TWIN-TURBINE CENTRIFUGAL COMPRESSOR
MODELS TT300, TT350, TT400 & TT500
Refrigerant R134a
APPLICATIONS MANUAL
Danfoss Turbocor Compressors Inc.
M-AP-001-ENG Rev. B
February 2012
This Page Left Intentionally Blank
Applications 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.turbocor.com
* Subject to change without notice.
* Danfoss Turbocor Compressors Inc. is committed to customer satisfaction through its continuous
product improvement policy. If you have anycomments or suggestions for the improvement of this
document please submit them to product.support@turbocor.com.
Danfoss Turbocor Compressors Inc.
M-AP-001-ENG Rev. B
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List of Changes
4
Revision
Date
Change
Page
B
Jan. 2012
Added Section 7 "Economizer Option" describing the
advantages of using an economizer with the DTC
compressor.
9
B
Jan. 2012
Updated economizer groove dimensions in Figure 19
"Discharge Side View (TT300, TT350, TT400 and
TT500)"
34
B
Jan. 2012
Added Section 18.2 "Economizer Option" to the System
Guidelines section.
46
B
Jan. 2012
Added Figure 34 "Typical Refrigeration Piping Schematic
With Flash Tank Economizer"
51
B
Jan. 2012
Added Figure 35 "Typical Refrigeration Piping Schematic
With Sub-Cooler Circuit Economizer"
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Applications Manual
List of Changes .................................................................................................................................................. 4
1 Introduction................................................................................................................................................... 7
2 Safety Summary............................................................................................................................................ 7
3 Product Certification..................................................................................................................................... 7
4 General Specifications .................................................................................................................................. 7
4.1 Maximum Pressure ....................................................................................................................... 8
4.2 Construction.................................................................................................................................. 8
4.3 Refrigerant Type ........................................................................................................................... 8
4.4 Environment.................................................................................................................................. 8
4.5 Noise ............................................................................................................................................. 9
5 Accessories ................................................................................................................................................... 9
6 Product Application ...................................................................................................................................... 9
7 Economizer Option ....................................................................................................................................... 9
8 Minimum Unloading Capacity ................................................................................................................... 13
9 Control Logic Guidelines For Multiple Compressors ................................................................................ 15
9.1 Staging of the Compressors ........................................................................................................ 15
10 Electrical Specifications............................................................................................................................ 17
10.1 Supply Voltage and Frequency................................................................................................. 17
10.2 Disconnects............................................................................................................................... 17
10.3 AC Input Line/Power Electronic Component Protection ......................................................... 18
10.4 Power Line Contactor ............................................................................................................... 19
10.5 CE Compliance and EMI/EMC Filtering ................................................................................. 20
10.6 Surge Protection........................................................................................................................ 20
10.7 Harmonic Filtering (IEEE 519) ................................................................................................ 20
10.8 Grounding (Earth) Connection Guidelines ............................................................................... 20
10.9 Equipment Panel ....................................................................................................................... 21
10.10 Mains Input Cable Specification............................................................................................. 22
11 Control Interface Wiring........................................................................................................................... 23
11.1 Control Wiring Connection Guidelines .................................................................................... 25
11.2 Interface Cable.......................................................................................................................... 25
11.3 Compressor I/O Board Mounting Details................................................................................. 27
12 Piping Considerations .............................................................................................................................. 28
13 Environmental Considerations.................................................................................................................. 29
13.1 Humidity ................................................................................................................................... 29
13.2 Vibration ................................................................................................................................... 29
14 Shipping Considerations ........................................................................................................................... 29
14.1 Vibration ................................................................................................................................... 29
15 Combined Temperature/Pressure Thermistor Specification..................................................................... 30
16 Physical Data ............................................................................................................................................ 31
16.1 Mounting Base.......................................................................................................................... 31
16.2 Clearance .................................................................................................................................. 31
16.3 Valve Flanges ........................................................................................................................... 31
17 Guide Specifications ................................................................................................................................. 42
17.1 General...................................................................................................................................... 42
17.2 Refrigerant ................................................................................................................................ 42
17.3 Compressor Bearings................................................................................................................ 42
17.4 Capacity Control ....................................................................................................................... 42
17.5 Compressor Motor .................................................................................................................... 42
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17.6 Compressor Electronics ............................................................................................................ 43
17.6.1 Ancillary Devices ............................................................................................................ 43
18 System Design Guidelines (R134a) .......................................................................................................... 44
18.1 General Requirements............................................................................................................... 44
18.2 Economizer Option ................................................................................................................... 46
18.3 Motor/Electronics Cooling Requirements ................................................................................ 46
18.4 Electrical Requirements............................................................................................................ 47
18.5 Control Requirements ............................................................................................................... 47
18.6 Application-Specific Requirements.......................................................................................... 47
18.6.1 Medium Evaporating Temperature Application (TT300) ............................................... 47
18.6.2 Air-Cooled Units ............................................................................................................. 48
18.6.3 Inverted Start ................................................................................................................... 48
18.6.4 Multiple Compressors on Common Circuit Using
One Evaporator and One Condenser ............................................................................ 49
18.6.5 Packaged Air-Side With DX-Type Evaporator and Multiple Evaporator Coils ............. 50
19 Sample Refrigeration Circuits................................................................................................................... 50
20 Sound Power Specifications ..................................................................................................................... 55
20.1 TT300 Sound Power Measurements......................................................................................... 55
20.1.1 Results ............................................................................................................................. 56
20.2 TT400 Sound Power Measurements......................................................................................... 59
20.2.1 Results ............................................................................................................................. 60
Appendix A: Acronyms ................................................................................................................................... 63
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Applications Manual
1
Introduction
This Application Manual is intended to inform application data / procedures specific to Turbocor TT Series
compressors. It is not intended to inform on fundamental safety, refrigeration and electrical design skills. It is
assumed and presumed that persons using this manual will be appropriately certified and have detailed
knowledge, experience and skills in respect to designing for and working with high pressure refrigerants and
medium voltage electrical components (to 1 KV high power AC & DC) as well as complex control systems.
Some potential safety situations may not be foreseen or covered in the manual. Danfoss Turbocor Compressors,
Inc. (DTC) expects personnel using this manual and working on DTC compressors to be familiar with, and carry
out, all safe work practices necessary to ensure safety for personnel and equipment.
2
Safety Summary
Safety precautions must be observed during installation, start-up, 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 equipment. 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.
3
Product Certification
The TT300, TT350, TT400 and TT500 compressors are ETL
accordance with UL Standard 984 and CSA Standard C22.2.
4
and CE
listed and have been tested in
General Specifications
NOTE
Please refer to Section 17 for a detailed
description of the specifications.
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4.1
Maximum Pressure
The maximum design high-side pressure is displayed in Table 4-1:
Table 4-1 Maximum Design High-Side Pressure
4.2
Unit
TT300
TT350
TT400
TT500
kPa
1800
1800
1240
1240
PSI
260
260
180
180
Construction
• Compressor - Semi-hermetic design
• Main Housing - Dimensionally-stabilized aluminum
• Covers - High-impact, UV stabilized, flame-resistant polymer
• Shaft - High-strength alloy
• Impellers - High-strength aluminum
• Motor - Permanent magnet, synchronous, DC
• Bearings - Integrated, digitally-controlled, magnetic
• Compressor Control - Integrated, digital capacity control
• Enclosure - IP54 rating as per UL 984 requirement
4.3
Refrigerant Type
NOTE
The TT compressor is totally oil-free and
optimized for use with refrigerant HFC-134a. Do
not use recycled refrigerant as it may contain oil,
which can affect system reliability. The
refrigerant should be pure and stored in virgin
containers.
