eco Setup Wizard MODBUS COMMUNICATIONS Determine the settings for the rs232 and rs485 modbus communication ports
17. Serial01 PCB_Serial02 PCB_Serial03 CC Sofiware rev BMC Sofiware rev Compressor model Technician 4 29 2010 Description Measurement Units Compressor Control Mode Startup Suction Press Trip 96 Startup Suction Press Trip Delay Time secs Run Status Contact Close RPM Inlet Guide Vane Start position Compressor Startup Speed Suction Press Alarm Discharge Press Alarm Discharge Press Trip Leaving Temp Alarm Leaving Temp Trip Discharge Temp Alarm Figure 47 Download Report Value English Manual 0 Os 9000 6000 step 0 167 14 6 14 6 459 6 459 6 32 4 Close the Service Monitoring Tool 5 Turn ON power to the compressor 6 Restart the Service Monitoring Tool Saving Commissioning Data to a Configuration File To save the data to a configuration file 1 Click the Save Configuration to File button 2 Inthe Save As dialog box name the file and save it in a designated location If modifications are made to the configuration data after the commissioning is complete the compressor must be re commissioned with the new values in order to create and save a new file if they are to be used to commission future compressors 5 6 6 4 Using a Saved Configuration File Follow the steps outlined here if you have bypassed the commissioning wizard in order to download a configuration file to the compressor 72 Danfoss Turbocor Compressors Inc CSS IOP DO01 L 1 V06 0 Installation and Operation Ma
18. be carried out as per Table 10 The operational checks evaluate the system performance fault history and system trends Table 10 Preventive Maintenance Tasks Item Task Frequency 6 12 Mos Mos Siner General Check for visible mechanical damage to compressor V Inspections Check for excessive vibration from other rotating Y equipment Electrical Check main power supply voltages y Inspections Ensure electrical terminals are tight V Check for signs of hot spots discoloration on power cables Ensure amperages are as per design Check DC bus voltage 96 Danfoss Turbocor Compressors Inc CSS IOP D01 L 1 V06 0 Installation and Operation Manual Table 10 Preventive Maintenance Tasks Continued Item Task Mos Frequency 12 Mos Other Replace capacitor assembly yrs Storage 5 yrs Operating 10 Check operation of all system safety devices and interlocks Perform moisture prevention measures see Service Manual ECD 00007 S Electronic Inspections Ensure all communication cables are secure Ensure all electronic modules are secure Check physical condition of all exposed printed circuit boards PCBs Check PWM connectors to bearings are secure and flush on feed throughs Check all exposed PCBs for dust build up and clean if necessary Check discharge and suction pressure temperature sensors for accuracy against
19. bearing system physically supports a rotating shaft while enabling non contact between the shaft and surrounding stationary surfaces A digital bearing controller and motor controller provide the PWM command signals to the Bearing PWM Amplifier and IGBT Inverter respectively The bearing controller also collects shaft position inputs from sensors and uses the feedback to calculate and maintain the desired shaft position Monitoring Functions The compressor controller monitors more than 60 parameters including Gas pressure and temperature monitoring Line voltage monitoring and phase failure detection Motor temperature Line currents External interlock Danfoss Turbocor Compressors Inc CSS IOP DO01 L 1 V06 0 Installation and Operation Manual 6 2 4 Abnormal Conditions The compressor controller responds to abnormal conditions by monitoring Surge RPMs Choke ARMs Power failure phase unbalance Low high ambient temperature High discharge pressure Low suction pressure e Stop start short cycle e Motor cooling circuit failure over temperature Refrigerant loss Power supply e Overcurrent 6 2 5 Bearing PWM Amplifier The Bearing PWM Amplifier supplies current to the radial and axial magnetic bearing actuators The PWM Amplifier consists of high voltage switches that are turned on and off at a high frequency as commanded by the PWM signal from the BMCC 6 2 6 Serial Driver The Serial Driver mo
20. incor rect methods canpr esenta serious danger to personnel and equipment 5 1 UO Jumper Setup and Initial Checks This section details the I O jumper settings and the initial system checks 5 1 1 UO Jumper Settings Check and if necessary set the jumpers on the compressor I O board as per application requirements see Table 4 For all inputs that are not connected install the associated jumper For level sensors install the jumpers between pins 2a and 3a and pins 2b and 3b see Figure 24 Danfoss Turbocor Compressors Inc 35 CSS IOP D01 L1 V06 0 Commissioning Table 4 Jumper Details Jumper Function and Set Up JP1 Determines the operating voltage range 0 5V or 0 10V of the ANALOG output If used set the jumper to the appropriate range JP2 Modbus termination jumper install the jumper if Modbus is used and if the Modbus connection is at the end of a run ENTRY Install the jumper if there is no temperature sensor connected to the Entering Chilled Water analog input LEAVE Install the jumper if there is no temperature sensor connected to the Leaving Chilled Water analog input JP5 JP6 Jumpers J5 and J6 are used to match the characteristics of the liquid level sensors Voltage type Level Sensor If using a voltage type sensor with 15V supply and 0 5V signal install jumpers between LVL pins 2a and 3a and pins 2b and 3b Connect the sensor leads to the S and ter
21. on the compressor nameplate Keep power cables and control interface cables in separate conduits Use metal cable glands for shielded cables to ensure good grounding If you are installing a DTC line reactor or EMI or harmonic filter in the mains input circuit refer to the applic able inst allation instruc tions in Appendix C Power Lin eAcce ssories Installation Figure 21 shows a typical schematic for the compressor s electrical connections Surge Suppressor Connect power wiring ground and ground of secondary optional tranformer including 24V control power to common ground point in electrical panel Fuse User Supplied l l GND A o d T Fog Oo l D o EMUEMC Fog u Filter Fog AC input i2 O oE optional tT voltage Fog L3 o oon Line Manual Disconnect Ciscuit Protection Reactor see Notes I l Harmonic User Supptied Filter Notes optional Fast acting fuses must be installed for the TT350 and TT400 models The TT350 TT400 and TT5OO use Class T 600VAC fast acting fuses The fuses are built into the TT3OO Circuit protection is required according to local electrical requirements Figure 21 Typical Electrical Connections Danfoss Turbocor Compressors Inc 33 CSS IOP D01 L1 V06 0 Installation 1 Release the four screws that secure the mains input cover to the compressor Lift away cover 2 Insert a cable gland customer s
22. on the application This may require some trial and error before arriving at the optimum values 60 Danfoss Turbocor Compressors Inc CSS IOP D01 L1 V06 0 Installation and Operation Manual The Integral part ofthe internal chiller controlleris switched off until the compressor reaches a speed of 18 500 RPMs Stopping the compressor and restarting also resets the Integral part to O 4 Click in the Chiller Enable check box to activate chiller control mode Ensure that the Interlock contact located on the compressor I O Board is open to prevent the compressor from starting before the commissioning sequence is complete 5 Click Next 6 Proceed to Section 5 6 2 Startup Settings 5 6 2 Startup Settings The Startup Settings window is used to set various parameters used by the compressor when starting up fog Setup Wizard DER START UP SETTINGS Determines how the compressor behaves on ramp up T Start Up Alarm Settings sn Temporary Suction Pressure Alarm 120 a Temporary Suction Pressure Delay Time seconds 21 ooo Compressor Starting Speed RPM 182 lt Suction Pressure Trip Value Gage Suction Pressure Alarm Value Gage Miscellaneous Settings 12000 Run Contact Close RPM 7 Inlet Guide Vane Starting Open tae ce C r Figure 40 Startup Settings To enter the startup parameters complete the following steps 1 Enter the Temporary Suction Pressure Alarm Danfoss
23. place 13 Route the cable into the cable passage on the right side of the high voltage HV DC DC converter down into the service side see Figure 5 and Figure 6 14 Danfoss Turbocor Compressors Inc CSS IOP DO01 L 1 V06 0 Installation and Operation Manual uda A Figure 6 Service Side Pass Through 14 Reinstall the mains input and top covers and tighten all screws 15 Reapply AC power to the compressor Danfoss Turbocor Compressors Inc 15 CSS IOP D01 L1 V06 0 Safety Summary 16 Using an appropriately rated voltmeter with the 1000VDC range selected insert the positive voltmeter lead into the DC F test harness lead and the negative voltmeter lead into the DC test harness lead See Table 2 for expected DC bus voltage If the voltage corresponds to Table 2 the DC bus voltage is correct and the HV DC fuse on the Soft Start Board is good If the voltage reads zero go to step 17 If the voltage is within acceptable limits this indicates that the Soft Start Board and SCRs are functioning correctly go to step 20 Table 2 Compressor Voltage Ranges Wa weiter Expected DC AC Voltage Range 575 VAC 518 632 VAC 632 900 VDC 460 VAC 414 506 VAC 550 720 VDC 400 VAC 360 440 VAC 485 625 VDC 380 VAC 342 418 VAC 460 595 VDC 17 Leaving the DC test lead in place relocate the positive test lead to DC If the DC voltage is consistent with Table 2 the HV DC fu
24. rubber mounts four sets of attaching hardware including 3 8 screws spring washers and flat washers 7 3 1 Mounting Instructions 1 Following the footprint dimensions given in Figure 63 drill two 9mm 11 32 holes in the base frame for each rubber mount 2 Align the rubber mounts over the holes and secure them with attaching hardware customer supplied 3 Place one flat washer on each rubber mount 4 Position the compressor over the rubber mounts and align the four holes in the compressor mounting rails with the rubber mounts 5 Assemble the four 3 8 screws with the spring washers Insert the screws into the rubber mounts and tighten them 6 Check that the compressor mounting rails are level 5mm 3 16 in the lateral and longitudinal planes 485 19 09 Rubber Mounts a 2 View A 9 5 i N Spring Mounting Di Washer Rail e Compressor w Flat EN Mounting Rail w Washer 4 T par co Rubber N SS ER E Mount x 5 e S See e ot ris View A 7 Customer Supplied Figure 63 Compressor Mounting Details Danfoss Turbocor Compressors Inc 107 CSS IOP D01 L1 V06 0 This Page Left Intentionally Blank Installation and Operation Manual Appendix C Power Line Accessories Installation Line Reactor Installation Instructions These instructions apply to the installation of the line reactor kit in a main supply panel See the Applications Manual for pro
25. speed and shut down the system within 60 seconds This type of fault requires a manual reset Critical faults include Discharge Pressure Fault 3 Phase Over Current Fault and Lock Out Fault If any of the following faults occur three times within a 30 minute period they also will require a manual reset Inverter Temperature Fault Cavity Temperature SCR Temperature Fault Motor High Current Fault and Motor back EMF is low Faults indicate an intolerable or unsafe condition that will result in equipment failure if unchecked They will cause the compressor controller to reduce speed and shut down the system within 60 seconds This type of fault has an automatic reset An insulated conductor connecting two circuits on opposite sides of a barrier such as a compressor housing or PCB Fully Integrated Electronics version of the compressor Full Load Amps A function of the compressor where the stator becomes a generator creating sufficient power to allow for the shaft to graduate slowly and drop onto the touchdown bearings safely This occurs when the inverter has insufficient power to sustain safe and normal operation and is typically due to a loss of power A type of grease In certain climates where the dew point falls below the operating temperature of some of the electronic components it is necessary to apply Genlanolin to certain parts of the compressor to prevent moisture accumulation Harmonics are multiples of the fundamental freque
26. v Control Mode rc 40 Starting output Max Wde for set delay time 30 5 Starting output delay time Seconds to hold start vdc 89 7 Di Discharge Pressure psig Iw Control Action Check box to make reverse acting 65 Proportional Gain 0 gt 100 6 Integral Gain 0 gt 100 0 a Derivative Gain 0 10022 35 EI Min V dc Output during operation Cancel lt Back Figure 42 Analog Output Setup To configure the Analog output 1 Select the control mode for the Analog output This selection determines which control variable will be the source for the Analog Output The options are Load Balance Valve Discharge Pressure Inlet Guide Vane Superheat Flange TP temperature and pressure measured at the Compressor suction flange Superheat FlangeP EWT pressure measured at the Compressor suction flange temperature measured by the sensor connected to the ENTRY terminals of I O board Superheat FlangeP LIQT pressure measured at the Compressor suction flange temperature measured by the sensor connected to the LIQDT terminals of I O board Danfoss Turbocor Compressors Inc CSS IOP DO01 L 1 V06 0 Installation and Operation Manual e Suction Pressure Leaving Temp temperature measured by the sensor connected to the LEAVE terminals of I O board Entering Temp pressure measured at the Compressor suction flange temperature by the sensor connected to the ENTRY terminals of I
