TWIN-TURBINE CENTRIFUGAL COMPRESSOR - Danfoss Rev. B Applications... · TWIN-TURBINE CENTRIFUGAL...

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APPLICATIONS MANUAL Danfoss Turbocor Compressors Inc. M-AP-001-ENG Rev. B February 2012 TWIN-TURBINE CENTRIFUGAL COMPRESSOR MODELS TT300, TT350, TT400 & TT500 Refrigerant R134a

Transcript of TWIN-TURBINE CENTRIFUGAL COMPRESSOR - Danfoss Rev. B Applications... · TWIN-TURBINE CENTRIFUGAL...

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

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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 [email protected]

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 [email protected].

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List of Changes

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)"

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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"

52

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List of Changes .................................................................................................................................................. 41 Introduction................................................................................................................................................... 72 Safety Summary............................................................................................................................................ 73 Product Certification..................................................................................................................................... 74 General Specifications .................................................................................................................................. 7

4.1 Maximum Pressure ....................................................................................................................... 84.2 Construction.................................................................................................................................. 84.3 Refrigerant Type ........................................................................................................................... 84.4 Environment.................................................................................................................................. 84.5 Noise ............................................................................................................................................. 9

5 Accessories ................................................................................................................................................... 96 Product Application ...................................................................................................................................... 97 Economizer Option ....................................................................................................................................... 98 Minimum Unloading Capacity ................................................................................................................... 139 Control Logic Guidelines For Multiple Compressors ................................................................................ 15

9.1 Staging of the Compressors ........................................................................................................ 1510 Electrical Specifications............................................................................................................................ 17

10.1 Supply Voltage and Frequency................................................................................................. 1710.2 Disconnects ............................................................................................................................... 1710.3 AC Input Line/Power Electronic Component Protection ......................................................... 1810.4 Power Line Contactor ............................................................................................................... 1910.5 CE Compliance and EMI/EMC Filtering ................................................................................. 2010.6 Surge Protection........................................................................................................................ 2010.7 Harmonic Filtering (IEEE 519) ................................................................................................ 2010.8 Grounding (Earth) Connection Guidelines ............................................................................... 2010.9 Equipment Panel ....................................................................................................................... 2110.10 Mains Input Cable Specification............................................................................................. 22

11 Control Interface Wiring........................................................................................................................... 2311.1 Control Wiring Connection Guidelines .................................................................................... 2511.2 Interface Cable.......................................................................................................................... 2511.3 Compressor I/O Board Mounting Details ................................................................................. 27

12 Piping Considerations .............................................................................................................................. 2813 Environmental Considerations.................................................................................................................. 29

13.1 Humidity ................................................................................................................................... 2913.2 Vibration ................................................................................................................................... 29

14 Shipping Considerations ........................................................................................................................... 2914.1 Vibration ................................................................................................................................... 29

15 Combined Temperature/Pressure Thermistor Specification..................................................................... 3016 Physical Data ............................................................................................................................................ 31

16.1 Mounting Base.......................................................................................................................... 3116.2 Clearance .................................................................................................................................. 3116.3 Valve Flanges ........................................................................................................................... 31

17 Guide Specifications ................................................................................................................................. 4217.1 General...................................................................................................................................... 4217.2 Refrigerant ................................................................................................................................ 4217.3 Compressor Bearings................................................................................................................ 4217.4 Capacity Control ....................................................................................................................... 4217.5 Compressor Motor .................................................................................................................... 42

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17.6 Compressor Electronics ............................................................................................................ 4317.6.1 Ancillary Devices ............................................................................................................ 43

18 System Design Guidelines (R134a) .......................................................................................................... 4418.1 General Requirements............................................................................................................... 4418.2 Economizer Option ................................................................................................................... 4618.3 Motor/Electronics Cooling Requirements ................................................................................ 4618.4 Electrical Requirements............................................................................................................ 4718.5 Control Requirements ............................................................................................................... 4718.6 Application-Specific Requirements.......................................................................................... 47