4.4
Environment
The compressor should be stored and operated within the following ambient temperature ranges:
• Storage: -30°C to 50°C (-22°F to 122°F).
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• Operation: -1°C to 46°C (30°F to 115°F).
• Electronic Minimum Operating Limit: -25°C (-13°F)
NOTE
Contact Danfoss Turbocor for lower ambient
temperature operations. Refer to “Operating
Range,” for details of the operating conditions.
These conditions are in line with the AHRI 540
Standard.
4.5
Noise
Refer to Section 20 for sound power measurements.
5
Accessories
Refer to the Accessories Manual for product descriptions and specifications.
6
Product Application
Turbocor compressors are to be used in stationary installations only. For any moving or marine applications,
contact DTC.
7
Economizer Option
Turbocor compressors use two stage centrifugal compression with interstage port availability. This feature
provides advantages of capacity and efficiency improvement by installing and operating an economizer. The
improvements in efficiency and capacity are a result of further subcooling of the liquid refrigerant. Two types of
economizer arrangements can be used: subcooler or flashtank. See Figure 34 and Figure 35. Refigerant must
enter the compressor in the “gas” state into the economizer port. Care must be taken to ensure that no liquid
enters the compressor.
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Operating Range
Figure 1 Operating Envelope, TT300 Design Sequence “D”(1)
Figure 2 Operating Envelope, TT300 Design Sequence “D”
(Medium Temperature Compressor)(1)
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Figure 3 Operating Envelope, TT350 Design Sequence “A”(1)
Figure 4 Operating Envelope, TT400 Design Sequence “C”(1)
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Figure 5 Operating Envelope, TT500 Design Sequence “A”(1)
(1)
Refer to the current authorized Compressor Selection Software or DLL for more exact values and conditions.
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Applications Manual
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Minimum Unloading Capacity
Due to the centrifugal compression nature of Turbocor compressors, the minimum unloading capacity depends on
the operating pressure ratio. The lower the pressure ratio, the lower the minimum unloading capability. For a
quick and easy reference, the following graphs have been created to determine the minimum unloading capacity
versus the saturated discharge temperature (SDT) for given saturated suction temperatures (SST).
The following graphs are intended as a guide that should be considered in system design. Refer to the relevant
selection program for more accurate values.
Figure 6 Minimum Unloading Capacity, TT300 Design Sequence of “D”(2)
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Figure 7 Minimum Unloading Capacity, TT350 Design Sequence “A”(2)
Figure 8 Minimum Unloading Capacity, TT400 Design Sequence of “C”(2)
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Applications Manual
Figure 9 Minimum Unloading Capacity TT500 Design Sequence “A”(2)
2 Refer to the current authorized Compressor Selection Software or DLL for more exact values and conditions.
9
Control Logic Guidelines For Multiple Compressors
Due to the nature of centrifugal compression, special control logic must be implemented for proper staging of
multiple Turbocor compressors when installed on a common circuit. This section is intended only as a guide
without going into details. Control details are specific to each OEM's individual control strategy. The Turbocor
centrifugal compressors can be controlled by staging compressors and running the on line compressors in
parallel.
9.1
Staging of the Compressors
Compressors can be staged one by one by staging the compressors depending on the system load and demand.
Using this approach to compressor control, the lead compressor starts and loads up close to its full capacity
before the next compressor is brought on line. Prior to energizing any lag compressor, the lead compressor should
run in a stable condition for a few minutes and demand should be checked to see if there is still enough load to
justify staging an additional compressor. The load must be high enough to ensure that the compressor(s) online
plus the compressor being added will not over shoot and/or surge.
If additional compressors need to be brought online after going through the above process, the operating
compressor(s) must be unloaded (slowed down) to decrease the discharge pressure and increase the suction
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pressure. Continue to reduce the pressure ratio to less than 2.4, then start the next compressor. Operate all
energized compressors in parallel and load them equally.
During the lag compressor staging, if the operating compressors cannot be unloaded down to less than a 2.4
pressure ratio before starting the lag compressor, the Load Balancing Valve needs to be activated. We recommend
installing the Load Balancing Valve upstream of the non-return valve to help the lag compressor at startup.
However, if the pressure ratio still stays higher than 2.4, the operating compressor(s) may need to be cycled off,
and then restarted with the lag compressor(s) in parallel.
A compressor should be cycled off when insufficient load causes operating multiple compressors to go into surge
so that the remaining operating compressors can speed up to meet the demand and operate more efficiently.
To improve operating efficiency during part loads in a multiple-compressor system, maximize the number of
compressors in operation without allowing them to go into surge.
During the staging operation, it is more efficient and stable to run the compressors in full vane away from surge
and choke lines as much as possible.
NOTE
These control guidelines are specifically written
for single-circuited (multiple compressors on a
common refrigerant circuit) applications.
Individually circuited applications have similar
staging requirements. However, the ramping
down before adding additional compressors may
not be required.
NOTE
Pressure ratio is the ratio of absolute discharge to
absolute suction pressure. It can be calculated as
follows:
•
•
16
(DP + 101) / (SP + 101) (kPa) OR
(DP + 14.7) / (SP + 14.7) (psi)
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Applications Manual
10 Electrical Specifications
10.1
Supply Voltage and Frequency
Turbocor compressors are designed to operate with a power supply that is within an acceptable tolerance for each
nominally rated voltage and frequency. The tables below specify the acceptable supply voltage and frequency
ranges. Using a supply voltage/frequency at or beyond the range limit will cause the compressor to shut down.
Table 10-1 Acceptable AC Voltage Range
Acceptable Voltage
Range
342 - 418 VAC
360 - 440 VAC
414 - 506 VAC
518 - 635 VAC
Table 10-2 Acceptable Frequency Range
Nominal
Frequency
Acceptable Frequency
Range
50Hz
50Hz ±5% (47Hz - 53Hz)
60Hz
60Hz ±5% (57Hz - 63Hz)
NOTE
The frequency ranges in the table above apply
only when generator power is being used.
10.2
Disconnects
An input disconnect (for example, a switch or circuit breaker) must be installed in the line before the compressor
in accordance with applicable local, national, and international codes (for example, NEC/CEC). Size the
disconnect according to the full-load current.
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!
• • • CAUTION! • • •
The full-load current rating is based on the
installation of a line reactor in the power line.
Refer to the Accessories Manual for
specifications. Failure to use a line reactor will
result in poor power factor and higher full-load
current.
Refer to Figure 10 for interconnection details.
Figure 10 Typical Electrical Connections
10.3
AC Input Line/Power Electronic Component Protection
Most codes require that upstream branch protection be provided to protect input power wiring personnel and
switching equipment from damage in the event of an over current condition or equipment failure. Standard fuses
and/ or circuit breakers do not provide adequate protection for the compressor Power Electronics components.