27. 5 4 2 5 4 3 Service Monitoring Tool Basics Starting the Service Monitoring Tool To start the Monitoring Program from the Start menu select All Programs Danfoss Turbocor Service Monitoring Tool Entering User Input When user input is required for the Service Monitoring Tool fields perform the following sequence 1 Click or double click the variable field or press Tab to step through 2 Scroll or type in the new setting 3 Press Enter Compressor Connection Manager The Compressor Connection Manager 4 is the window that first displays when the Service Monitoring Tool is opened It contains fields that must be filled to enable communication between the Service Monitoring Tool and the compressor The comm settings default to the most recently used values E 4 Compressor Connection Manager Connection Settings Slave Address 1 s Compressor Info e Connecting Serial Port COMT vi BaudRate 19200 i Recent Compressors Search Addresses 0 20 Figure 34 Compressor Connection Manager Danfoss Turbocor Compressors Inc 53 CSS IOP D01 L1 V06 0 Commissioning 5 4 4 54 To begin using the Service Monitoring Tool complete the following steps 1 Set the fields on the Compressor Connection Manager or you can use the default values The fields are Slave Address 1 64 1 default Serial Port Serial Communication Port that the computer will use to connect to the compr
28. 77 CSS IOP D01 L1 V06 0 Functional Description LIQUID REFRIGERANT INLET TO MOTOR MOTOR COOLING CONTROL LOOP IGBT COOLING CIRCUIT RECTIFIER COOLING l l l l l l l I CIRCUIT l l l MOTOR COOLING TEMPERATURE CONTROL LOOP SENSOR IGBT M TEMPERATURE SENSOR MOTOR CAVITY Boro 2 STATOR COOLING CIRCUIT OLN 2 AS RETURN TO SUCTION Figure 50 Compressor Cooling Circuit TT300 ACCESS SCHRADER VALVE ACCESS SCHRADER VALVE t T ELECTRONICS COOLING LOOP MOTOR COOLING LOOP Figure 51 Compressor Cooling Circuit TT300 Split Cooling and TT350 TT400 and TT500 78 Danfoss Turbocor Compressors Inc CSS IOP DO01 L 1 V06 0 Installation and Operation Manual 6 1 3 Inlet Guide Vanes The Inlet Guide Vane IGV assembly is a variable angle guiding device that pre rotates refrigerant flow at the compressor intake and is also used for capacity control The IGV assembly consists of movable vanes and a motor The vane angle and hence the degree of pre rotation to the refrigerant flow is determined by the BMCC and controlled by the Serial Driver The IGV position can vary between approximately 0 percent and 110 percent open 6 2 Compressor Control Overview Figure 52 shows a functional block diagram of the compressor control and monitoring system Figure 53 displays the component locations The major components include Motor Drive e Soft Start Board Bearing Motor Compressor Controller BMCC
29. 99909090990990095 Backplane PCB 720119_6 Turbocor Inc 5203 Figure 26 Backplane Test Points Danfoss Turbocor Compressors Inc 41 CSS IOP D01 L1 V06 0 Commissioning 5 2 Configuring the Compressor Using the Service Monitoring Tool This section describes compressor configuration using the Service Monitoring Tool Installation and operation of the Service Monitoring Tool Commissioning Wizard are also covered Fora de tailed de scription ofth e Se nice Monitoring Tool refer to the Service Monitoring Tool User Manual eo Series unituring foul 2184 10 liye COMZE 39400 uad pata PCY Master EX Er Compresso Euro ECB File Window Layout Advanced Capture Data 2 Ss o KJ TURBOCOR Ts sat 3 8 C Te sat 54 7 C 81 3 kW 54 T 1 T TofSat 141814 14 21 07 14 24 00 3 Phase Power 82 80 Power 14181 4 1421 07 1424 00 37510 37500 37490 37480 i 7 i Motor Speed 4 18 14 14 21 07 14 24 00 111 00 110 00 103 00 AM Suction Temperature lav 141814 142107 142400 1 00 Si 0 00 No Faults Suction Pressure No Alarms 1 007 i Jpn GESESER Ae AREEN Interlock Status Closed Reset Graphs Figure 27 eZ Compressor Control Window 42 Danfoss Turbocor Compressors Inc CSS IOP DO01 L 1 V06 0 5 2 1 Installation and Operation Manual System Requirements The Service Monitoring Tool must be installed on a PC that meets the minimum requirements
30. D Valve Flange Kit Installation Instructions The instructions provided in this section apply to the following Turbocor valve flange kits e Suction flange or service valve Discharge flange or service valve Economizer flange or service valve NOTE Please consult Acce ssories M anualforp art numbers and availability Each individual valve kit includes an O ring lubrication and attaching hardware razing without the use of dry nitrogen wi result in debris being d eposited in the pipework potentially causing blockage and or damage e heat generated from brazing can damage valve c omponents Alwaysus ein dustry standard practices to reduce valve temperature Danfoss Turbocor Compressors Inc 113 CSS IOP D01 L1 V06 0 7 3 6 Mounting Instructions 1 Assemble the four sets of M16 x 45 hex head screws and spring washers 2 Align the suction valve flange with the compressor suction port and insert the four hex head screws Tighten the screws to 75 Nm 55 ft Ibs 3 Assemble the six sets of M10 x 35 hex head screws and spring washers 4 Align the discharge valve flange with the compressor discharge port and insert the four hex head screws Tighten the screws to 22 Nm 16 25 ft Ibs 5 If applicable align the economizer valve flange with the compressor economizer port and insert the two hex head screws Tighten the screws to 22 Nm 16 25 ft lbs Disc harge e Econommer Suction Figure 68 C
31. Double Click on the SMT V 2 1 86 zip file that is displayed The File Download window opens Danfoss Turbocor Compressors Inc CSS IOP DO01 L 1 V06 0 Installation and Operation Manual File Download bj Do you want to open or save this file e Name SMT V 2 1 86 zip Type jzip archive File 7 39MB From www turbocor com Open Save Cancel Always ask before opening this type of file i x While files from the Internet can be useful some files can potentially e harm your computer If vou do not trust the source do not open or save this file What s the risk 7 Click Open The files download and the Zip window displays SG wg e Now Archive Open ardie Add Extract Ven addes IN OQ wum Nee Type Sce Reo Packed Qo Fle Folder E changelog tat Test Docu Ie mm 8 67 290 Bloc tege Setup mei Windows In 4 770 904 a oen Dag zg A ek ger SI vin 1 Lader shale A 8 Click Extract on the Zip window toolbar jZip SMT V 2 1 86 zip File Actions View Help New Archive Open Archive Add Extract View Style The Extract window opens Danfoss Turbocor Compressors Inc 45 CSS IOP D01 L1 V06 0 Commissioning Extract to C SMT H C3 i386 C3 Monitor E C3 Novadigm H O oracle 3 Program Files ProgramData C3 QUARANTINE m CH sMr O CVIRTE HI RI My Documents My Computer Files Selected files folders C All files folders in cur
32. G position Dezhbarge pressure 27 Installation Table 3 Control Wiring Details yo Description COM shield Shield for RS 485 communication Modbus RS 485 NetB NetA Modbus over RS 485 communication port EXV 1 Phase 1A 1B 2A 2B and EXV 2 Phase 1A 1B 2A 2B Optional output connections for controlling the main electronic expansion valve evaporator or auxillary electronic expansion valve economizer or load balancing valve Level Sensor 15V Evaporator Power supply for level sensor 1 Sensor Signal Evaporator Input from a level sensor to control the main expansion valve evaporator Level Sensor 15V Economizer Power supply for level sensor 2 Sensor Signal Economizer Input from a level sensor to control the auxiliary expansion valve economizer Demand 0 10V Analog input from customer supplied controller to drive the compressor i e 0 max kW input with a deadband of 2VDC for the respective compressor model Interlock Connects to a set of external normally closed contacts that typically open in the event of loss of chilled water or air flow Status An internal contact that is closed during normal operation and opens in the event of a compressor fault With the circuit open the compressor will not restart until the demand signalhas been reset to 0 via chiller unit controller Circuit rated at 1A 30VDC 24VAC Motor Speed Monitor An
33. HV DC DC Converter mounted on the topside of the compressor The Backplane is also equipped with status indicating LEDs All LEDs are yellow except for the alarm LED which is green red Table 9 describes the LEDs functions Danfoss Turbocor Compressors Inc 89 CSS IOP D01 L1 V06 0 Functional Description 6 2 8 90 Table 9 Backplane LEDs LED Function 5V 15V LEDs are lighted when DC 17HV 24V power is available Cool H Cool L LEDs are lighted when their respective coil is energized Run LED is lighted when the shaft is spinning Alarm LED is green when in normal status red when in alarm status D13 D14 D15 LEDs indicate IGV status and D16 flash when IGV is moving High Voltage DC DC Converter DC DC converters supply and electrically isolate the high and low DC voltages that are required by the control circuits The HV DC DC Converter delivers 24VDC and 250VDC from an input of 460 900VDC The 24VDC and 250VDC are used to power the Backplane and magnetic bearing PWM Amplifier respectively Danfoss Turbocor Compressors Inc CSS IOP D01 L1 V06 0 Installation and Operation Manual 6 3 6 3 1 6 3 2 Magnetic Bearing System Overview A rotating shaft under changing load conditions will experience forces in both radial and axial directions In order to compensate for these forces a five axis bearing system is used incorporating two radial bearings of two axes
34. Have installing electrical contractor switch ON 3 phase mains power Verify correct voltage as per nameplate for all 3 phases 3 On the backplane check the status of the following LEDs see Figure 26 5V illuminated e 15V illuminated 17V illuminated 24V illuminated Danfoss Turbocor Compressors Inc 39 CSS IOP D01 L1 V06 0 Commissioning Table 6 Initial Checks Compressor ON Continued 4 Check that all DC voltages on the backplane are within the specified range as follows P S Range e HV HV 237 5 to 262 5 e 17HV HV 16 15 to 17 85 e 24V 0V 22 8 to 25 2 e 15V 0V 14 25 to 15 75 e 15V 0V 14 25 to 15 75 e 5V 0V 4 75 to 5 25 5 Replace the service side cover 6 Listen for distinctive clunks that indicate the completion of the compressor self check within two minutes of power being applied 7 Reconnect terminal strip J2 on the I O Board 40 Danfoss Turbocor Compressors Inc CSS IOP D01 L1 V06 0 Installation and Operation Manual 5VDC Test Point OV Test Point 15VDC Test Point 15VDC Test Point 24VDC Test Point Qu Li E35 EW Tie Cd tie sep 5 RA O IGV ne 9 ZS 17VDC Test Point High Voltage Test Point 250 VDC JI8 J19 J20 J10 a Kc AV N 3 ee ES IIII A High Voltage TANTO d s Test Point 250 VDC C 2 GE dE s i zs DA ITPA Jos Sei Ee mum c26 ces J24 m EIN 99999
35. PSD Jumper Settings Ec m ab System COMBOS e 38 Configuring the Compressor Using the Service Monitoring Tool eeseeeeeeeeen 42 System Requirements creer e tete e nente r nian rand cR xn Er Ent tI na Ke reenen 43 SoftWare Install Nell ssc sce aceetemicert cep ciui tiu ct up usu tacui Sup bote Age 44 Monitoring Tool Installation E 44 Establishing a Connection ett E 51 RS 232 CONNECCION ett caer Ble rhode Set te an ia ea aaea 52 RS 489 CONNEC ON ege iaiaaeaia Dee 52 Service Monitoring Tool Basics eese eruere tenente nnno none ne crea tuta UR tea pun EREMER 53 Starting the Service Monitoring Tool ccce nne 53 Entering UE gu EE 53 Compressor Connection Manager sssssssssssseeeneenennnn 53 A CMMI NG Ee 54 Changing Access Codes teased share ca secre rinnen n niar 55 Monitor w o elg iei qo o oo TS 56 Using the Compressor Commissioning Wzard 57 Chiller Control Mode C 60 Danfoss Turbocor Compressors Inc 3 CSS IOP D01 L1 V06 0 Ewe Le CN 61 Electronic Valve Control Me metals 63 Analog Output SEU C 66 Modbus Communications tee ee 68 Review and For Download Settings sseeeeeeene 69 PRUNING cf ECE 73 Functional Description BEE 75 Compressor Faldaiel iles sseccueacu tuecedatat ue GolasdsmidePetcisulkctta uisu adii est eescctendadutu 75 E af ELI EE 75 jeje disse E 77 iNet uide
36. Turbocor Compressors Inc 61 CSS IOP D01 L1 V06 0 Commissioning 62 The Temporary Suction Pressure Alarm is a percentage of the existing Suction Pressure Limit in the Eeprom For example if a suction pressure trip of 270 kPa was set and the temporary suction pressure alarm was set to 50 percent the temporary suction pressure trip limit would be 135 kPa This temporary alarm isonly active while the Suction Pressure Delay timer is counting down Enter the Temporary Suction Pressure Delay Time The Temporary Suction Pressure Delay Time parameter represents the time in seconds that the temporary suction pressure alarm is ineffect The timer starts to count down when the drive is enabled Enter the Compressor Starting Speed If the estimated minimum speed is greater than the starting speed setting the compressor will ramp up to the estimated minimum speed If the starting speed setting is greater than the estimated minimum speed the compressor will ramp up to the starting speed In both cases the compressor speed will increase at the full ramp rate Enter the Run Contact Close RPM The compressor Serial Driver contains a normally open NO relay contact that closes while the compressor is running The speed at which the contact closes is determined by the Run Contact Close RPM Enter the Inlet Guide Vane Starting Open Typically the IGV Starting Open should be a minimum of 25 and usually 50 70 is optimal to prevent check val