18.6.1 Medium Evaporating Temperature Application (TT300) ............................................... 4718.6.2 Air-Cooled Units ............................................................................................................. 4818.6.3 Inverted Start ................................................................................................................... 4818.6.4 Multiple Compressors on Common Circuit Using

One Evaporator and One Condenser ............................................................................ 4918.6.5 Packaged Air-Side With DX-Type Evaporator and Multiple Evaporator Coils ............. 50

19 Sample Refrigeration Circuits................................................................................................................... 5020 Sound Power Specifications ..................................................................................................................... 55

20.1 TT300 Sound Power Measurements......................................................................................... 5520.1.1 Results ............................................................................................................................. 56

20.2 TT400 Sound Power Measurements......................................................................................... 5920.2.1 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 and CE listed and have been tested in accordance with UL Standard 984 and CSA Standard C22.2.

NOTE

4 General Specifications

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

Unit TT300 TT350 TT400 TT500

4.2 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

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).

kPa 1800 1800 1240 1240

PSI 260 260 180 180

NOTEThe 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.

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• Operation: -1°C to 46°C (30°F to 115°F).

• Electronic Minimum Operating Limit: -25°C (-13°F)

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.

NOTEContact 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.

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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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8 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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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.

NOTEThese 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.

NOTEPressure ratio is the ratio of absolute discharge to absolute suction pressure. It can be calculated as follows:

• (DP + 101) / (SP + 101) (kPa) OR

• (DP + 14.7) / (SP + 14.7) (psi)

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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 10-2 Acceptable Frequency Range

Nominal Frequency

Acceptable Frequency Range

NOTE

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.

Table 10-1 Acceptable AC Voltage Range

Acceptable Voltage Range

342 - 418 VAC

360 - 440 VAC

414 - 506 VAC

518 - 635 VAC

50Hz 50Hz ±5% (47Hz - 53Hz)

60Hz 60Hz ±5% (57Hz - 63Hz)

The frequency ranges in the table above apply only when generator power is being used.

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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.

! • • • CAUTION! • • •

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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.

10.4 Power Line Contactor

The power line contactor is optional. Consult local codes to determine if a contactor is necessary for your application.

• • • 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.

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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.

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

NOTEThe 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.

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 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 user-configurable 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 0-10V via onboard jumpers.

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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.

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).

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.

NOTEIf 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.

Table 11-1 Control Wiring Details (Continued)

I/O Description

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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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12 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 non-return 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

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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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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

Compressor valve flange details are shown in Figure 28 and Figure 29. Refer to the product specifications in the Accessories Manual for further details.

! • • • 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.

Danfoss Turbocor Compressors Inc. 31 M-AP-001-ENG Rev. B

Figure 17 Suction/Front View (TT300, TT350, TT400 and TT500)

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Figure 18 Service Side View (TT300, TT350, TT400 and TT500)

Danfoss Turbocor Compressors Inc. 33 M-AP-001-ENG Rev. B

Figure 19 Discharge Side View (TT300, TT350, TT400 and TT500)

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Gas Flow

Figure 20 Discharge Port Details (TT300)

Gas Flow

Figure 21 Discharge Port Details (TT350)

Danfoss Turbocor Compressors Inc. 35 M-AP-001-ENG Rev. B

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. 37 M-AP-001-ENG Rev. B

Figure 25 Suction Port Detail (TT300, TT350, TT400)

Gas Flow

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Figure 26 Suction Port Detail (TT500)

Gas Flow

Danfoss Turbocor Compressors Inc. 39 M-AP-001-ENG Rev. B

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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Figure 28 TT300 Flange Footprint Details

Figure 29 TT350 and TT400 Flange Footprint Details

Figure 30 TT500 Flange Footprint Details

Danfoss Turbocor Compressors Inc. 41 M-AP-001-ENG Rev. B

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 de-levitation 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 variable-speed 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. 43 M-AP-001-ENG Rev. B

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.

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.

NOTEThe 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.

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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.

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.

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”

NOTEIf steel pipe is used, the pipe must be selected to give the equivalent inside diameter to copper pipe.

Danfoss Turbocor Compressors Inc. 45 M-AP-001-ENG Rev. B

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.