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User-supplied, properly sized and selected fast-acting fuses must be installed according to the applicable local,
national, and international codes. The fuses must be installed in the line before each compressor’s AC input
terminals.
Use only properly rated fast-acting line fuses suitable for semiconductor protection, such as Littelfuse JLLS
series, Siemens Sitor 3NE1 series, or equivalent.
• • • DANGER! • • •
Fast-acting fuses are for the compressor’s power
electronics only. Properly sized and selected fast
acting fuses must be installed.
Sub-circuit protection must be considered
separately, according to local electrical
requirements.
User-supplied branch circuit protection must be
installed according to local, national, and
international codes (for example, NEC/CEC).
The fuses must be installed in the line before the
compressor AC input terminals.
10.4
Power Line Contactor
The power line contactor is optional. Consult local codes to determine if a contactor is necessary for your
application.
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10.5
CE Compliance and EMI/EMC Filtering
To address EMI/EMC problems, DTC recommends the installation of a UL-approved EMI/EMC filter device on
the input power line. Refer to the Accessories Manual for details.
Although the TT300, TT350, TT400 and TT500 compressors are CE listed, the compliance of the compressor
with the EMC directive depends on the use of the CE EMI/EMC filter provided by DTC (see Accessories Manual
for further details). If this is not possible because of the nature of your application and/or installation, an
alternative component with the same attenuation characteristics must be used to maintain compliance with the
EMC Directive. It is the responsibility of the user to maintain compliance with the Directives. Contact a DTC
sales representative for more details.
Proper installation of the EMI/EMC filter can have a dramatic effect on overall performance. Although the filter
reduces electrical noise on the power lines (conducted emissions), it should be located as close as possible to the
compressor to reduce broadcasting of the noise (radiated emissions) from the power lines themselves. The
capacitors within the filter short the noise to ground, so it is imperative that the filter maintains a good ground. 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 many fine strands is recommended for best
grounding performance. The multiple-strand cabling provides more surface area in order to conduct the high
frequencies that are on the grounding cable.
Radiation of noise is also a concern for power line routing as it can effectively bypass the filter. Input and output
filter leads should be separated by a maximum practical distance within enclosures and should be routed
separately in interconnecting conduits when used.
10.6
Surge Protection
The TT300, TT350, TT400 and TT500 compressors have been tested in accordance with IEC Standard 1000-4-4.
Electrical Fast Transient/Burst Requirement. For additional protection, a surge suppressor can be installed in
parallel with the compressor. It is recommended to install surge suppression in sites that are susceptible to
lighting.
10.7
Harmonic Filtering (IEEE 519)
Danfoss Turbocor recommends the installation of a harmonic filter device in parallel with the compressor in
order to comply with IEEE 519 requirements, as shown in Figure 10.
10.8
Grounding (Earth) Connection Guidelines
1.
All metal parts should be connected to ground, including the shields of electrical cables.
2.
Verify continuity of all ground connections.
3.
Ensure solid ground connections (both mechanical and electrical). Connections must be clean and grease
and paint free.
4.
At one point, usually the entrance of the power supply panel, all grounds should be connected together
(refer to Section 10.9).
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From an EMC standpoint, it is best to categorize different types of grounds and treat them independently (see
Figure 11):
• Safety ground (Protective Earth [PE]) and shields of mains cables.
• Analog grounds, shielding of interface cables.
• Digital grounds.
• Reference ground (panel doors, backplate, etc.).
Figure 11 Typical Ground Connections
10.9
Equipment Panel
Normally, the line reactor, EMI/EMC filter(s), and the harmonic filter will be installed in a panel. This could be
the same panel where the controls are located. When designing a panel, attention should be given to the following
recommendations:
• All metal parts should be properly connected to ensure an electrical connection. Connect panel doors with
braided cable.
• Separate panel into sections for power and interface/control functions.
• Keep power cables and interface cables separate. Use metal cable glands for shielded cables.
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• In case of a wire-loom going to the panel door, shield it using a metal-braided hose that is connected to ground
at both ends.
• Electrical panel must have a dedicated ground conductor as per relevant electrical codes.
• Verify that the panel ground conductor is sized in accordance with relevant electrical codes.
NOTE
The installing electrical contractor is responsible
for connecting the panel ground to the facility
ground in accordance with relevant electrical
codes and standards, such as NEC Section 250 in
the U.S. or its equivalent for other countries.
Special filtering and measuring may be required
in installations such as hospitals that are prone to
being influenced by other electronic equipment.
10.10
Mains Input Cable Specification
The aim of electrical cables is to be a carrier (conductor) for electrical power. The influence of the power source
on the environment, or the influence of the environment on the power source, should be such that neither the
proper functioning of the compressor nor equipment in its environment is adversely affected. Therefore, Danfoss
Turbocor advises to use some type of shielded cable for the mains input.
When using shielded cable, select a cable with an effective shield. A cable with an aluminum foil will be far less
effective than a specially designed conductive braid. It is best to connect both ends of the cable shield to ground,
since the shield is not part of the signal path.
The mains input cable should be CSA, UL, or CE approved, three-wire with a common shield and single ground.
The cable must be rated for 90°C (194°F) minimum and maximum current according to the applicable
model. It is recommended that the cable be double-jacketed, i.e., teck cable type. Refer to Table 10-3 Main
Cable Connector Plate Hole Sizes for cable gland specifications.
Table 10-3
Main Cable Connector Plate Hole Sizes
Actual Size
50.0 mm (1.97”)
63.0 mm (2.48”)
76.2 mm (3.00”)
88.9 mm (3.50”)
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11 Control Interface Wiring
The Compressor I/O Board is the entry point for control wiring from the chiller/plant to the compressor.
Figure 12 Typical Control Wiring
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Table 11-1 Control Wiring Details
I/O
24
Description
COM (shield)
Shield for RS-485 communication.
Modbus RS-485 NetB/NetA
Modbus over RS-485 communication port.
EXV1 Phase 1A, 1B, 2A, 2B
Optional output connections for controlling the main electronic
expansion valve (evaporator).
EXV2 Phase 1A, 1B, 2A, 2B
Optional output connections for controlling the auxiliary
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 (1 - 10VDC Input)
Analog input from customer-supplied controller to drive the
compressor, i.e., 0 - max. kW input for the respective compressor
model.
Interlock
Connects to a set of external contacts that typically open in the
event of loss of chilled water or air flow. Typically a 1.5VDC
output signal.
Status
Via an internal normally open contact that is closed during
normal operation and opens in the event of a compressor fault.
With circuit open, compressor will not restart until demand signal
has been reset to 0 (via chiller/unit controller). Circuit rated at 1A
@ 30 VDC/24VAC or 0.3A @ 120VAC.
Motor Speed Monitor
Analog output indicating compressor RPM. 0 to 5.0VDC = 0 to
50,000 RPM.
Liquid Temperature
Optional input for monitoring temperature. The temperature
sensor must be an NTC type 10K @ 25°C thermistor.
Run
An internal N/O contact that is closed while the compressor is
running. The speed at which the contact closes is userconfigurable via the monitor program. Circuit rated at 1A @ 30
VDC/24VAC or 0.3A @ 120VAC.
Analog
Universal analog output for load balancing valve, IGV position,
or discharge pressure. Operating range can be set to 0-5V or 010V via onboard jumpers.