37. a high v oltage 380 604VAC haz ard Removing the top cover will expose you to a hig h voltage 6 00 900VDC hazard Exercise care wh en w orking a round energized circuits When servicing or re placing a com pressor the high voltage cap acitors must be dischar ged before op ening a ny of the com pressor a ccess covers Perform steps in Section 3 3 on the next page 11 Safety Summary 3 2 Voltage Checks Using DC Bus Test Harness Safety Cable Voltage checks with the top covers removed should not be performed All voltage checks should be performed using the DC Bus Test Harness PN 100326 Follow the steps below to safely remove power from the compressor and install the DC Bus Test Harness see DANGER Before using the DC Bus Test Harness integrity of the fuses resistors and cable must be checked see Section 3 3 3 3 Voltage Checks Using DC Bus Test Harness 1 Turn off AC power input to the compressor 2 12 Secure lock out tag out the isolating switch to ensure against accidental or unauthorized reapplication of the AC power Wait at least 15 minutes then remove the mains input cover by releasing the four screws that secure the cover NOTE Please ensure that the screws do not fall into the compressor Retain the screws for installation Using an appropriately rated voltmeter confirm that the AC voltage is still isolated Confirm integrity of the fuses and resistors in the DC
38. alog output indicating compressor RPMs 0 to 5 0V 0 to 50 000 RPMs Liquid Temperature Provides superheat readings for EXV control Run An internal contact that is closed while the compressor is running The speed at which the contact closes is user configurable via the Monitor Program Circuit rated at 1A 30 VDC 24VAC Analog Universal analog output for load balancing valve IGV position or discharge pressure Operating range can be set to 0 5V or 0 10V via onboard jumpers 28 Danfoss Turbocor Compressors Inc CSS IOP D01 L1 V06 0 Installation and Operation Manual Table 3 Control Wiring Details Continued UO Description Entering Chilled Water Temp Analog input indicating water temperature The temperature sensor must be an NTC type 10K 25 C thermistor Refer to the Application Manual for thermistor specification Leaving Chilled Water Temp Analog input indicating water temperature The temperature sensor must be an NTC type 10K 25 C thermistor Refer to the Application Manual for thermistor specification Spare T Refer to the Application Manual for thermistor specification Spare P Can be connected to a 0 5V type pressure sensor 4 5 5 Circuit Grounding Improper grounding or voltage in circuits connected to the compressor I O board can lead to component failures In particular the interlock and analog output circuits are sensitive to improperly co
39. ation between products on the factory floor This protocol has become a de facto standard for exchanging data and control between Programming Logic Controllers PLC systems Modbus is a registered trademark of Modicon Corp Danfoss Turbocor Compressors Inc 51 CSS IOP D01 L1 V06 0 Commissioning 5 3 1 RS 232 Connection 1 Connect one end of the RS 232 cable user supplied to the DB9 connector on the Compressor I O Board see Figure 33 2 Connect the other end of the cable to an available USB or COM port on the PC This may require an adapter 3 Confirm that jumpers JP2 and JP7 are in the proper positions before starting JP2 is the Modbus termination jumper Install the jumper if the Modbus connection is at the end of a cable run JP7 provides 5VDC to Pin 1 of the DB9 connector Remove JP7 to enable RS 232 communication with the PC Install JP7 if using Bluetooth RS232 Po iam DB9 Connector 3 Termina Connector Compressor I O Board Figure 33 RS 232 and RS485 Connectors Compressor I O Board 5 3 2 RS 485 Connection To set up the RS485 connection complete the following steps 1 Connect the RS 485 RS 232 adapter user supplied directly to the PC 2 Connect the other side of the adapter to the RS485 3 terminal connector 3 Follow your RS 485 RS 232 adapter instructions 52 Danfoss Turbocor Compressors Inc CSS IOP D01 L1 V06 0 Installation and Operation Manual 5 4 5 4 1
40. between the contactor and the line reactor The European version of an EMI filter is required for CE compliance Line Reactor The line reactor acts as an input buffer between the motor drive power circuits and the AC line power Line reactors provide additional circuit impedance that improves power factor reduces line current harmonics and dampens the transient voltages on the power line Harmonic Filter The harmonic filter operates in conjunction with the line reactor to minimize low frequency harmonics on the power line emanating from the switching devices on the compressor It should be located between the line reactor and the compressor Danfoss Turbocor Compressors Inc 93 CSS IOP D01 L1 V06 0 Functional Description 6 5 6 5 1 94 Compressor Operating Modes There are four modes for controlling compressor operation ranging from fully automatic to manual as follows Analog mode Chiller mode Modbus mode e Manual mode Manual mode is reserved for authorized service personnel only see the Service Manual for further information Analog Mode This control mode is used when an external controller controls the chiller compressor An analog control signal is applied to the compressor that represents the setpoint for the compressor loading The relationship is as follows 2 10VDC 0 100 of maximum power available for that given compressor model number and operating condition see the following example
41. bocor Compressors Inc 43 CSS IOP D01 L1 V06 0 Commissioning Table 7 Minimum Requirements Continued Memory Hard Disk Display Input Device 128 MB of RAM 256 MB recommended 110 MB of hard disk space required 40 MB additional hard disk space required for installation 150 MB total 800 x 600 or higher resolution display with 256 colors recommended Microsoft mouse or compatible pointing device 5 2 2 5 2 3 44 Software Installation The Service Monitoring Tool is installed on the PC and communicates with the compressor using the Modbus protocol over a RS 232 or RS 485 serial link Administrator privileges may be required to install and remove software on the PC Security software may block the installation as well If a previous version of the Service Monitoring Tool is already installed on the PC it must be uninstalled before proceeding with the current installation To uninstall the Service Monitoring Tool from the Start menu select Settings Control Panel Double click Add Remove Programs From the list select Danfoss Turbocor Service Monitoring Tool and then click the Remove button Monitoring Tool Installation To download and install the Monitoring Tool complete the following steps 1 From Internet Explorer go to www turbocor com 2 Click on Product Support 3 Log in using your user name and password 4 Click on Monitoring Program 5 Select Full Integrated Electronics 6
42. both types of D Sub connectors DTC Danfoss Turbocor compressors Inc EEPROM Electrically Erasable Programmable Read Only Memory A small chip holds bits of data code that can be rewritten and erased by an electrical charge one byte at a time EEPROM data cannot be selectively rewritten the entire chip must be erased and rewritten to update its contents EER Energy Efficiency Ratio EMC Electromagnetic Compatibility EMF Electromotive Force EMI Electromagnetic Interference EMI Filter A circuit or device that provides electromagnetic noise suppression for an electronic device EPC Extended Performance Compressor ETL ETL Testing Laboratories now a mark of Intertek Testing Services EXV Electronic Expansion Valve Pressure independent refrigerant metering device driven by electrical input Event Log A record of events occurring during the compressor s lifecycle indicating when events and faults occur and in what order The event log is held in the BMCC 102 Danfoss Turbocor Compressors Inc CSS IOP D01 L1 V06 0 Installation and Operation Manual Acronym Term Definition Faults Critical Faults Non Critical Feedthrough FIE FLA Generator Mode Genlanolin Harmonics HFC HFC 134a Hermetic Motor ICD IEEE IGBT IGV Impeller Critical faults indicate an intolerable or unsafe condition that will result in equipment failure if unchecked They will cause the compressor controller to reduce
43. by the axial bearing Bearing Motor compressor Controller The BMCC is the central processor board of the compressor Based on its sensor inputs it controls the bearing and motor system and maintains compressor control within the operating limits Heavy gauge metal conductors used to transfer large electrical currents A passive component that stores energy in the form of an electrostatic field NTC temperature sensor located behind the Backplane for the purpose of sensing motor cooling vapor temperature Provides overheat protection to motor windings Conformance European The CE marking also known as CE mark is a mandatory conformity mark on many products placed on the single market in the European Economic Area The CE marking certifies that a product has met EU health safety and environmental requirements which ensure consumer safety Definitive point on compressor map where mass flow rate is at maximum for compressor speed and lift conditions The absolute discharge pressure divided by the absolute suction pressure Canadian Standards Association www csa ca High DC voltage simultaneously connected to multiple compressor components via metallic bus bars including the capacitors An assembly of four DC capacitors four bleeder resistors and positive and negative bus bars Danfoss Turbocor Compressors Inc 101 CSS IOP D01 L1 V06 0 Acronym Term Definition DC DC Converter Dielectric Diffuser D
44. calibrated pressure temperature gauges Refrigeration Check operation of IGV assembly Check system refrigeration charge Check superheat level control if applicable Danfoss Turbocor Compressors Inc CSS IOP D01 L1 V06 0 97 Operational Maintenance Checks Table 10 Preventive Maintenance Tasks Continued Item Task Frequency 6 12 Mos Mos Ses Check system and motor cooling liquid line to ensure d sufficient subcooling Verify Poppet part 100419 100513 or 100579 If there is backward gas flow immediately after stopping the compressor or if the pressure equalizes in a short period of time providing the Liquid Line Solenoid Valve is in place Y and functioning properly shut OFF power to the compressor and open the Check Valve and check the Poppet Replace if necessary Check operating conditions external to the compressor Y Inspect clean motor cooling strainer if service has taken As required place 98 Danfoss Turbocor Compressors Inc CSS IOP D01 L 1 V06 0 Installation and Operation Manual 7 3 Checking the Main Supply Voltage see DANGER emoving the mains input cover will expose you to a high voltage 380 604VAC hazard Exercise care when working around energized circuits Service Tools Test Equipment 2 Phillips bit and driver e Voltmeter 1 Release the four captive screws that secure the ma
45. compressor Danfoss Turbocor Compressors Inc 109 CSS IOP D01 L1 V06 0 Surge Suppressor Connect power wiring ground and ground of secondary optional tranformer including 24V control power to common ground point in electrical panel Fuse User Supplied GND o e H e o i EMUEMC T Filter AC Input i2 O optional Voltage H Manual Disconnect Circuit Protection see Notes Harmonic User Supptied Filter optional Notes top 4 Fast acting fuses must be installed for the TT350 and TT400 models The TT350 TT400 and TT50OO use Class T 600VAC fast acting fuses The fuses are built into the TT300 Circuit protection is required according to local electrical requirements Figure 64 Main Input Schematic Red line 1 Ground Black line 2 connected to vs panel wall To External AC Disconnect connected to panel wall To Compressor Terminal Block Figure 65 Line Reactor Connections 110 Danfoss Turbocor Compressors Inc CSS IOP DO01 L 1 V06 0 Installation and Operation Manual EMI EMC Filter Installation Instructions 1 Mount the filter on the floor or on a wall in a vertical position 2 Ensure there is a minimum of 60mm 2 3 8 of space for the cooling slots 7 3 4 Line Side Connection Input and output filter leads should be separated by a maximum practical distance within the enclosure and should be routed separately in interco
46. d LIQ LEV1 Liquid Level 2 control using a level sensor connected to the terminals on the compressor I O Board labeled LIQ LEV2 For liquid level sensing two types of level sensors can be used a level sensor with a supply of 15VDC and an output of 0 5VDC or a resistive type level sensor 0 90 Ohm see Table 4 Refer to vendor documentation for wiring these types of sensors to the compressor I O Board Load Balance The Load Balance control mode uses the compressor s own internal control algorithm to determine the best mix of speed control inlet guide vane opening and load balance valve opening Use this mode only if a load balancing valve is installed in the system Since the load balancing valve is connected to the compressor s capacity control algorithm selecting this mode without a valve installed will add a delay to the loading unloading process i e the compressor will try to open and close the valve for 2 minutes rather than close the vane or change the speed Danfoss Turbocor Compressors Inc CSS IOP D01 L1 V06 0 65 Commissioning 5 6 4 66 Analog Output Setup The compressor features a universal Analog output that is proportional to the selected Control Mode This output can be selected as 0 5v DC or 0 10v DC by jumper JP1 on the I O board Rag Setup Wizard ANALOGUE OUTPUT SETUP Determine settings for an input device connected to the ANALOG T terminals Discharge Pressure