NOTE

18.3 Motor/Electronics Cooling Requirements

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.

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.

Filter dryer, sight glass and service valve must be fitted in the motor-cooling liquid line.

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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

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)

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.

NOTEThe factory-installed temperature sensor on the compressor suction port should not be used for this purpose.

NOTEMedium Evaporating Temperature is defined as between 0 and -10 degrees C (between 32 and 14 degrees F).

Danfoss Turbocor Compressors Inc. 47 M-AP-001-ENG Rev. B

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.

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

NOTEAir Cooled compressors must include a staging valve in the refrigerant circuit.

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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.

NOTEContact Danfoss Turbocor for compressor selection and technical advice.

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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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Figure 33 Typical Refrigeration Piping SchematicWith Staging and Load Balancing Valve

Figure 34 Typical Refrigeration Piping Schematic With Flash Tank Economizer

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Figure 35 Typical Refrigeration Piping Schematic With Sub-Cooler Circuit Economizer

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Figure 36 Typical Refrigeration Piping Schematic Using Motor-Cooling Pressure- Regulating Valve

(Medium Temperature Compressors Only)

Figure 37 Typical Refrigeration Piping Schematic With Multiple DX Evaporators

Danfoss Turbocor Compressors Inc. 53 M-AP-001-ENG Rev. B

Figure 38 Typical Refrigeration Piping Schematic Using Multiple Compressorson a Common Circuit With a Flooded Evaporator

NOTEContact 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

Below are the results from “Sound Power Measurements on a Turbocor TT300 Compressor.

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.

Danfoss Turbocor Compressors Inc. 55 M-AP-001-ENG Rev. B

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

Table 20-2 Sound Pressure Calculation

Distance inRelation to

Compressor (meters)

Operational Mode of Compressor (Capacity)

250 kW (70 Ton) dBA

315 kW (90 Ton) dBA

250 kW 81.5 81.5 1070 Hz

315 kW 86.0 85.5 1180 Hz

1 72.5 78.0

2.5 65.5 70.0

5 59.5 64.0

8 55.5 60.0

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Table 20-3 Sound Power at Third Octave Band, TT300 Compressor 250 kW Mode

Third octaveband (Hz)

Sound PowerLinear scale

(dB)

Sound PowerA-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. 57 M-AP-001-ENG Rev. B

Table 20-4 Sound Power at Third Octave Band, TT300 Compressor 315 kW Mode

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

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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

Below are the results from “Sound Power Measurements on a Turbocor TT400 Compressor.

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.

Danfoss Turbocor Compressors Inc. 59 M-AP-001-ENG Rev. B

20.2.1 Results

The sound power measured with the discrete point method under two operational modes is presented in Table 20-5. 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

Table 20-6 Sound Pressure Calculation

Distance in Relation to

Compressor (meters)

Operational Mode of Compressor (Capacity)

420 kW (120 Ton)dBA

525 kW (150 Ton)dBA

420 kW 88.4 89.1

563 kW 88.1 89.2

1 81 82

1.5 77 78

3 71 72

5 68 69

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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

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Table 20-8 Sound Power at Third Octave Bandof TT400 Compressor, 525 kW Mode

Third octave band (Hz)

Sound Power Linear scale

(dB)

Sound Power A-weighted (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

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Appendix A: AcronymsAC 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

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AAC 63

voltage range 17accessories 9acronyms 63AHRI 63air-cooled units 48ancillary devices 43application

temperature 47Bbase

mounting 31bearings 42Ccable

AC input - see specification, cableinterface 25

capacity control 42CE 63

compliance 20CE Certification

TT300 7TT350 7TT400 7

CE Certification TT500 7CE compliance 20certification 7clearance 31compliance

CE 20compressor

bearings 42discharge side view 34electronics 43I/O board mounting 27motor 42multiple on common circuit 49service side view 33suction side view 32

compressor bearings 42considerations

environmental 29piping 28shipping 29

construction 8contactor

power line 19

controlcapacity 42parallel 15staged 15

Control Interface Wiring 23control logic

multiple compressors 15control logic guidelines

multiple compressors 15parallel control 15staged control 15

control requirementssystem design 47

control wiring 23connection guidelines 25details 24typical 23

CSA 63Ddata

physical 31DC 63design guidelines 44

application-specific requirements 47control requirements 47electrical requirements 46general requirements 44