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Table 11-1 Control Wiring Details (Continued)
I/O
Description
Entering Chilled Water Temp.
Analog input indicating water temperature. The temperature
sensor must be an NTC type 10K @ 25°C thermistor. Refer to
“Combined Temperature/Pressure 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
“Combined Temperature/Pressure Thermistor Specification,”.
Spare T +/-
Refer to Figure 16 for thermistor specification.
Spare P +/-
Can be connected to a 0-5V type pressure sensor.
11.1
Control Wiring Connection Guidelines
To ensure proper control wiring techniques, follow these guidelines:
1.
The ground reference of the external circuit connected to the Compressor I/O Board must be at the same
potential as the ground reference on the Compressor I/O Board.
2.
The Interlock circuit should be voltage-free For example, all external contactors/switches must not
introduce 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 I/O Board.
4.
All interlock and analog output cables should be shielded with one end of the shield connected to the
common analog or digital ground bus. The other end of the shield must not be grounded as this would
create a ground loop.
11.2
Interface Cable
The cable that carries the I/O communication to the compressor is 5 meters (16.4 feet) in length and is equipped
with high-density 44-pin connectors (female at one end and male at the other end). An extension cable is
available from your local supplier.
NOTE
If an I/O extension cable is used, heat-shrink
tubing should be applied to the mating cable
connectors to maintain good conductivity and
protect the connection from heat and humidity.
For RS-485 communication, the maximum cable length should not exceed 100 meters (328 feet). If using RS-232
communication, the cable length should not exceed 15 meters (50 feet) between the PC and the compressor (refer
to Figure 13).
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Figure 13 I/O Wiring Specifications
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11.3
Compressor I/O Board Mounting Details
The Compressor I/O Board (Figure 14) must be installed in a UL-approved electrical enclosure equipped with
DIN EN 50022, 50035, or 50045 mounting rails.
Figure 14 Compressor I/O Board
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Piping Considerations
Care should be exercised when selecting pipe sizes as they will vary according to their application. Section 18,
“System Design Guidelines (R134a),” provides examples of compressor piping arrangements for the most
common applications.
The motor-cooling line should be channeled from the liquid line; refer to Section 18.2 for more information.
Danfoss Turbocor requires the installation of a sight glass and full-flow liquid dryer in the motor-cooling line.
Applications may require alternative arrangements. Contact Danfoss Turbocor for further assistance, if required.
!
• • • CAUTION! • • •
The discharge line must be fitted with a nonreturn valve to prevent reverse flow into the
discharge port, which can cause damage to
compressor components.
It is recommended that a strainer be installed in
the suction line for the first 100 hours of
operation, at 80-100% load, to prevent the
ingress of foreign particles into the compressor.
IGV and/or impeller damage caused by foreign
particles will void the warranty.
All pipe work should be carried out in
accordance with industry standards. Brazing
without the use of nitrogen will result in debris
being deposited in the pipes, potentially leading
to blockage or damage.
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13 Environmental Considerations
13.1
Humidity
If the compressor is installed in a humid environment, drip trays may be required to collect condensate. Insulation
should be installed on the suction valve/piping and the end cap as this is where condensation is most likely to
form.
It is recommended to fit an End Cap insulator in a humid environment.
13.2
Vibration
External copper piping should be braced to minimize the transfer of vibration to the compressor.
14 Shipping Considerations
14.1
Vibration
When shipping the compressor as an integral part of a chiller unit, precautions should be taken to protect the
compressor motor cooling line from excessive vibration. Due to the flexibility of the compressor’s isolation
mounts, compressor vibration during transit can fracture the motor cooling line’s rigid piping. Danfoss Turbocor
suggests the temporary installation of an anti-vibration bracket between the compressor’s base frame and
mounting rail during transit, as shown in Figure 15.
Figure 15 Anti-Vibration Bracket
Danfoss Turbocor Compressors Inc.
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29
15 Combined Temperature/Pressure Thermistor
Specification
The compressor controller software that monitors the combined pressure/temperature sensor at the suction port
and spare input on the Compressor I/O Board is based on the NTC thermistor data detailed in Figure 16.
Figure 16 Temperature vs. Resistance
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Applications Manual
16 Physical Data
This section contains data relative to compressor mounting, service clearance, and piping connections (see
Figure 18, and Figure 19).
16.1
Mounting Base
The compressor must be mounted on a rigid surface of sufficient structural integrity to support the weight of the
compressor and valves (see Figure 27 and Table 16-1). A mounting kit is available to isolate the compressor
from the supporting structure and to minimize vibration from other rotating equipment. The compressor
mounting rails should be level ± 3/16” (5mm) in the lateral and longitudinal planes.
16.2
Clearance
Adequate clearance around the compressor is essential to facilitate maintenance and service. Removal of the
compressor top and service-side covers requires a minimum clearance of 24" (600mm) and 16" (406mm),
respectively.
16.3
Valve Flanges
!
• • • CAUTION! • • •
The discharge line must be fitted with a check
valve to prevent reverse flow into the discharge
port, which can cause damage to compressor
components.
Compressor valve flange details are shown in Figure 28 and Figure 29. Refer to the product specifications in the
Accessories Manual for further details.
Danfoss Turbocor Compressors Inc.
M-AP-001-ENG Rev. B
31
Figure 17 Suction/Front View (TT300, TT350, TT400 and TT500)
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Danfoss Turbocor Compressors Inc.
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Figure 18 Service Side View (TT300, TT350, TT400 and TT500)
Danfoss Turbocor Compressors Inc.
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33
Figure 19 Discharge Side View (TT300, TT350, TT400 and TT500)
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Danfoss Turbocor Compressors Inc.
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Gas Flow
Figure 20 Discharge Port Details (TT300)
Gas Flow
Figure 21 Discharge Port Details (TT350)
Danfoss Turbocor Compressors Inc.
M-AP-001-ENG Rev. B
35
Gas Flow
Figure 22 Discharge Port Detail (TT400)
Gas Flow
Figure 23 Discharge Port Detail (TT500)
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Figure 24 Suction Port (TT300, TT350, TT400, TT500)
Danfoss Turbocor Compressors Inc.
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Gas Flow
Figure 25 Suction Port Detail (TT300, TT350, TT400)
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Danfoss Turbocor Compressors Inc.
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Gas Flow
Figure 26 Suction Port Detail (TT500)
Danfoss Turbocor Compressors Inc.
M-AP-001-ENG Rev. B
39
Figure 27 Mounting Base (TT300, TT350, TT400, TT500)
Table 16-1 Physical Dimensions
Length
31.02" (788 mm)
(valve)
excludes suction service
Width
20.4" (518 mm)
Height
9.17" (487 mm)
Shipping weight
TT300: 265 lbs. (120 kg)
TT350: 290 lbs. (132 kg)
TT400: 290 lbs. (132 kg)
TT500: 306 lbs. (139 kg)
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Danfoss Turbocor Compressors Inc.
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Applications Manual
Figure 28 TT300 Flange Footprint Details
Figure 29 TT350 and TT400 Flange Footprint Details
Figure 30 TT500 Flange Footprint Details
Danfoss Turbocor Compressors Inc.