47. de Connector erer e 111 Mounting Instructions cC 114 4 Danfoss Turbocor Compressors Inc CSS IOP D01 L 1 V06 0 Installation and Operation Manual Proprietary Notice This publication contains information proprietary and confidential to Danfoss Turbocor Compressors Inc DTC This document may be reproduced and distributed provided no fee is charged the text is not modified and the copyright notice is included DTC reserves the right to make changes without notice in product or component design as warranted by evolution in user needs or advancements in engineering or manufacturing technology DTC has exercised its best efforts to ensure that the information contained in this manual is correct However no warranty of reliability or accuracy is given with respect to the information and DTC shall not be responsible or liable for the correctness or suitability of the information or for any error or omission If you encounter any difficulty in using this manual please forward your query to DTC or its authorized sales agent All brand names and product names used in this manual are trademarks registered trademarks or trade names of their respective holders For product support issues corrections or inquiries contact Product Support product support turbocor com Danfoss Turbocor Compressors Inc 1769 East Paul Dirac Drive Tallahassee Florida 32310 USA Telephone 1 850 504 4800 Fax 1 850 575 2126 www
48. duct specifications 7 3 2 AC Line Cable Connection From External Disconnect NOTE The custo mer is resp onsible for supplying the mounting hardware for the line reactor Figure 65 shows a schematic of the main input circuit and connections to the line reactor Use this schematic as a guide for choosing the location of the line reactor 1 2 Feed the AC line cable through the opening in the side of the main supply panel Attach the AC line wires to the line reactor terminals as shown in Figure 66 Attach the ground cable to the mounting block on the panel wall Ensure there is good electrical mechanical contact between the ground cable and the panel wall Secure the AC line cable to the main supply panel using approved methods i e cable gland 7 3 3 AC Line Cable Connection to Compressor Terminal Le 2 Feed the AC line cable through the opening in the side of the main supply panel Attach the AC line wires to the line reactor output terminals as shown in Figure 67 If a harmonic filter is being installed attach its AC line wires to the line reactor output terminals Attach the ground wire to the mounting block on the panel wall Ensure there is good electrical mechanical contact between the ground wire and the panel wall Secure the AC line cable to the main supply panel using approved methods i e cable gland See Section 4 6 Power Wiring for instructions on completing the AC input connection to the
49. dule performs serial to parallel conversion on the stepper motor drive signals from the BMCC The module also contains four normally open relays under BMCC control Two of the relays drive the motor cooling solenoids and the other two are used to indicate compressor fault status and running status The status relays can be wired to external control circuits Danfoss Turbocor Compressors Inc 83 CSS IOP D01 L1 V06 0 Functional Description Startup Control Startup check Approx 75 secs IGV amp EXV Calibration approx 120 secs Read Demand from Chiller Interface module or Modbus Master or Chiller Control Interlock Closed Wait for fault to be Cleared by demand toggle Check for fault condition No Figure 54 Compressor Controller Operational Flow Chart 1 of 6 84 Danfoss Turbocor Compressors Inc CSS IOP D01 L1 V06 0 Installation and Operation Manual Shutdown Start Ramp up Read demand Set desired rpm IGV EXV s and analog output to prestart positions To Control Demand 0 or Strategy critical fault surge spd Yes startup rpm Lower compressor speed to 0 RPM Set desired rpm surge rpm No Speed 0 Process Analog Inputs pm gt Startup rpm Yes Delevitate shaft Control Start Active Open IGV to minimum Drive EXV s to zero position 096 Close EXV s Figure
50. e Just em 16 Click Next Danfoss Turbocor Compressors Inc 49 CSS IOP D01 L1 V06 0 Commissioning i Danfoss Turbocor Service Monitor Tool The installer is ready to install Danfoss Turbocor Service Monitor Tool on your computer Click Next to start the installation Figure 31 Service Monitor Tool Confirm Installation Form 17 Click Next The Service Monitoring Tool will install 50 Danfoss Turbocor Compressors Inc CSS IOP D01 L1 V06 0 Installation and Operation Manual GG Danfoss Turbocor Service Monitor Tool er E Ehe Danfoss Turbocor Service Monitor Tool has been successfully installed Click Close to exit Please use Windows Update to check for any critical updates to the NET Framework Close Figure 32 Service Monitor Tool Successful Install 18 Click Close 5 3 Establishing a Connection The Service Monitoring Tool communicates with the compressor via the Modbus protocol using either the RS 232 or RS 485 connection at the Compressor I O Board RS 485 communication requires an adapter appropriate for the computer being used user supplied RS 232 communication is recommended for cable lengths not exceeding 15 meters 50 feet between the PC and compressor For cables that run up to 100 meters 328 feet RS 485 communication is recommended Always use shielded twisted pair cable for data communications The Modbus protocol was originally developed to exchange inform
51. e impeller Centrifugal compressor Snubbers Capacitors responsible for eliminating electrical noise harmonics from the DC Bus before it reaches the IGBT Danfoss Turbocor Compressors Inc 105 Acronym Term Definition Soft Start Board Soft Starter SST Surge Thrust Bearing Ton Touchdown Bearings TT Two Stage Centrifugal compressor TXV UL Up Trip Voltage VAC Vaned Diffuser Vaneless Diffuser VDC VFD The Soft Start Board limits in rush current by progressively increasing the conduction angle of the SCRs This technique is used at compressor startup while the DC capacitors are charging up The Soft Start Board takes as input a 3 phase voltage source at 50 60Hz from the input terminal and a DC voltage signal from the SCR output In turn it outputs pulses to the SCR and provides power to the High Voltage HV DC DC Converter All voltages from the Soft Start Board are with respect to the positive DC bus and not the compressor ground Saturated Suction Temperature The condition at which the compressor cannot sustain the discharge pressure allowing refrigerant to temporarily and rapidly re enter the compressor fluid path creating a cavitating effect This is an undesirable situation that should be avoided A bearing that absorbs the axial forces produced in a centrifugal compressor by the refrigerant pressure differential across the impeller The basic unit for measuring the rate of heat tran
52. each and one thrust axial bearing see Figure 60 Axial Bearing cross sectional view Rear Radial Bearing Front Radial Bearing Rotor Zz x axial bearing Impeller End front amp rear radial bearing front amp rear radial bearing Axes of Control Figure 60 Magnetic Bearing Configuration Bearing Control System The Bearing Control System uses rotor position feedback to close the loop and maintain the rotor in the correct running position see Figure 60 The Bearing Controller issues position commands to the Bearing PWM Amplifier The position commands consist of five channels with each channel allocated to one of the five bearing actuator coils one coil for each axis The amplifier uses IGBT technology to convert the low voltage position commands to the 250VDC PWM signals that are applied to each bearing actuator coil Rotor position sensors are located on rings attached to the front and rear radial bearing assemblies The front sensor ring contains sensors that read the rotor position along the X Y and Z axes The rotor position along the Z or axial axis is read by measuring the distance between the sensor and a target sleeve mounted on the rotor The rear sensor ring contains sensors that read the position along the X and Y axes Information from the position sensors is continuously fed back to the bearing controller Danfoss Turbocor Compressors Inc 91 CSS IOP D01 L1 V06 0 Functional De
53. ed Monitor 0000000000 Universal Analog Output Universal Analog Output ST je O0O000 000 ASS 6300 rev 3 PCB 74028 ev 3 Danfoss Turbocor Compressors Inc CSS IOP D01 L1 V06 0 Figure 19 Grounding Check 31 Installation 4 5 6 Voltage Free Contacts Prior to connecting the interlock terminals of the compressor I O board measure the resistance across the customer s interlock terminals see Figure 20 Ensure that the interlock contacts are closed The measured value should be less than 10 Interlock Circuit 0 0V l Lock Interlock Circuit Figure 20 Interlock Circuit Tests Measure the voltage between each customer interlock terminal and the frame ground while the interlock contacts are open and closed In either contact state if the measured voltage is not zero verify the source of the voltage Do not connect the interlock terminals until the voltage Source is removed see Figure 20 32 Danfoss Turbocor Compressors Inc CSS IOP D01 L1 V06 0 Installation and Operation Manual 4 6 Power Wiring This section describes the connection of the power wiring to the compressor NOTE The AC in put cable should be CSA UL or CE approved 3 wire with a comm on shie Id an d single ground It is recommended that the cable be double jacketed for exam ple a teck cab le type The cable must be rated for 90 C 194 F minimum with am aximumcu rrent rating corresponding to the LRA va lue
54. erify that they match the display readings Using a temperature probe check the suction intermediate and discharge temperatures and verify that they match the display readings Ensure operational temperatures and pressures are as per application N A N A 5V 45V__ MIO 24V 250V___ 15V Commissioning Notes Attach a screen capture of the monitor display to this log sheet Danfoss Turbocor Compressors Inc CSS IOP D01 L1 V06 0 Installation and Operation Manual Technician Name Company Date Telephone No Note This commissioning report must be duly completed and returned to DTC for warranty pur poses Danfoss Turbocor Compressors Inc 117 CSS IOP D01 L1 V06 0 This Page Left Intentionally Blank Installation and Operation Manual A abnormal conditions 83 analog mode 94 B Backplane 89 LEDs 90 Bearing Control System 91 Bearing Motor Compressor Controller 81 Bearing PWM Amplifier 83 C Capacity Control 82 check main supply voltage 99 checks iniital checks with compressor off 38 iniitial with compressor on 39 initial system 35 system 38 Chiller Interface Module mounting 24 chiller mode 95 commissioning 35 I O jumper setup 35 system checks 35 Component Locations 80 Compressor fundamentals 75 general data page 42 operating modes 94 compressor placement 19 Compressor Control 82 overview 79 Compressor Controller operational flow chart 84 85
55. essor The serial ports listed reflect the names of the serial ports currently available on the host computer Baud Rate 19 200 or 38 400 baud 2 To view recent compressors connected through the Service Monitoring Tool click Recent Compressors Select the compressor to connect 3 To search for a compressor enter the Search Addresses and then click Search Select the compressor to connect 4 Click Connect to connect to the compressor The connection status and compressor details display in the lower right pane of the Compressor Connection Manager 5 If necessary change the access level Enter the access code in the Access Code field and then click Submit Confirm that the correct access level is displayed in the right hand pane of the Compressor Connection Manager Controlling User Access The access code system allows OEM customers to set their own unique access codes thereby restricting access to company authorized personnel only These access codes control access to all adjustable parameters via the Modbus communications protocol The access levels are Level 1 This level is Read Only and is intended for the plant operator building maintenance personnel or owner This is the default user level and no access code is required e Level 2 This level allows minimal adjustments to be made such as leaving chilled water temp display units chiller enable disable etc and is intended for the technician commission
56. he 15VAC is not within 10 percent replace the Soft Start Board refer to the Service Manual If the 15VAC is correct proceed to the next step 21 Verify the SCR gate terminals refer to the Service Manual If the SCR gate terminals are not within specifications replace the SCRs refer to the Service Manual If the gate terminals are OK proceed to the next step 22 Verify the SCRs refer to the Service Manual If the SCRs are not within specifications replace them refer to the Service Manual If the SCRs are OK replace the Soft Start Board refer to the Service Manual see DANGER The DC Bus Test Harness is not designed to be left in the compressor during normal op eration When voltage checks are complete dis connect and remove the DC Bus Test Harness Danfoss Turbocor Compressors Inc 17 CSS IOP D01 L1 V06 0 Safety Summary ORIGINAL CONNECTIONS Soft Start Board Top Side Harness to DC Bus and AC Line Harness to DC DC Converter CONNECTIONS WITH DC BUS TEST HARNESS Harness to Soft Start Board DC Bus and AC Line Top Side Harness to DC DC Converter DC Bus Test Harness Volt Meter Terminals c Figure 7 DC Bus Test Harness Connection Diagram 18 Danfoss Turbocor Compressors Inc CSS IOP D01 L1 V06 0 4 1 4 2 4 3 Installation and Operation Manual Installation Unpacking and Inspection The compressor should be carefully inspected for vis
