TWIN-TURBINE CENTRIFUGAL COMPRESSOR - AND OPERATION MANUAL Danfoss Turbocor Compressors Inc....

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Transcript of TWIN-TURBINE CENTRIFUGAL COMPRESSOR - AND OPERATION MANUAL Danfoss Turbocor Compressors Inc....

  • TWIN-TURBINE CENTRIFUGAL COMPRESSOR

    INSTALLATION AND OPERATION MANUAL

    Danfoss Turbocor Compressors Inc. CSS-IOP-D01-L1-V06.0July 2010

  • This Page Left Intentionally Blank

  • Installation and Operation Manual

    Table of Contents

    Proprietary Notice ........................................................................................................... 5List of Changes ............................................................................................................... 6Introduction ...................................................................................................................... 9Tools ................................................................................................................................ 9Safety Summary............................................................................................................. 10

    Safety Warnings ................................................................................................. 10Voltage Checks Using DC Bus Test Harness (Safety Cable) ............................ 12Voltage Checks Using DC Bus Test Harness .................................................... 12

    Installation ...................................................................................................................... 19Unpacking and Inspection .................................................................................. 19Rigging Requirements........................................................................................ 19Unit Placement ................................................................................................... 19Piping Connections ............................................................................................ 21Control Wiring..................................................................................................... 24

    Compressor I/O Board - Mounting Instructions ............................................. 24Control Wiring Connections .......................................................................... 24Control Wiring Connection Guidelines ................ .......................................... 25Control Wiring Details ................................................................................... 27Circuit Grounding .......................................................................................... 29Voltage-Free Contacts .................................................................................. 32

    Power Wiring ...................................................................................................... 33Commissioning............................................................................................................... 35

    I/O Jumper Setup and Initial Checks.................................................................. 35I/O Jumper Settings ...................................................................................... 35System Checks ............................................................................................. 38

    Configuring the Compressor Using the Service Monitoring Tool ....................... 42System Requirements ................................................................................... 43Software Installation ...................................................................................... 44Monitoring Tool Installation ........................................................................... 44

    Establishing a Connection.................................................................................. 51RS-232 Connection ....................................................................................... 52RS-485 Connection ....................................................................................... 52

    Service Monitoring Tool Basics .......................................................................... 53Starting the Service Monitoring Tool ............ ................................................. 53Entering User Input ....................................................................................... 53Compressor Connection Manager ................................................................ 53Controlling User Access ................................................................................ 54Changing Access Codes ............................................................................... 55

    Monitor w/o Connection...................................................................................... 56Using the Compressor Commissioning Wizard.................................................. 57

    Chiller Control Mode ..................................................................................... 60

    Danfoss Turbocor Compressors Inc. 3CSS-IOP-D01-L1-V06.0

  • Startup Settings ............................................................................................ 61Electronic Valve Control ................................................................................ 63Analog Output Setup ..................................................................................... 66Modbus Communications ............................................................................. 68Review and For Download Settings ............. ................................................. 69

    Running Checks ................................................................................................. 73Functional Description.................................................................................................... 75

    Compressor Fundamentals ................................................................................ 75Main Fluid Path ............................................................................................. 75Motor Cooling ................................................................................................ 77Inlet Guide Vanes ......................................................................................... 79

    Compressor Control Overview ........................................................................... 79Motor Drive System ...................................................................................... 81Soft-Start Board ............................................................................................ 81Bearing Motor Compressor Controller ........... ............................................... 81Abnormal Conditions ..................................................................................... 83Bearing PWM Amplifier ................................................................................. 83Serial Driver .................................................................................................. 83Backplane .............. ....................................................................................... 89High-Voltage DC-DC Converter .................................................................... 90

    Magnetic Bearing System .................................................................................. 91Overview ............ ........................................................................................... 91Bearing Control System ................................................................................ 91

    Power Line Control and Filtering ........................................................................ 93Power Line Contactor ................................................................................... 93Power Line Filters and Line Reactor .............. ............................................... 93

    Compressor Operating Modes ........................................................................... 94Analog Mode ................................................................................................. 94Chiller Mode .................................................................................................. 95Modbus Mode ............................................................................................... 95

    Expansion Valve Control .................................................................................... 95Operational Maintenance Checks .................................................................................. 96

    Owner's Responsibilities .................................................................................... 96Frequency of Inspections ................................................................................... 96Checking the Main Supply Voltage .................................................................... 99

    Mounting Instructions .................................................................................. 107AC Line Cable Connection (From External Disconnect) ............................. 109AC Line Cable Connection (to Compressor Terminal) ................................ 109Line Side Connection .................................................................................. 111Load Side Connection ................................................................................. 111Mounting Instructions .................................................................................. 114

    4 Danfoss Turbocor Compressors Inc.CSS-IOP-D01-L1-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 adva