M-AP-001-ENG Rev. B
41
17 Guide Specifications
This section contains written specifications for the TT300/TT350/TT400/TT500 compressors for use in system
design specifications.
17.1
General
Construction shall utilize a two-stage, variable-speed, centrifugal compressor design requiring no oil for
lubrication. Compressor shall be constructed with cast aluminum casing and high-strength thermoplastic
electronics enclosures. The two-stage centrifugal impellers shall consist of cast and machined aluminum. The
motor rotor and impeller assembly shall be the only major moving parts.
17.2
Refrigerant
Compressors shall be designed for use with HFC-134a.
17.3
Compressor Bearings
The compressor shall be provided with radial and axial magnetic bearings to levitate the shaft, thereby
eliminating metal-to-metal contact, and thus eliminating friction and the need for oil. The magnetic bearing
system shall consist of front, rear, and axial bearings. Both the front and the rear bearings are to levitate the shaft
at X and Y directions, and the axial at Z direction. Each bearing position shall be sensed by position sensors to
provide real-time repositioning of the rotor shaft, controlled by onboard digital electronics.
17.4
Capacity Control
The compressor shall have a Variable Frequency Drive (VFD) for linear capacity modulation, high part-load
efficiency and reduced in-rush starting current under 2 amps at 460V. It shall include an Insulated Gate Bipolar
Transistor (IGBT) type inverter that converts the DC voltage to an adjustable three-phase AC voltage. Signals
from the compressor controller shall determine the inverter output frequency, voltage and phase, thereby
regulating the motor speed. In case of power failure, the compressor shall be capable of allowing for a normal delevitation and shutdown.
Compressor speed shall be reduced as condensing temperature and/or heat load reduces, optimizing energy
performance through the entire range from 100 percent to 30 percent or below, depending on the pressure ratio, of
full-load capacity of each compressor given Air Conditioning, Heating and Refrigeration Institute (AHRI)
standard unloading conditions. Capacity modulates infinitely as motor speed is varied across the range. Inlet
Guide Vanes (IGVs) shall be built-in to further trim the compressor capacity in conjunction with the variablespeed control to optimize compressor performance at low loads. Refer to DTC Selection Software for
performance calculations and limits.
17.5
Compressor Motor
The compressor shall be provided with a direct-drive, high-efficiency, permanent-magnet synchronous motor
powered by pulse-width-modulating (PWM) voltage supply. The motor shall be compatible with high-speed
variable-frequency operation that affords high-speed efficiency, compactness and soft start capability. Motor
cooling shall be by liquid refrigerant injection.
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17.6
Compressor Electronics
The compressor shall include a microprocessor controller capable of controlling magnetic bearings and speed
control. The controller shall be capable of providing monitoring, including commissioning assistance, energy
outputs, operation trends, and fault codes via a ModBus interface.
17.6.1
Ancillary Devices
A check valve shall be installed on the discharge port of the compressor to protect against backflow of refrigerant
during coastdown. It is recommended that the valve be located after the properly designed discharge cone
adaptor, preferably close to the condenser in the packaged system. The system shall also be provided with an
appropriately sized line reactor.
Danfoss Turbocor Compressors Inc.
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43
18 System Design Guidelines (R134a)
In addition to the instructions detailed in the TT300, TT350, TT400 and TT500 technical documentation set, this
section provides basic guidelines and requirements for the design and manufacture of R134a systems equipped
with Danfoss Turbocor compressors.
Refer to the applicable Danfoss Turbocor technical manual for applications, operating, installation and
commissioning instructions.
NOTE
The compressor internal safety control settings
are designed to provide protection for the
compressor only. Designers MUST provide
SYSTEM protection within their control design.
DTC will not be responsible for system
protection other than the compressor.
18.1
General Requirements
1.
Check for compliance with all installation, operating, commissioning and service steps, as outlined in the
TT300, TT350, TT400 and TT500 documentation set. Check for the appropriate operating envelope and
minimum unloading capacity for the intended application.
2.
System components such as evaporators, condensers, valves, etc., should be properly selected and sized for
appropriate performance and compatibility to suit R134a refrigerant.
3.
The system suction and discharge piping should be properly designed and selected for minimum pressure
drop. This requirement is more critical with the suction line. Since the Turbocor compressor operates
without lubricating oil, conventional piping considerations that ensure oil return, such as multiple risers
and traps, are not required. In all cases of suction and discharge lines, bigger diameter is better.
4.
For improved efficiency and better control, particularly at low load / low compression ratios, electronic
expansion valves (EXVs) are strongly recommended. If it is intended to take advantage of low pressure
ratio operation to improve low load performance and efficiency, EXV capacity should be selected
accordingly. It is strongly recommended that the EXV manufacturer controller be used to control valves.
These should be initiated from the system controller in conjunction with a liquid line solenoid valve.
Thermal expansion valves (TXVs) are not recommended due to the general inability of these devices to
adequately cover the operating spectrum of centrifugal compressors, particularly at low compression
ratios.
5.
Take all necessary precautions to prevent any possibility of liquid floodback to the compressor. This means
consideration during the ON and OFF cycles, particularly in multiple compressor installations. This WILL
include, but is not limited to, the inclusion of a liquid line solenoid valve and piping, evaporator and
condenser arranged in a manner that prevents free drainage of liquid to compressor.
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6.
The refrigeration piping system must be clean and free of all debris according to refrigeration-industry best
practices Particles can damage the compressor.
7.
Each compressor MUST be fitted with its own positive sealing discharge line check valve. This valve
MUST be selected as a minimum pressure drop at full capacity and low 'crack open' pressure. A robust
good quality valve must be selected to ensure good performance as valves may 'hammer' during start up,
particularly in air cooled and/or multiple compressor systems. It is recommended that the valve be located
after the properly designed discharge cone adaptor, preferably close to the condenser in the packaged
system.
8.
For outdoor installations, a weather-proof enclosure is recommended to house the compressor.
9.
Installation of staging valves are recommended on each compressor discharge line in the multiple
compressor systems to aid the lag compressor startup.
10.
It is recommended that a Load Balancing Valve (LBV) be installed to aid unloaded operation and lag
compressor start-up in multiple-compressor systems.
11.
The system control should not be designed based on pump down cycle. The system cannot be completely
pumped down due to the surge characteristics of centrifugal compressors.
12.
Use the table below for recommended minimum pipe sizes.
Table 18-1 Recommended Minimum Copper Tube Size
TT300
TT350
TT400
TT500
Suction
4”
4”
5”
5”
Discharge
2 5/8”
3 1/8”
4”
4”
NOTE
If steel pipe is used, the pipe must be selected to
give the equivalent inside diameter to copper
pipe.
Properly tapered trumpets with smooth transitions must be used to connect the compressor flanges to the
pipework.
The discharge line exit transition should not be at an angle greater than eight degrees inclusive. The suction
line length should be straight for 1.5 times the pipe diameter before entry into the compressor.
13.
In humid environments, the bell housing of the compressor should be insulated. A motor end cover thermal
insulator is available as an accessory.
Danfoss Turbocor Compressors Inc.