57. hod Analog Input 0 to 10vde Modbus Network Compressor is a slave on a R5485 Network Chiller Control Compressor generates its own demand Manual Control Figure 38 General Compressor Settings 3 Select the appropriate units of measurement metric or imperial see Figure 38 4 Select the appropriate compressor control method Analog Input Compressor loading is controlled using an Analog demand signal of 0 10VDC from an external controller The variable demand signal corresponds to the range of 0 percent to 100 percent maximum power available Modbus Network The compressor receives a demand from an external computer PLC or building management system using the Modbus protocol on an RS 232 or RS 485 communication link Chiller Control This mode is fully automatic The chilled water temperature is controlled using a temperature sensor connected directly to the compressor I O Board This mode can also be used to control evaporating temperature which is derived from the suction pressure measurement A control mode must be selected to continue with the commissioning process While the compressor is linked to an external controller changes cannot be made to the Loading Demand Inlet Guide Vane or Desired Shaft Speed fields via theService Monitoring Tool These values are being determined based on the signal being received from the external controller 5 Click the Next button Danfoss Turbocor Compressors
58. ible signs of damage Check for loose bolts and damage to covers or outer casing Damage should first be reported to the carrier not DTC DTC Customer Support and Service can be contacted to assist in determining the extent of damage or if compressor should be returned to DTC Damage should be specified on the Bill of Lading or transportation freight forwarder documentation Open all containers and verify all parts against the packing list Report any shortages to DTC Contact DTC to conduct report actions via the Incident Report form Rigging Requirements Care must be exercised at all times when rigging or handling the compressor to protect it from damage Two eyebolts one at each end are provided for compressor rigging A spreader bar should be used to safely position the compressor into its final location see Figure 8 Unit Placement 1 If mounting the compressor with the DTC mounting kit refer to Appendix B Mounting Kit Instructions if not install four isolation pads in accordance with the footprint dimensions given in Figure 9 2 Mount the compressor onto the isolation pads Ensure the compressor mounting rails are properly isolated from the base frame once the attaching hardware is secured for example the screw should not extend from the compressor mounting rails to the base frame see Figure 10 and Figure 11 3 Check that the compressor mounting rails are level x 5mm 3 16 in the lateral and longitudinal planes Danfos
59. id floo d back and da mage to th e compressor Danfoss Turbocor Compressors Inc 63 CSS IOP D01 L1 V06 0 Commissioning 64 2 Select the control mode for the expansion valve Available options are superheat liquid level or load balance See Table8 for a description of the modes Enter the Starting Valve Position 96 If desired at compressor startup the valves can be Set to open to a pre start value for a given time This value represents the percentage of maximum steps and is sent to the motor when the shaft starts to rotate The stepper motor will hold at this position until the stepper start delay timer has expired Enter the Valve Starting Position Delay Time This parameter represents the time in seconds that the starting valve position is in effect The timer starts to count down when the drive is enabled Enter the Control Setpoint suction superheat or Liquid level in accordance with the control mode selected Not applicable to load balance control mode as compressor fixes best position Enter the Valve Control Loop Speed This value represents the reaction time of the control loop to a process error and replaces the PID proportional integral and derivative controller gains Enter the Minimum Closure During Operation This is the minimum close position for the valve while the compressor is in operation Click Next to continue Repeat steps 1 through 7 for electronic expansion valve 2 Click
60. in tegral strainert o protectth e co oling circ uit fr om blockage T he motor cooling line re quires the installation of a se rvice valve not included to enable r efrigerant iso lation during comp ressor servicing The compressor is pres surized with nitrogen to 173 kPa 25 psi Pressure should be relieved th rough th e Schrader valveon the compressor end bell pr ior tore moving th e suction a ndd ischarge conn ection b lanking plates see Figure 13 1 After releasing the pressure remove the suction and discharge connection blanking plates from the new compressor 2 Ensure flange surfaces are clean and free from debris Install new O rings 3 Attach the suction discharge and economizer if applicable connections Install O rings Ensure th e discharge line is fitted witha non return valve Dur ingasur ge condition or shutdown the non return valve prevents reverse flow in to the dischar ge po rt which can cau se damage to compressor components Dry fit the pipework to th e valves andver ify the connections are aligned and there is no strain on the joints 4 Solder all joints according to approved practice ensuring that dry nitrogen is used at all times 5 Attach the motor cooling connection at the rear of the compressor see Figure 13 6 Install a strainer in the suction line It should be located between the compressor and the service valve as close as possible to the suction port of the compressor
61. ing the compressor and performing limited fault finding operations A Basic Level User access code is required Level 3 This level allows most adjustments to be made such as operating the compressor in manual mode or calibrating the bearings and is intended for the OEM trained certified technician An OEM Level User access code is required Danfoss Turbocor Compressors Inc CSS IOP DO01 L 1 V06 0 Installation and Operation Manual 5 4 5 Changing Access Codes This feature can only be accessed with an OEM user access level To change access codes complete the following steps 1 To change the access code select Access Codes from the Advanced menu item The Access Codes window displays 23 Access Codes Select the Access Code to Change Low Level Access Code New Access Code H Current Access Code 0 New Access Code D a Confirm Access bd Change Access Code Figure 35 Access Codes Window 2 Select the appropriate radio button 3 Select the current access code followed by the new access code for the selected user level if you enter the incorrect access code nothing will be changed 4 Re enter the new access code in the Confirm Access Code field 5 Click the Change Access Code button The new access code does not take effect until you cycle power to the compressor so that the information is written to the Eeprom Danfoss Turbocor Compressors Inc 55 CSS IOP D01 L1 V06 0 Commissioning
62. ins input cover to the compressor Lift away cover 2 With a voltmeter measure the voltage between each phase and a grounding point such as the main input bracket 3 Verify that the voltage is as per design value 10 4 Replace and secure the mains input cover Danfoss Turbocor Compressors Inc 99 CSS IOP D01 L1 V06 0 This Page Left Intentionally Blank Installation and Operation Manual Appendix A Acronyms Acronym Term Definition Alarms AHRI ASHRAE ASIC ASTM Axial Bearing Backplane Balance Piston BMCC Bus Bars Capacitor Cavity Sensor CE Choke Compression Ratio CSA DC Bus DC Capacitor Assembly Alarms indicate a condition at the limit of the normal operating envelope compressor alarms will still allow the compressor to run but speed is reduced to bring the alarm condition under the alarm limit Air Conditioning Heating and Refrigeration Institute www ari org www ahrinet org American Society of Heating Refrigeration and Air Conditioning Engineers www ashrae org Application Specific Integrated Circuit American Society for Testing and Materials www astm org Bearing that controls the horizontal movement Z axis of the motor shaft A PCB for the purpose of power and control signal transmission Many other components connect to this board Component within the compressor that provides primary counter to impeller thrust Impeller thrust is trimmed
63. iode Down Trip Voltage DC DC converters supply and electrically isolate the high and low DC voltages that are required by the control circuits When the compressor is switched on the High Voltage HV DC DC Converter receives its 15VAC supply from the Soft Start Board Once the DC bus voltage has risen to a pre determined level the HV DC DC Converter s onboard circuits are powered by the DC bus 460 900VDC The HV DC DC Converter delivers 24VDC with respect to OV to the Backplane and HV 250VDC with respect to HV to the magnetic Bearing Pulse Width Modulation PWM Amplifier via the Backplane A dielectric is a nonconducting substance Although dielectric and insulator are generally considered synonymous the term dielectric is more often used when considering the effect of alternating electric fields on the substance while insulator is more often used when the material is being used to withstand a high electric field Part of a centrifugal compressor in the fluid module that transforms the high velocity low pressure gas exiting the impeller into higher pressure low velocity gas discharged into the condenser A two terminal device between which current may flow in one direction only A voltage threshold where if the incoming AC voltage drops below it the SCRs will shut down D Sub A type of connector plug male and female for control wiring The RS 232 and large connectors on either side of the I O cable are
64. ioning sequence you can download the commissioning data to the compressor save it to a file for later use or do both Download the settings Save to compressor Load Configuration from file Save Configuration to file Figure 45 Download Settings Window 5 6 6 2 Downloading Commissioning Data to the Compressor To download the new commissioning data to the compressor 1 Click the Save to Compressor button ever attempt a download while the compressor is running as it can lead to a loss of compressor control Open inter lock cont acts on the Compressor I O Board befor e d ownloading configuration data 70 Danfoss Turbocor Compressors Inc CSS IOP D01 L1 V06 0 Installation and Operation Manual In order for the commissioning data to take effect perform the following steps 2 When the message Done Cycle power before running the compressor appears turn OFF power to the compressor see Figure 46 Wait at least 5 minutes then check that the LEDs on the Backplane and or compressor UO Board are OFF za Setup Wizard X Download the settings Save to compressor Done cycle power before running the compressor Load Configuration from file Save Configuration to file Figure 46 Download Settings Window After Download 3 Click Finish A report is displayed Danfoss Turbocor Compressors Inc CSS IOP D01 L1 V06 0 71 Commissioning Main Report iITURBOCOR Serial_Number PCB
65. ious modes 4 Using a pressure gauge check the suction and discharge pressures and verify that they match the display readings If the compressor is equipped with the economizer option also check the intermediate pressure Danfoss Turbocor Compressors Inc 73 CSS IOP D01 L1 V06 0 Commissioning 5 Using a temperature probe check the suction and discharge temperatures and verify that they match the display readings 6 Ensure that operational temperatures and pressures are as per application After the compressor has been operating for 100 hours at 80 percent to 100 percent load remove the suction strainer 74 Danfoss Turbocor Compressors Inc CSS IOP D01 L1 V06 0 Installation and Operation Manual Functional Description 6 1 Compressor Fundamentals Compressor operation begins with a call for cooling from a chiller controller or from the compressor itself in the chiller control mode The compressor controller then begins compressor spin up 6 1 1 Main Fluid Path The following paragraphs describe the flow of refrigerant from the intake to the discharge port of the compressor see Figure 48 and Figure 49 The refrigerant enters the suction side of the compressor as a low pressure low temperature super heated gas The refrigerant gas passes through a set of adjustable Inlet Guide Vanes IGVs that are used to control the compressor capacity at low load conditions The first compression element the gas encounters is
66. is the central processor of the compressor Danfoss Turbocor Compressors Inc 81 CSS IOP D01 L1 V06 0 Functional Description 6 2 3 1 6 2 3 2 6 2 3 3 6 2 3 4 6 2 3 5 82 Compressor Control The Compressor Controller is continuously updated with critical data from external sensors that indicate the compressor s operating status Under program control the compressor controller can respond to changing conditions and requirements to ensure optimum system performance Figure 54 to Figure 59 shows how the controller responds to chiller demands Capacity Control One ofthe Compressor Controller s primary functions is to control the compressor s motor speed and IGV position in order to satisfy load requirements and to avoid surge and choke conditions However the majority of capacity control can be achieved via motor speed Expansion Valve Control The on board Electronic Expansion Valve EXV controller uses a simplified loop gain to control the response characteristics of the valve The valve opening is determined by either superheat or liquid level sensing Depending on the application a load balancing hot gas bypass valve can be driven by the auxiliary EXV output Load balancing allows the compressor to obtain lower capacities at higher pressure ratios The valve opens to lower the overall pressure ratio and thereby reduces the lift enabling the compressor to reduce speed unload Motor Bearing Control The magnetic
67. l changes that do not affect technical content Danfoss Turbocor Compressors Inc 7 CSS IOP D01 L1 V06 0 This Page Left Intentionally Blank Installation and Operation Manual 1 Introduction The purpose of this manual is to inform original equipment manufacturers OEMs contractors and their engineers of the recommended methods for proper installation and operation for the Danfoss Turbocor twin turbine two stage centrifugal compressor 2 Tools The following table lists the hand tools required to perform the procedures outlined in this manual see DANGER All electrical instruments must be rated to 1kVAC and 60 OVDC This includ es voltage leads an d probes Table 1 Service Tools Test Equipment e 15 16 deep socket 13mm 24mm combination wrenches Adjustable 14 wrench Torque wrenches 22 Nm 200 in Ibs 75 Nm 55 ft Ibs Precision slotted screwdriver Phillips 2 screwdriver Multimeter 1KVAC 600VDC with ammeter clamp Voltmeter minimum Cat 3 with diode setting and capable of reading 1KVDC Level Danfoss Turbocor Compressors Inc 9 CSS IOP D01 L1 V06 0 Safety Summary 10 Safety Summary Safety Warnings Safety precautions must be observed during installation startup and service of the compressor due to the presence of refrigerant charge and high voltage hazards Only qualified personnel should install start up and service this equip
68. ls 6 7 19 10 29 Updated Spare P description 6 7 19 10 26 Updated Figure 16 Compressor I O Board Connections 6 7 19 10 31 Added Figure 19 Grounding Check 6 7 19 10 33 Updated Power Wiring note to include grounding 6 7 19 10 33 Updated Figure 21 Typical Electrical Connections 6 7 19 10 34 Updated and re ordered procedures 5 6 and 7 in Power Wiring Procedure 6 7 19 10 34 Updated Figure 23 Compressor AC Input Terminals 6 7 19 10 40 Updated step 6 in Initial Checks Compressor ON table 6 Danfoss Turbocor Compressors Inc CSS IOP D01 L 1 V06 0 Installation and Operation Manual Version Date Page Description of Change 6 7 19 10 35 to 73 Updated entire Compressor Configuration section with Service Monitoring Tool Version 86 information 6 7 19 10 73 Updated Running Checks procedures 6 7 19 10 80 Updated Figure 53 Component Locations 6 7 19 10 96 Added step in Electronic Inspections section of Table 10 Preventive Maintenance Tasks 6 7 19 10 99 Changed T25 Torx bit and driver to 2 Phillips bit and driver 6 7 19 10 109 Updated step 4 to main supply panel from box connector 6 7 19 10 109 Added step 4 to secure AC line cable to the main supply panel 6 7 19 10 110 oe Figure 65 Line Reactor Connections to include line 1 2 and 6 7 19 10 114 Modifed Mounting Tools procedures to remove tools used NOTE This list does not include editoria
69. mains on even when the compressor is in the off state The compressor motor requires a variable frequency three phase source for variable speed operation The AC line voltage is converted into a DC voltage by Silicon Controlled Rectifiers SCRs DC capacitors at the SCR output serve as energy storage and filter out the voltage ripple to provide a smooth DC voltage The Insulated Gate Bipolar Transistor IGBT is an inverter that converts the DC voltage into an adjustable three phase AC voltage Pulse Width Modulation PWM signals from the Bearing Motor compressor Controller BMCC control the inverter output frequency and voltage By modulating the on and off times of the inverter power switches three phase variable sinusoidal waveforms are obtained If the power should fail while the compressor is running the motor switches into generator mode thereby sustaining the capacitor charge The rotor can then spin down safely in a controlled sequence preventing damage to components Soft Start Board The Soft Start Board limits inrush current by progressively increasing the conduction angle of the SCRs This technique is used at compressor start up while the DC capacitors are charging up The soft start function and the variable speed drive combined limit the inrush current at startup Bearing Motor Compressor Controller The hardware and software for the compressor controller and the bearing motor controller physically reside in the BMCC The BMCC
70. ment Safety information is located throughout the manual to alert service personnel of potential hazards The safety information is identified by the headings DANGER and CAUTION DANGER signifies an essential operating 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 CAUTION signifies an essential operating 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 The following DANGER notices must be strictly followed e DANGER The compressor is p ressurized with nitr ogen to 173 kPa 25 p si Pre ssure must be relieved through the Schrader valve on the comp ressor end bell prior to r emoving the b lanking p lates see Figure 13 Iso lation an d r ecovery of the refrigerant must bep erformed byaq ualified technician Always wear Dt opersafe ty equipment when handling refrigerants Danfoss Turbocor Compressors Inc CSS IOP D01 L1 V06 0 Danfoss Turbocor Compressors Inc CSS IOP D01 L1 V06 0 Installation and Operation Manual see DANGER This e quipment co ntains haza rdous volt ages that can cause injury or death Only qualified and trained per sonnel sh ould wo rk on hig h voltage electrical equipment Removing the mains input cover will expose you to
71. minals on the Interface module Consult vendor documentation for sensor lead identification Resistive type Float Sensor If using a resistive type sensor install jumpers between LVL pins 1a and 2a and pins 1b and 2b Connect the sensor leads to the and S terminals on the Interface module Superheat Control For superheat control adjustable via the compressor control monitoring program install jumpers between LVL pins 2a and 3a and pins 2b and 3b JP7 Supplies 5VDC to pin 1 on the 9 pin connector to power an optional Bluetooth adapter Install if Bluetooth device is being used in RS 232 connection DB9 36 Danfoss Turbocor Compressors Inc CSS IOP D01 L1 V06 0 Installation and Operation Manual Row b Rowa d 3svdS 1 3avds Row b Rowa Figure 24 UO Jumper Location Danfoss Turbocor Compressors Inc 37 CSS IOP D01 L1 V06 0 Commissioning 5 1 2 System Checks This section covers the initial system checks Table 5 Initial Checks Compressor OFF Step Procedure Verify the following 1 Confirm mains power is isolated Remove the top and mains input covers Check DC bus voltage Check that the mains input terminals and all mounting screws DC bus SCR etc are tight Replace the mains input and top covers see Figure 25 2 Compressor is powered OFF 3 Compressor is level 5mm 3 16 4 External pipework is adequately sup
72. ncel Various internal components The Code Project Open License CPOL 1 02 Preamble This License governs Your use of the Work This License is intended to allow developers to use the Source Code and Executable Files provided as part of the Work in any application in any form IDo Not Agree Agree Figure 29 License Agreement 12 If any of the prerequisites Crystal Reports runtime NI LabWindows CVI Run Time Engine or NET need to be installed the program will install them for you Follow the directions on the windows for the installation 13 Read the License Agreement and then click Agree 14 Click Next 48 Danfoss Turbocor Compressors Inc CSS IOP D01 L1 V06 0 Installation and Operation Manual CL e e w Danfoss Turbocor Service Monitor Tool The installer will install Danfoss Turbocor Service Monitor Tool to the following folder To install in this folder click Next To install to a different folder enter it below or click Browse Folder C Program Files Danfoss TurbocorsD anfoss Turbocor Service Monit Install Danfoss Turbocor Service Monitor Tool for yourself or for anyone who uses this computer Everyone Just me Figure 30 Service Monitor Tool Installation Form The default path is shown The following message is also displayed Install Danfoss Turbocor Service Monitor Tool for yourself or for anyone who uses this computer 15 Select one of the following Everyon
73. ncy distortions found in electrical power subjected to continuous disturbances Hydrofluorocarbon A positive pressure chlorine free refrigerant having zero ozone depletion potential A motor that is sealed within the refrigerant atmosphere inside the compressor Integrated compressor Design Institute of Electrical and Electronic Engineers www ieee org Insulated Gate Bipolar Transistor The IGBT Inverter converts the DC bus voltage into an adjustable frequency and adjustable amplitude three phase simulated AC voltage Inlet Guide Vanes The IGV assembly is a variable angle guiding device that pre rotates refrigerant flow at the compressor intake and is also used for capacity control The IGV assembly consists of movable vanes and a motor The vane angle and hence the degree of pre rotation to the refrigerant flow is determined by the BMCC and controlled by the Serial Driver The IGV position can vary between approximately 0 percent and 110 percent open Rotating part of a centrifugal compressor that increases the pressure of refrigerant vapor from the cooler pressure to the condenser pressure Danfoss Turbocor Compressors Inc 103 CSS IOP D01 L1 V06 0 Acronym Term Definition UO Board Inverter IPLV LBV LED Levitation Line Reactor LLSV LR LRA Mid Bus Modbus Monitor Program MOP Motor Back EMF Input Output Board facilitating a connection between the compressor controller a
74. nd or PC and the compressor It allows the user to control the compressor and allows the compressor to return status and sensor information to the user See IGBT Integrated Part Load Value Load Balance Valve A modulating valve that can be installed to bypass discharge gas to the inlet of the evaporator to provide gas flow at certain conditions such as startup surge and further unloading of the compressor Light Emitting Diode The elevation or suspension of the compressor shaft by the magnetic field created by the magnetic bearings A transformer like device designed to introduce a specific amount of inductive reactance into a circuit When this occurs it limits the change in current in the line which in turn filters the waveform and attenuates electrical noise and harmonics associated with an inverter drive output Liquid Line Solenoid Valve Line Reactor Locked Rotor Amps A connection between the capacitors allowing them to be connected in series and in parallel simultaneously Two capacitors in a series make up the DC and two in a series make up the DC and those two sets of two are connected in parallel A serial communications protocol published by Modicon in 1979 for use with its programmable logic controllers PLCs It has become a de facto standard communications protocol in industry and is now the most commonly available means of connecting industrial electronic devices Modbus allows for communication between many de
75. nnected external circuits see Figure 18 Prior to connecting the control wiring to the compressor I O board check for improper grounding Improper grounding can be identified by measuring the voltage between the customer s negative terminals and the ground J1 COM or Modbus shield terminal on the compressor I O board see Figure 19 If the measured voltage is not zero determine the source of the voltage The most likely cause of voltage is insufficient insulation of the external circuit In case of uncertainty of the grounding connect the negative terminals of the external circuit to a ground and then connect the external ground to the ground on the compressor I O board Danfoss Turbocor Compressors Inc 29 CSS IOP D01 L1 V06 0 Installation 30 8 yOIUaS ww IC Igor Caes 1S 2 ONY e sniv nna Snaaaas d ELIN WM SL re 9 oO lo O o OG d eg OO OO IN Interlock Contact Safety N C IN Interlock Contact Safety N C OUT Motor Speed Monitor OUT Motor Speed Monitor OUT Universal Analog Output OUT Universal Analog Output Figure 18 Interlock and Motor Speed Connections Danfoss Turbocor Compressors Inc CSS IOP D01 L1 V06 0 Installation and Operation Manual OOOO OOOO i OOoOO ss Te 2i Zeg ei Le 1 33v j igit i 0 0V Motor Speed Monitor Motor Spe
76. nnecting conduits when used see Figure 66 1 Insert the line wires into the terminals labelled L1 L2 and L3 on the Line side of the filter Tighten the terminal screws 2 Attach the ground lug to the main ground bus and tighten the nut see Figure 67 NOTE A short heavy stranded conductor from the filter chassis to the main ground bus is recommended for top performance A battery braid litz wire or flexible welding cable with man y fine strands is recommended for best grounding performance 7 3 5 Load Side Connection 1 Insert the load wires from the line side of the line reactor into the terminals labelled L1 L2 and L3 on the Load side of the filter Tighten the terminal screws 2 Attach the ground lug to the main ground bus and tighten the nut Harmonic Filter If a Harmonic Filter is to be installed follow the manufacturers instructions Connection of a Harmonic Filter should be made on the Load side of the Line Reactor Figure 9 Danfoss Turbocor Compressors Inc 111 CSS IOP D01 L1 V06 0 112 CORRECT INCORRECT Interconnection s Interconnection Layout al Layout Filter Enclosure Condut ThLoad sm d Figure 66 Interconnection Layout SHORT HEAVY BRAIDED CABLE FILTER GROUND LUG MAIN GROUND BUS Figure 67 Grounding Diagram Danfoss Turbocor Compressors Inc CSS IOP DO01 L 1 V06 0 Installation and Operation Manual Appendix