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18.2
Economizer Option
Turbocor compressors use two stage centrifugal compression with interstage port availability. This feature
provides advantages of
capacity and efficiency improvement when an economizer is installed. The improvements in efficiency and
capacity are a result of further subcooling of the liquid refrigerant. Two types of economizer arrangements can be
used: subcooler or flashtank. See Figure 34 and Figure 35. Refigerant must enter the compressor in the “gas”
state into the economizer port. Care must be taken to ensure that no liquid enters the compressor.
To determine compressor capacity and efficiency, the economizer performance rating option is available in the
Compressor Performance Rating (CPR) selection software. The circuit must be properly designed to reflect the
specified heat exchanger approach with minimized pressure drops across the liquid side and expansion side.
Piping design, including expansion device selection and pipe sizing should be in accordance with best practices.
18.3
Motor/Electronics Cooling Requirements
NOTES
• Sub-cooled liquid must be fed to the motor/
electronics cooling port of the compressor.
• It must be solid liquid with a minimum of 6°
F (3.5°C) sub cooled at the connection point
to the motor/electronics cooling port of the
compressor.
NOTE
Filter dryer, sight glass and service valve must be
fitted in the motor-cooling liquid line.
To ensure sub-cooled liquid, it is important that the condenser is fitted with a sub-cooler (integrated or separate).
It is essential that compressor motor and power electronics cooling is available immediately at start up. The
compressor motor cooling liquid feed line must be configured and located so that this occurs. Recommended
minimum pipe size is 1/2” for all models. A larger size may be necessary in some situations such as systems with
low subcooling on start or extended piping runs. A full flow filter / drier must be installed and a liquid sight glass
must be installed adjacent to each compressor.
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Applications Manual
18.4
Electrical Requirements
1.
Power is permanently connected to the compressor connection terminals. A line reactor must be connected
in series with the compressor connection. The line reactor enclosure or box should be properly ventilated to
avoid overheating.
2.
Danfoss Turbocor strongly recommends installation of a properly selected surge suppressor on the power
supply to the compressor (refer to Figure 10).
3.
Fast Acting fuses with an appropriate CAT and current rating must be supplied and fitted externally for the
TT350, TT400, and TT500. Fuses should be sized for 1.25 times compressor FLA. Fuses are fitted
standard with the TT300.
4.
3 phase power wiring between compressor and line reactor must be either fully shielded and sheathed type
or carried in a properly grounded metal conduit.
18.5
Control Requirements
NOTE
The factory-installed temperature sensor on the
compressor suction port should not be used for
this purpose.
A single compressor can operate with its own in built control system, however, an external third party supplied
and programmed controller is required for multiple-compressor operation. See the OEM Programming Guide for
compressor control and multiple compressor staging startup options.
Alternatively, ModBus communication with the compressor can be used to record speed and initiate open/close
from the external controller.
18.6
Application-Specific Requirements
18.6.1
Medium Evaporating Temperature Application (TT300)
NOTE
Medium Evaporating Temperature is defined as
between 0 and -10 degrees C (between 32 and 14
degrees F).
1.
Check operating envelope for limits, required compressor version, and accessories.
2.
For medium-temperature applications, an evaporator pressure regulating valve must be installed external to
the compressor between the main suction line and the compressor motor suction line fitting adjacent to the
inter stage port. The recommended valve is Sporlan ORIT-10 7/8”, set at 200 kPa (30 psi) for R134a. The
medium-temperature compressor is fitted with a 5/8” flare adapter.
Danfoss Turbocor Compressors Inc.
M-AP-001-ENG Rev. B
47
18.6.2
Air-Cooled Units
For best and most efficient performance at low ambient conditions it is strongly recommended that EXVs be
utilized as expansion devices and VSD control of some or all condenser fans is used. In any event rapid cycling of
condenser fans is to be strenuously avoided.
Internal controls will limit compressor speed if compressor choke is encountered particularly during start up
where pressure ratio is low and it may be necessary to raise condensing pressure to allow compressor to speed up.
In any event the pressure ratio should be raised above at start-up and should not drop below 1.3 during operation
with evaporator at design temperature.
Careful consideration must be given to compressor selection when applied in air cooled chillers. Pressure ratio
lift requirements at high ambient temperatures will reduce the compressor's ability to unload. Lower speed will be
higher due to surge. If it is required to start compressors at high ambient temperatures, the Pressure ratio cannot
be lowered below 3.0. Consideration should be given to shut down all running compressors, and then start all
compressors together.
NOTE
Air Cooled compressors must include a staging
valve in the refrigerant circuit.
18.6.3
Inverted Start
Inverted Start, commonly called "Monday Morning Start Up", can be a combination of high evaporation load
(high building heat inertia). This inertia may lead to compressor capacity limitations due to choke at low Pressure
ratio. See Figure 31.
Figure 31 Centrifugal Performance Dynamics
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Applications Manual
This performance chart (Figure 31) is representative of a maximum capacity curve that you would see with
Turbocor centrifugal compressors, At point A, certain low pressure/high evaporator load conditions such as hot
building start-up, can limit the maximum capacity of the centrifugal.
If more capacity is desired, it is advisable to raise the discharge pressure temporarily to increase the pressure ratio
(point B) until the sensible lead in the building dissapates. This can be achieved by raising the condensing
temperature (pressure) on starting for other compressors. After the building load is under control, a lower
pressure ratio can be resumed.
18.6.4
Multiple Compressors on Common Circuit Using
One Evaporator and One Condenser
1.
Motor-cooling liquid should be fed from the common liquid line before the main LLSV. Follow the
instructions in Section 18.2.
2.
It is recommended to apply similar, or ideally the same, suction and discharge piping layout and size for all
individual compressors.
3.
Each compressor must have a positive sealing check valve fitted in its discharge line. This valve should be
sized for minimum pressure drop (<7kpa [1 psi]) at full load and low 'crack open' pressure.
4.
Where multiple compressors are to be connected to a single port on evaporator and condenser shells,
header manifold pipe work must be fabricated. These manifolds must be sized and configured for
minimum full load pressure drop and ensuring maximum flow balance between compressors. Suction and
condenser line connection to header manifolds should be from/to the top.
5.
A special control algorithm is required if multiple compressors are to be installed in parallel on a single
circuit.
6.
During the compressor staging process, to get the lag compressor online, the system pressure ratio should
be below a maximum level of 2.4.
7.
An LBV is required for staging multiple compressors at a high-pressure ratio. The take-off point from the
discharge line should be upstream of the non-return valve.
8.
The maximum start-up pressure ratio is about 2.4. If the pressure ratio is higher than 2.4, an LBV is
required to reduce the pressure ratio before starting the compressor.
NOTE
Contact Danfoss Turbocor for compressor
selection and technical advice.
Danfoss Turbocor Compressors Inc.
M-AP-001-ENG Rev. B
49
18.6.5
Packaged Air-Side With DX-Type Evaporator and Multiple Evaporator Coils
1.
Each evaporator must be controlled by an independent expansion system, using its outlet header for
superheat control reference. Common suction temperature or pressure should not be used for individual
evaporator superheat control reference points,
2.
Each evaporator liquid line should be equipped with a solenoid valve.
3.
Connection of a generously-sized header to the suction line of the evaporators is recommended to minimize
pressure-drop differences.
4.
It is highly recommended to install a suction line accumulator.
5.
Motor-cooling liquid should be fed from the common liquid line Follow the instructions in Section 18.2.