77. nual Never attempt a download while the compressor is running as it can lead to a loss of compressor control Open inter lock cont acts on the Compressor I O Board befor ed ownloading configuration data Click the Load Configuration From File button see Section 5 6 6 4 Using a Saved Configuration File 2 Inthe Open File dialog box browse to the location of the configuration ttc file 3 Click Open 4 Click Download to Compressor button 5 When the message Done Cycle power before running the compressor appears turn OFF power to the compressor see Figure 46 Wait at least 5 minutes then check that the LEDs on the Backplane and or Compressor I O Board are OFF 6 Close the Service Monitoring Tool 7 Turn ON power to the compressor 8 Restart the Service Monitoring Tool 5 7 Running Checks This section contains the running checks that should be performed following compressor configuration 1 Disable Power Remove the mains input cover Enable power Using a voltmeter check the line voltages at the Compressor terminals and verify that they match the display readings under the heading of Soft Start Data on the VSPMM form of the Service Monitoring Tool Disable power Replace the mains input cover Enable power 2 If necessary clear alarms before running the compressor 3 Start compressor Refer to the Service Monitoring Tool User Manual for instructions on starting the compressor in var
78. o cool the electronic mechanical and electromechanical components see Figure 50 and Figure 51 e ee DANGER A minim um op erating pr essure ratio of 1 5 is required to maintain ad equate coolin g of th e compressor The sub cooled refrigerant enters the compressor through two solenoid valves and associated fixed orifices located behind the service access cover The orifices cause the refrigerant to expand thereby lowering its temperature Both valves operate relative to the temperature at the sensors that are located at the Insulated Gate Bipolar Transistor IGBT Inverter and motor cavity When the temperature at either sensor reaches a pre determined threshold one solenoid valve opens If the temperature increases to the point where it equals a higher temperature threshold the second solenoid valve opens From the outlet of the orifices the refrigerant is directed to the heatsink plate of the IGBT Inverter and then to the underside of the SCR heatsink From there the refrigerant passes through grooves surrounding the motor stator As the refrigerant flows through the grooves it vaporizes into a gas At the coil outlet the refrigerant gas is channeled back to the suction inlet via the motor cavity thereby cooling the rotor The TT350 TT400 TT500 and some models of the TT300 use a split cooling method where the motor and electronics portions are cooled separately by refrigerant liquid Danfoss Turbocor Compressors Inc
79. oduce current into the circuit 3 Analog outputs such as Motor Speed must be received by the external circuit without sending current back to the Compressor Interface Module 4 All interlock and analog output cables must be shielded with one end of the shield connected to the Compressor Interface Module ground The other end of the shield can not be grounded as this would create a ground loop NOTE 1 The maximum values are the tested length of the cables The compressor functionality has not been proven with cable length above the maximum values specified here RS485 shielded twisted pair data cable Compressor I O Board max 100m 328 feet Sensor Stepper Motor Cables Compressor max 20m 65 feet A Cable supplied with compressor Extension Cable 1 m y T s 5m 16 4 feet max 5m 16 4 feet p RS232 Cable Ba Um 7 KS See Note 2 max 15m 50 feet NOTE 2 EXTENSION CABLE SPECIFICATION If an I O extension cable is used heat shrink tubing should be applied to the mating cable connectors to maintain good Cable UL style 2464 44 conductors 24AWG conductivity and protect the connection from heat and humidity stranded copper foil braid shield PVC jacket Connectors A male 44 pins high density D sub to a female 44 pins high density D sub Figure 15 UO Wiring Specifications Danfoss Turbocor Compressors Inc 25 CSS IOP D01 L1 V06 0 Installation
80. ompressor Ports 114 Danfoss Turbocor Compressors Inc CSS IOP DO01 L 1 V06 0 Appendix E Commissioning Log Job Details Job Name Customer equipment manufacturer Installation and Operation Manual Compressor Serial No O Equipment Serial No L C Contractor L Contact O Tel O L Application Air cooled chiller DX Air cooled chiller flooded Water cooled chiller DX Water cooled chiller flooded Air cooled rooftop Evaporatively cooled chiller DX Evaporatively cooled chiller flooded Evaporatively cooled rooftop Retrofit Other specify Danfoss Turbocor Compressors Inc CSS IOP D01 L1 V06 0 115 116 Step Procedure Display Value Measured Value Confirm that the line voltage is as per rated input 10 Remove the mains input cover Using a voltmeter check the line voltages at the compressor terminals and verify that they match the display readings under the heading of Soft Start Data on the VSPMM form of the Monitor Program Replace the mains input cover Check that all DC voltages on the Backplane are within the specified range as follows P S Range 5V 49 514V 15V 14 7 15 6V 17V 16 6 17 5V 24V 23 7 24 5V 250V 237 5 262 5V 15V 14 6 15 7V Complete the commissioning sequence using the Monitor Program Using a pressure gauge check the suction intermediate and discharge pressures and v
81. ported and aligned to the compressor ports 5 Electrical power and control wiring are connected in accordance with Danfoss Turbocor specifications and application requirements 6 ger switches customer supplied are connected to the interlock circuit and all contacts are close 7 System was leak tested evacuated and charged with refrigerant in accordance with industry standards 8 Compressor I O Board terminals are tight 9 Remove the service side cover Check that all modules and cable connectors are secure Check that the PWM module s heatsink mounting screws are tight and that the heatsink is firmly seated against the main compressor housing see Figure 25 10 Check that size and type of fuses installed are according to specifications 11 Check grounding 12 All refrigerant service valves including motor cooling liquid line are open 13 Installation and orientation of discharge line check valve 14 Continue the steps in Table 6 38 Danfoss Turbocor Compressors Inc CSS IOP D01 L1 V06 0 Installation and Operation Manual Service side Cover 6 screws Modules Mains Input Cover 4 screws Figure 25 TT300 Compressor Details Table 6 Initial Checks Compressor ON Step Procedure 1 Check that the chiller unit controller is in OFF mode before the mains power is switched ON to the compressor Verify that the demand input to the compressor is zero Unplug terminal strip J2 from the I O Board 2
82. ree from vibration and electrical noise see Figure 14 DIN Rail Compressor I O Board Profile Figure 14 Compressor I O Board Compressor UO Board Installation 4 5 2 Control Wiring Connections Figure 15 shows the control wiring connections to the compressor UO Board Table 3 provides details for the module terminal connections Incorrect w iring of the terminals can severely damage the module and other components 24 Danfoss Turbocor Compressors Inc CSS IOP D01 L1 V06 0 Installation and Operation Manual The interface cable connects the compressor to the compressor I O board To connect the cable e Plug the cable connector into connector J6 on the compressor I O board For RS 485 communication the total length of the interface cable and control wiring can be extended up to 100 meters 328 feet see Figure 15 If the compressor is going to be monitored over an RS 232 line the total cable length between the compressor and the PC should not exceed 15 meters 50 feet See Section 4 5 3 4 5 3 Control Wiring Connection Guidelines To ensure proper control wiring techniques the following guidelines must be adhered to 1 The ground reference of the external circuit connected to the Compressor Interface Module must be at the same potential as the ground reference on the Compressor Interface Module 2 The Interlock circuit must be voltage free i e all external contactors switches must not intr
83. rent Folder All files folders in archive My Network O Files in Archive Places E 3 Monitoring tool with DOTNET Fix C Open Explorer window Cl overwrite existing Files Skip older files Cancel 9 Select a folder to extract the files to Click Extract The following icons will be created id CVIRTE DTCI Monitor Setup Windows Installer Package 10 Double click on setup changelog Gen Text Document 35 KB 4 i setup Setup setup Setup 11 The Danfoss Turbocor Service Monitor Tool Installation window opens Click Next 46 Danfoss Turbocor Compressors Inc CSS IOP D01 L1 V06 0 Installation and Operation Manual iz Danfoss Turbocor Service Monitor Tool The installer will guide you through the steps required to install Danfoss Turbocor Service Monitor Tool on your computer WARNING This computer program is protected by copyright law and international treaties Unauthorized duplication or distribution of this program or any portion of it may result in severe civil or criminal penalties and will be prosecuted to the maximum extent possible under the law Figure 28 Service Monitor Tool Installation Window Danfoss Turbocor Compressors Inc 47 CSS IOP D01 L1 V06 0 Commissioning E i Danfoss Turbocor Service Monitor Tool Please take a moment to read the license agreement now If you accept the terms below click Agree then Next Otherwise click Ca
84. s Turbocor Compressors Inc 19 CSS IOP D01 L1 V06 0 Installation 20 UK si i A qm 3 Figure 8 Rigging Set up 485 19 09 Mounting Holes 4 places View A II jen 40 REF 1 57 3 8 REF ke 15 gt ep REF 24 75 REF 2 95 Figure 9 Mounting Details eae ee ae L i 300 11 81 REF Danfoss Turbocor Compressors Inc CSS IOP D01 L 1 V06 0 Installation and Operation Manual Spring Screw Compressor Mounting Rail e AN 277 Flat Washer lege Nut Base Frame Screw too long Figure 10 Incorrect Compressor Mounting Pad Installation Spring Screw Compressor Washer i Mounting Rail p Flat Washer e N u Nut L Rubber Mount Xm sus p SR LI e Base Frame Figure 11 Correct Compressor Mounting Pad Installation 4 4 Piping Connections Install new O rings wh en at taching the ba Il valves n on return valves o r flangesto the compressor O r ings mu st be of typ e polychloroprene rubber also kn own b y thetr adena me Neoprene compound C1 278 for R1 34a re frigerant O ring grease must be silicone based and compatible with R134a Danfoss Turbocor Compressors Inc 21 CSS IOP D01 L1 V06 0 Installation The motor cooling line should be channeled from the liquid line see Figure 12 On the TT300 the motor cooling p ort is e quipped with a n
85. scription Bearing Motor Position Feedback Compressor Position Feedback PETS DEAR TSR ATES ATT Controller aca BMCC Channel Assignments Position Command Y Signals Axis Bearing Channel X Shaft Front Radial Z Front Radial jee Rear Radial as Rear Radial Amplifier Axial Shaft axes monitored by position sensors Y axis Position Channels Y axis Target Sensor Fx Fy Position Sleeve Sensor Channels Channel Rx Ry Axi Touchdown Bearings Impellers Z axis Rear 7 Position Radial Radial Geer Sensor Bearing Bearing Sensor Ring Sensor Ring Figure 61 Magnetic Bearing Control System 92 Danfoss Turbocor Compressors Inc CSS IOP D01 L 1 V06 0 Installation and Operation Manual 6 4 6 4 1 6 4 2 6 4 2 1 6 4 2 2 6 4 2 3 Power Line Control and Filtering Power Line Contactor Consult local codes to determine if a power line contactor is necessary for your application It is not recommended to use the contactor to start stop the compressor during normal operation compressor generator mode is used for emergency purposes only Power Line Filters and Line Reactor The equipment described in this section may be available from Danfoss Turbocor as compressor accessories For equipment specifications see the Applications Manual EMI Filter The EMI filter minimizes harmonics in the higher frequency domain typically above 1KHz It should be located
86. se on the Soft Start Board is defective Refer to the Service Manual to verify the HV DC DC converter 18 Reset the multimeter scaling to read 15VAC and connect to the 15VAC lead in the DC Bus Test Hamess If the reading is zero isolate the three phase supply in accordance with steps 1 7 19 When access is safe remove the four screws that hold the Soft Start Board in position and check fuses F2 and F3 for continuity these fuses are located next to the J5 fan connector and between the J1 and J7 connectors on the underside of the Soft Start Board Fuse F4 or external in line as appropriate should also be checked for continuity e If fuses are found to be defective replace them and return to step 16 NOTE See th e Se rvice M anualfor pr ocedureso n determining the cause of the blown fuse If voltage is present but outside specifications go to step 20 16 Danfoss Turbocor Compressors Inc CSS IOP D01 L1 V06 0 Installation and Operation Manual NOTE The fuse locations in this procedure apply to the Rev J ver sion of the Soft Start board Co ntact Customer Su pport a bout other versions of the Soft Start board Fuse F2 25A protects an output of transformer T1 which supplies 15V AC to the HVD C DC Converter Fuse F3 1 04 protects an output of T2 which supplies power to the Soft Start Board Fuse F4 pr otects th e incoming AC to the Soft Start Board 20 Measure the 15VAC from the Soft Start Board If t