19 Sample Refrigeration Circuits
Figure 32 Typical Refrigeration Piping Schematic
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Applications Manual
Figure 33 Typical Refrigeration Piping Schematic
With Staging and Load Balancing Valve
Figure 34 Typical Refrigeration Piping Schematic With Flash Tank Economizer
Danfoss Turbocor Compressors Inc.
M-AP-001-ENG Rev. B
51
Figure 35 Typical Refrigeration Piping Schematic With Sub-Cooler Circuit Economizer
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Figure 36 Typical Refrigeration Piping Schematic Using Motor-Cooling PressureRegulating Valve
(Medium Temperature Compressors Only)
Figure 37 Typical Refrigeration Piping Schematic With Multiple DX Evaporators
Danfoss Turbocor Compressors Inc.
M-AP-001-ENG Rev. B
53
Figure 38 Typical Refrigeration Piping Schematic Using Multiple Compressors
on a Common Circuit With a Flooded Evaporator
NOTE
Contact Danfoss Turbocor for
compressor selection and further
technical advice.
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20 Sound Power Specifications
20.1
TT300 Sound Power Measurements
The sound power levels on the TT300 compressor are measured in compliance with ISO 9614-1 (1993) and are
given in decibels and in A-scale dB(A).
Three series of sound power measurements were performed on the unit while in two different modes:
• 250kW (70 ton) Refrigeration capacity
• 315kW (90 ton) Refrigeration capacity
NOTES
• The sound data below should be used as a guide only.
• The following sound measurements are based on a specific physical setup, such as
suction/discharge piping, evaporator and condensers, as well as specific pressure
ratios. Any OEM system design would not necessarily match these conditions.
• OEMs are responsible for their system sound level measurements and their published
data.
Below are the results from “Sound Power Measurements on a Turbocor TT300 Compressor.
Danfoss Turbocor Compressors Inc.
M-AP-001-ENG Rev. B
55
20.1.1
Results
The sound power measured under each operational mode is presented in Table 20-1. Table 20-2 presents the
results of sound pressure calculations for various distances while the compressor is installed on top of a building.
Table 20-1 Sound Power Measurements
Operation
Mode
Sound Power
(A-Scale)
dBA
Sound Power
(Linear Scale)
dB
Dominant
Frequency
250 kW
81.5
81.5
1070 Hz
315 kW
86.0
85.5
1180 Hz
Table 20-2
Distance in
Relation to
Compressor
(meters)
56
Sound Pressure Calculation
Operational Mode of Compressor
(Capacity)
250 kW (70
Ton) dBA
315 kW (90
Ton) dBA
1
72.5
78.0
2.5
65.5
70.0
5
59.5
64.0
8
55.5
60.0
Danfoss Turbocor Compressors Inc.
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Applications Manual
Table 20-3 Sound Power at Third Octave Band, TT300 Compressor 250 kW Mode
Third octave
band (Hz)
Sound Power
Linear scale
(dB)
Sound Power
A-weighted
(dBA)
160
55.5
41.8
200
62.0
51.7
250
63.9
55.6
315
68.7
62.0
400
66.9
62.3
500
71.5
68.6
630
60.2
58.4
800
65.1
64.5
1000
76.5
76.7
1250
66.2
66.9
1600
69.9
71.0
2000
69.6
70.9
2500
68.6
69.9
3150
72.3
73.6
4000
71.3
72.3
Danfoss Turbocor Compressors Inc.
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Table 20-4 Sound Power at Third Octave Band, TT300 Compressor 315 kW Mode
58
Third octave
band (Hz)
Sound Power
Linear scale
(dB)
Sound Power
A-weighted
(dBA)
160
59.6
45.8
200
64.9
54.9
250
67.7
59.5
315
69.9
63.4
400
66.6
62.2
500
65.7
62.6
630
71.8
69.8
800
67.7
67.2
1000
70.5
70.6
1250
82.3
83.0
1600
72.6
73.9
2000
73.3
74.7
2500
72.8
74.3
3150
75.3
76.7
4000
74.6
75.8
Danfoss Turbocor Compressors Inc.
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Applications Manual
20.2
TT400 Sound Power Measurements
The sound power levels on the TT400 compressor are measured in compliance with ISO 9614-1 (1993) and are
given in decibels and in A-scale dB(A).
The series of sound power measurements were performed under two sets of operating conditions:
• 420kW (120 ton) refrigeration capacity
• 525kW (150 ton) refrigeration capacity
NOTES
• The sound data below should be used as a guide only.
• The following sound measurements are based on a specific physical setup, such as
suction/discharge piping, evaporator and condensers, as well as specific pressure
ratios. Any OEM system design would not necessarily match these conditions.
• OEMs are responsible for their system sound level measurements and their published
data.
Below are the results from “Sound Power Measurements on a Turbocor TT400 Compressor.
Danfoss Turbocor Compressors Inc.
M-AP-001-ENG Rev. B
59
20.2.1
Results
The sound power measured with the discrete point method under two operational modes is presented in Table 205. Table 20-6 presents the results of sound pressure calculations for various distances while the compressor is
installed on top of a building.
Table 20-5 Sound Power Measurements
Operation
Mode
Sound Power
(A-Scale)
dB(A)
Sound Power
(Linear Scale)
dB
420 kW
88.4
89.1
563 kW
88.1
89.2
Table 20-6 Sound Pressure Calculation
Distance in
Relation to
Compressor
(meters)
60
Operational Mode of Compressor
(Capacity)
420 kW (120
Ton)
dBA
525 kW (150
Ton)
dBA
1
81
82
1.5
77
78
3
71
72
5
68
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Table 20-7
Sound Power at Third Octave Band of TT400 Compressor, 420 kW Mode
Third octave
band (Hz)
Sound Power
Linear scale
(dB)
Sound Power
A-weighted
(dBA)
160
51
65
200
49
61
250
60
70
315
60
68
400
64
71
500
63
65
630
78
79
800
80
81
1000
83
82
1250
82
81
1600
77
76
2000
77
76
2500
75
74
3150
75
75
4000
72
71
Danfoss Turbocor Compressors Inc.
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61
Table 20-8 Sound Power at Third Octave Band
of TT400 Compressor, 525 kW Mode
62
Third octave
band (Hz)
Sound Power
Linear scale
(dB)
Sound Power Aweighted (dBA)
160
55
70
200
50
62
250
61
70
315
62
69
400
65
75
500
62
66
630
76
79
800
78
80
1000
82
83
1250
81
81
1600
75
74
2000
75
74
2500
76
76
3150
75
76
4000
73
73
Danfoss Turbocor Compressors Inc.
M-AP-001-ENG Rev. B
Applications Manual
Appendix A: Acronyms
AC
Alternating Current
AHRI
Air-Conditioning, Heating and Refrigeration Institute
CE
Conformance European
CSA
Canadian Standards Association
DC
Direct Current
DTC
Danfoss Turbocor Compressors Inc.