87. sfer 12 000 BTU H 3 516 kw H Carbon races or ball bearing for the purpose of preventing mechanical interference between the shaft and the magnetic bearings should they lose power or fail Twin Turbine Type of centrifugal compressor having two impellers The first stage impeller raises the pressure of the refrigerant vapor approximately halfway from the cooler pressure to the condenser pressure and the second stage impeller raises the pressure the rest of the way With a two stage compressor an interstage economizer may be used to improve the refrigeration cycle efficiency Thermal Expansion Valve A pressure dependent refrigerant metering device that operates independently and is controlled by temperature Underwriters Laboratories www ul com When the DC bus reaches the up trip voltage the SCRs will be gated open continuously Volts Alternating Current An assembly of plates with curved vanes that serve to slow compress and reduce refrigerant rotation as it enters the second stage impeller Similar to a Vaned Diffuser except that it does not possess any de swirl vanes Volts Direct Current Variable Frequency Drive Danfoss Turbocor s commitment to excellence ensures continuous product improvements Subject to change without notice 106 Danfoss Turbocor Compressors Inc CSS IOP D01 L 1 V06 0 Installation and Operation Manual Appendix B Mounting Kit Instructions The compressor mounting kit includes four
88. specified in Table 7 Minimum Requirements NOTE Please consult the Microso ft d ocumentation or web site for the operating system requirements The Service Monitoring Tool was developed for the NET Framework and requires that NET Framework 3 5 be installed on the PC where the program runs If you do not have the prerequisite software it will be installed as part of the Service Monitoring Tool installation The latest Windows service packs and security updates should also be installed on the PC see Table 7 Table 7 Minimum Requirements Operating System The Monitoring Program is supported on the following platforms Required Add On e NET Framework 3 5 Software Windows XP 32 bit e Windows Vista 32 bit Windows 7 32 bit The Service Monitoring Tool was found NOT to work properly on Windows 2000 Windows XP x64 Windows Vista x64 e Windows 7 x64 All care is taken to check that the Monitoring Program operates as intended with the above operating systems and standard configuration computers However Danfoss Turbocor Compressors Inc makes no guarantee that this program will work bug free in all circumstances We would appreciate notification of any operating difficulty encountered along with as much detail possible to product support turbocor com Crystal Reports Basic for Visual Studio 2008 x86 Redistributable Package 32 bit NI LabWindows CVI 7 1 Run Time Engine Danfoss Tur
89. still present No To Control Strategy Is speed 7 surge RPM margin Yes N Close IGV and Is IGV fully closed o increase speed depends on pressure ratio Yes Is fault still present N o To Control Strategy Yes To Shutdown Figure 58 Compressor Controller Operational Flow Chart 5 of 6 88 Danfoss Turbocor Compressors Inc CSS IOP DO01 L 1 V06 0 Installation and Operation Manual Fault Handling FAULT CODE Check for fault condition Demand NOT EQUAL 0 Fault Present AND Shaft Not Levitated AULT CODEno equal to 0 demand 0 READY_TO_CLEAR_FLAG TRUE Shaft Not Levitated READY_TO_CLEAR_FLAG FALSE READY_TO_CLEAR_FLAG Clear CC fault Set System to TRUE Clear BMC fault Ready to Clear Set READY TO CLEAR FLAG FAULT CODE 0 False Reset the Status Contacts FAULT CODE Recheck Fault After Clear Start Active Control 6 2 7 Backplane Figure 59 Compressor Controller Operational Flow Chart 6 of 6 The Backplane physically interconnects the on board plug in modules with the power electronics IGV stepper motor motor cooling solenoids rotor position sensors and pressure temperature sensors The Backplane also features on board low voltage DC DC converters for generating 15V 15V 5V and 17V from an input of 24VDC The Backplane receives its 24VDC power input from the High Voltage
90. t System Commissioning from the Advanced menu item The Turbocor Compressor Commissioning Setup wizard displays see Figure 37 Danfoss Turbocor Compressors Inc 57 CSS IOP D01 L1 V06 0 Commissioning j Setup Wizard Turbocor Compressor Commissioning Welcome to the Turbocor compressor setup wizard The setup wizard will quide you through setting up Control Mode Startup settings Stepper motor controls expansion Valve controls and user limits such as discharge pressure and suction pressure cut outs Click next to proceed with your Setup r Check to bypass wizard and download a saved setup file Retrieving Data Cancel Figure 37 Turbocor Compressor Commissioning Setup Wizard Initial Window To bypass the Turbocor Compressor Commissioning wizard and use a saved configuration file to set up the compressor check the check box and click Next Continue with section Section 5 6 6 4 Using a Saved Configuration File 2 Click Next The General Compressor Settings window displays 58 Danfoss Turbocor Compressors Inc CSS IOP D01 L1 V06 0 Installation and Operation Manual 3 Setup Wizard d z GENERAL COMPRESSOR SETTINGS eae Which Measurement unit would you like to setup the compressor for Units Metric Units kPa C K and kw s English Units Psi F R and kw s Which Control Method do you wish to use How will demand be supplied to the compressor Control Met
91. the first stage impeller The centrifugal force produced by the rotating impeller results in an increase in both gas velocity and pressure The high velocity gas discharging from the impeller is directed to the second stage impeller through de swirl vanes The gas is further compressed by the second stage impeller and then discharged through a volute via a diffuser a volute is a curved funnel increasing in area to the discharge port As the area of the cross section increases the volute reduces the speed of the gas and increases its pressure From there the high pressure high temperature gas exits the compressor at the discharge port Danfoss Turbocor Compressors Inc 75 CSS IOP D01 L1 V06 0 Functional Description 1st Stage Impeller Volute Assembly Discharge Port High Pressure High Temperature Gas Low Pressure Low Temperature Gas Inlet Guide Vanes 2nd Stage Impeller ll Vaned Diffuser Figure 48 Compressor Fluid Path TT300 Volute Assembly Discharge Port High Pressure High Temperature Gas Inlet Guide gt 2nd Stage Vanes Impeller IGV S 3 d Vaneless ewe De ewirl Vanes Diffuser Figure 49 Compressor Fluid Path TT350 TT400 TT500 76 Danfoss Turbocor Compressors Inc CSS IOP D01 L1 V06 0 Installation and Operation Manual 6 1 2 Motor Cooling Liquid refrigerant is channelled at full condenser pressure from the main liquid line to the compressor t
92. turbocor com Subject to change without notice Danfoss Turbocor s commitment to excellence ensures continuous product improvements Danfoss Turbocor Compressors Inc 5 CSS IOP D01 L1 V06 0 List of Changes List of Changes Version Date Page Description of Change 6 7 19 10 Entire Reformatted to one column Applied new numbering Added updated Manual Danger Caution and Note symbols Updated cover to new logo and graphic 6 7 19 10 9 Removed T25 Torx bit and driver and 16mm 17mm sockets and driver from the Service Tools Equipment table 6 7 19 10 15 Updated Figure 5 Cable Passage 6 7 19 10 15 Updated Figure 6 Service Side Pass Through 6 7 19 10 16 Modifed description of the location of the fuses 6 7 19 10 l Updated the fuse size to 1 0A 6 7 19 10 20 Updated Figure 8 Rigging Set up 6 7 19 10 22 Modified step 1 in procedure to include After releasing the pressure 6 7 19 10 22 Modified step 2 in procedure to include Install new O Rings 6 7 19 10 22 Modifed step 7 in procedure to include and charge 6 7 19 10 23 Updated Figure 13 Motor Cooling Connection and Access Port 6 7 19 10 25 Updated Control Wiring Connections procedure 6 7 19 10 25 Added Control Wiring Connection Guidelines 6 7 19 10 28 Added EXV 1 to Control Wiring Details 6 7 19 10 28 Added EXV 2 to Control Wiring Detai
93. upplied into the opening in the mains input bracket 3 Fasten the cable gland to the bracket with the locknut 4 Feed the AC input cable through the cable gland 5 Attach the ground cable to the ground post on the compressor housing 6 Attach and secure the ground nut to the ground post see Figure 22 Ground Stud Mains Input cl Ground Cable Soft Start Ground Wire Lock foe ee Washer dl See H K4 RE Sh en el SS NS Figure 22 Ground Connection Details 7 Attach the three main power cables to the compressor terminals see Figure 23 Tighten the terminal nuts to 21 7 Nm 192 in Ibs AC Input Connections Figure 23 Compressor AC Input Terminals 8 Tighten the gland nut to secure the cable to the mains input bracket 9 Replace the mains input cover and secure it using four screws Tighten the screws to 7 Nm 62 in Ibs 34 Danfoss Turbocor Compressors Inc CSS IOP DO01 L 1 V06 0 Installation and Operation Manual 5 Commissioning Commissioning of the compressor is organized into three main tasks 1 Setting the I O jumpers and performing initial checks 2 Configuring the compressor via the Service Monitoring Tool 3 Performing running checks see DANGER The compressor sh ould be co mmissioned on ly by a technician spe cifically tra ined on Danfoss Turbocor comp ressorsa nd commissioning service procedures Many procedures are quite different fro m conven tional pro cedures therefore
94. ve chatter Click Next to continue Danfoss Turbocor Compressors Inc CSS IOP D01 L1 V06 0 Installation and Operation Manual 5 6 3 Electronic Valve Control This section explains how to set up the expansion valves for various applications Both valves can be operated independently or in parallel Expansion valves with different numbers of total steps can be used Consult the valve manufacturer s literature for design step numbers see Figure 41 za Setup Wizard ELECTRONICYALYE CONTROL 1 Determine settings for a stepper motor driven valve connected to EX 1 Terminals 1596 Number of Steps to drive Valve fully closed to fully open Initialize steps amp utomatically set to 110 of max Load Balance E Control Mode r 10 Starting Valve position open for set delay time 90 al Starting Valve position delay time Seconds to hold start position Compressor Will Decide its own setpoint 50 Valve Control Loop Speed 0 gt 100 ES Minimum Closure during operation Cancel ce Je Figure 41 Electronic Valve Control Setup For Expansion Valve 1 1 Enter the number of steps to drive the valve from fully closed to fully open e incorrect number of steps is selecte e valves may not have enough travel to allow the required amount of r efrigerant flow or the valve may not be able to throttle down to the r equired amount of re frigerant flow This si tuation cou Id cause liqu
95. via the Modbus over an RS 485 link The compressor will adjust its speed in order to attain the desired setpoint The compressor controller will keep monitoring all critical parameters and ensure safe operation Expansion Valve Control The compressor has the optional functionality to control two electronic expansion valves These valves should be of the stepper motor design see the Applications Manual for details on which valves can be used The first expansion valve or main expansion valve can be set up to cortrol liquid level superheat or load balancing hot gas by pass valve When controlling liquid level it will normally control the level in the evaporator or condenser The second valve or auxiliary expansion valve can also be set up to control liquid level superheat or load balancing When controlling liquid level it will normally be for economizer level control Danfoss Turbocor Compressors Inc 95 CSS IOP D01 L1 V06 0 Operational Maintenance Checks 7 Operational Maintenance Checks 7 1 Owner s Responsibilities Report any compressor damage Report any faults that occur with the compressor Turn off the compressor if fault condition persists Maintain a safe working environment in the plant room free from obstructions and debris Maintain adequate lighting Ensure plant room ventilation is adequate and as per government regulations 7 2 Frequency of Inspections DTC recommends that on site operational checks
96. vices connected to the same network for example a system that measures temperature and humidity and communicates the results to a computer A software program provided by DTC that can be downloaded to a PC or laptop computer to monitor regulate control or verify the operation of a compressor Maximum Operating Pressure Back electromotive force is a voltage that occurs in electric motors where there is relative motion between the armature of the motor and the external magnetic field and is also a parameter used to evaluate the strength of the permanent magnets of the shaft One practical application is to use this phenomenon to indirectly measure motor speed as well as estimate position NEC National Electric Code www necplus org Nm Newton meter A unit of torque 1 Nm 0 738 pound force foot Ibf f NTC Negative Temperature Coefficient Refers to thermistor characteristic Decrease in temperature results in a rise in resistance ohms OEM Original Equipment Manufacturer 104 Danfoss Turbocor Compressors Inc CSS IOP D01 L 1 V06 0 Installation and Operation Manual Acronym Term Definition Open Impeller PCB Permanent Magnet Motor PLC Pressure Ratio Proximity Sensor PWM Radial Bearing Rectifier Resistor RMA SCR Serial Driver SDT SEER Shaft Orbit Shrouded Impeller A compressor impeller with exposed vanes similar to a boat propeller or turbocharger Printed Circuit Board

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