EMC
Electromagnetic Compatibility
EMI
Electromagnetic Interference
EPC
Extended Performance Compressor
ETL
ETL Testing Laboratories, now a mark of Intertek
Testing Services
EXV
Electronic Expansion Valve
FLA
Full Load Amps
FLC
Full Load Current
GUI
Graphical User Interface
HFC
Hydrofluorocarbon
ID
Inside Diameter
IEEE
Institute of Electrical and Electronic Engineers
IGBT
Insulated Gate Bipolar Transistor
IGV
Inlet Guide Vane
IP
Industry Pack
LBV
Load Balance Valve
LLS
Liquid Line Solenoid
LRA
Locked Rotor Amps
NTC
Negative Temperature Coefficient
OD
Outside Diameter
PE
Protective Earth
PLC
Programmable Logic Controller
PWM
Pulse Width Modulation
SDT
Saturated Discharge Temperature
SST
Saturated Suction Temperature
TT
Twin Turbine
TXV
Thermal Expansion Valve
UL
Underwriters Laboratories
UV
Ultraviolet
VFD
Variable Frequency Drive
Danfoss Turbocor Compressors Inc.
M-AP-001-ENG Rev. B
63
THIS PAGE INTENTIONALLY LEFT BLANK.
64
Danfoss Turbocor Compressors Inc.
M-AP-001-ENG Rev. B
Applications Manual
A
AC 63
voltage range 17
accessories 9
acronyms 63
AHRI 63
air-cooled units 48
ancillary devices 43
application
temperature 47
B
base
mounting 31
bearings 42
C
cable
AC input - see specification, cable
interface 25
capacity control 42
CE 63
compliance 20
CE Certification
TT300 7
TT350 7
TT400 7
CE Certification TT500 7
CE compliance 20
certification 7
clearance 31
compliance
CE 20
compressor
bearings 42
discharge side view 34
electronics 43
I/O board mounting 27
motor 42
multiple on common circuit 49
service side view 33
suction side view 32
compressor bearings 42
considerations
environmental 29
piping 28
shipping 29
construction 8
contactor
power line 19
Danfoss Turbocor Compressors Inc.
M-AP-001-ENG Rev. B
control
capacity 42
parallel 15
staged 15
Control Interface Wiring 23
control logic
multiple compressors 15
control logic guidelines
multiple compressors 15
parallel control 15
staged control 15
control requirements
system design 47
control wiring 23
connection guidelines 25
details 24
typical 23
CSA 63
D
data
physical 31
DC 63
design guidelines 44
application-specific requirements 47
control requirements 47
electrical requirements 46
general requirements 44
dimensions
flanges 41, 42
mounting base 35
Discharge Port Detail
TT300 35
TT400 36
TT500 36
discharge side
view 34
Discharge Side View
TT300 34
TT350 34
TT400 34
TT500 34
disconnects 17
DTC 63
E
electrical
requirements 46, 47
electrical connections
typical 18
65
electrical specifications 17
disconnects 17
electronics 43
EMC 63
EMI 63
EMI/EMC filtering 20
environment 8
environmental considerations 29
EPC 63
equipment panel 21
ETL 63
ETL certification
TT300 7
TT350
ETL certification
TT400 7
TT500 7
connection 20
system design 44
H
harmonic filtering 20
HFC 63
humidity 29
I
I/O board
mounting details 27
ID 63
IEEE 63
IGBT 63
IGV 63
interface cable 25
IP 63
L
evaporator
requirements 50
EXV 63
LBV 63
line protection 18
LLS 63
LRA 63
F
M
filter
EMI/EMC 20
harmonic 20
filtering
EMI/EMC 20
harmonic 20
FLA 63
flange details
TT300 41
TT350 and TT400 41
TT500 41
flanges
valve 31
FLC 63
frequency range 17
Mains Input Cable
specification 22
Maximum Pressure
TT300 8
TT350 8
TT400 8
TT500 8
maximum pressure 8
measurements
sound power (TT300) 56
sound power (TT400) 59
Minimum Unloading Capacity
TT300 13
TT350 14
TT400 14
TT500 15
motor
compressor 42
cooling line 28
Mounting Base
(TT300, TT350, TT400, TT500) 40
mounting base 31
dimensions 35
mounting details
I/O board 27
multiple compressors
common circuit 49
G
general specifications 7
grounding
connection guidelines 20
Earth connection guidelines 20
grounding connections
typical 21
GUI 63
guidelines
control wiring 25
control wiring connections 25
grounding
66
Danfoss Turbocor Compressors Inc.
M-AP-001-ENG Rev. B
Applications Manual
control logic 15
N
noise 9
NTC 63
O
OD 63
Operating Envelope
TT300 10
TT350 11
TT400 11
TT500 12
operating range 10
extended performance compressor 10
medium temperature compressor 10
P
panel
equipment 21
parallel control 15
PE 63
physical data 31
piping
considerations 28
piping considerations 28
PLC 63
power line
contactor 19
pressure
maximum 8
protection
surge 20
PWM 63
R
range
AC voltage 17
frequency 17
operating 10
refrigerant 42
type 8
refrigerant type 8
refrigeration
sample circuits 50
typical piping schematic 53, 54
Refrigeration Piping
schematic using motor-cooling pressure regulating
valve 53
schematic using multiple compressors on a common circuit 54
schematic with flash tank economizer 51
Danfoss Turbocor Compressors Inc.
M-AP-001-ENG Rev. B
schematic with load balancing valve 51
schematic with multiple DX evaporators 53
schematic with sub-cooler circuit economizer 52
typical schematic 50
requirements
application-specific 47
control 47
electrical 46, 47
evaporator 50
general 44
resistance
vs. temperature 30
S
safety summary 7
SDT 63
Service Side View
TT300 33
TT350 33
TT400 33
TT500 33
shipping considerations 29
sound 55
sound power
measurements 56
measurements (TT400) 59
sound pressure
calculation 56
sound pressure calculation 60
specification
accessories 55
cable 22
supply voltage 17
temperature/pressure thermistor 30
specifications
ancillary devices 43
capacity control 42
compressor bearings 42
compressor electronics 43
compressor motor 42
electrical 17
general 7
refrigerant 42
TT300 42
TT350 42
TT400 42
TT500 42
SST 63
staged control 15
67
Suction Front View
TT300 32
TT350 32
TT400 32
TT500 32
Suction Port
T300 37
TT350 37
TT400 37
TT500 37
Suction Port Detail
TT300 37
TT350 37
TT400, 37
TT500 37
suction side view
compressor 32
supply voltage
specification 17
surge protection 20
system design
general requirements 44
guidelines 44
T
temperature
application 47
vs resistance 30
temperature/pressure thermistor
specification 30
TT 63
TT300
minimum unloading capacity 13
operating envelope 10
sound power measurements 55
valve flange details 41
TT350
mnimum unloading capacity 14
operating envelope 11
68
valve flange details 41
TT400
minimum unloading capacity 14
operating envelope 11
sound power measurements 59
valve flange details 41
TT500
flange valve details 41
minimum unloading capacity 15
operating envelope 12
TXV 63
U
UL 63
units
air-cooled 48
unloading capacity
minimum 13
UV 63
V
valve
flanges 31
valve flange
details TT300 41
valve flange details TT400 41
valve flanges 31
VFD 63
vibration 29
view
discharge side 34
suction side 32
voltage range
AC 17
W
wiring
control 23
control interface 23
Danfoss Turbocor Compressors Inc.
M-AP-001-ENG Rev. B
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 © 2011
Printed in USA