dimensionsflanges 41, 42mounting base 35

Discharge Port DetailTT300 35TT400 36TT500 36

discharge sideview 34

Discharge Side ViewTT300 34TT350 34TT400 34TT500 34

disconnects 17DTC 63Eelectrical

requirements 46, 47electrical connections

typical 18

Danfoss Turbocor Compressors Inc. 65 M-AP-001-ENG Rev. B

electrical specifications 17disconnects 17

electronics 43EMC 63EMI 63EMI/EMC filtering 20environment 8environmental considerations 29EPC 63equipment panel 21ETL 63ETL certification

TT300 7TT350

ETL certificationTT400 7

TT500 7evaporator

requirements 50EXV 63Ffilter

EMI/EMC 20harmonic 20

filteringEMI/EMC 20harmonic 20

FLA 63flange details

TT300 41TT350 and TT400 41TT500 41

flangesvalve 31

FLC 63frequency range 17Ggeneral specifications 7grounding

connection guidelines 20Earth connection guidelines 20

grounding connectionstypical 21

GUI 63guidelines

control wiring 25control wiring connections 25grounding

connection 20system design 44

Hharmonic filtering 20HFC 63humidity 29II/O board

mounting details 27ID 63IEEE 63IGBT 63IGV 63interface cable 25IP 63LLBV 63line protection 18LLS 63LRA 63MMains Input Cable

specification 22Maximum Pressure

TT300 8TT350 8TT400 8TT500 8

maximum pressure 8measurements

sound power (TT300) 56sound power (TT400) 59

Minimum Unloading CapacityTT300 13TT350 14TT400 14TT500 15

motorcompressor 42cooling line 28

Mounting Base(TT300, TT350, TT400, TT500) 40

mounting base 31dimensions 35

mounting detailsI/O board 27

multiple compressorscommon circuit 49

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control logic 15Nnoise 9NTC 63OOD 63Operating Envelope

TT300 10TT350 11TT400 11TT500 12

operating range 10extended performance compressor 10medium temperature compressor 10

Ppanel

equipment 21parallel control 15PE 63physical data 31piping

considerations 28piping considerations 28PLC 63power line

contactor 19pressure

maximum 8protection

surge 20PWM 63Rrange

AC voltage 17frequency 17operating 10

refrigerant 42type 8

refrigerant type 8refrigeration

sample circuits 50typical piping schematic 53, 54

Refrigeration Pipingschematic using motor-cooling pressure regulating

valve 53schematic using multiple compressors on a com-

mon circuit 54schematic with flash tank economizer 51

schematic with load balancing valve 51schematic with multiple DX evaporators 53schematic with sub-cooler circuit economizer 52typical schematic 50

requirementsapplication-specific 47control 47electrical 46, 47evaporator 50general 44

resistancevs. temperature 30

Ssafety summary 7SDT 63Service Side View

TT300 33TT350 33TT400 33TT500 33

shipping considerations 29sound 55sound power

measurements 56measurements (TT400) 59

sound pressurecalculation 56

sound pressure calculation 60specification

accessories 55cable 22supply voltage 17temperature/pressure thermistor 30

specificationsancillary devices 43capacity control 42compressor bearings 42compressor electronics 43compressor motor 42electrical 17general 7refrigerant 42TT300 42TT350 42TT400 42TT500 42

SST 63staged control 15

Danfoss Turbocor Compressors Inc. 67 M-AP-001-ENG Rev. B

Suction Front ViewTT300 32TT350 32TT400 32TT500 32

Suction PortT300 37TT350 37TT400 37TT500 37

Suction Port DetailTT300 37TT350 37TT400, 37TT500 37

suction side viewcompressor 32

supply voltagespecification 17

surge protection 20system design

general requirements 44guidelines 44

Ttemperature

application 47vs resistance 30

temperature/pressure thermistorspecification 30

TT 63TT300

minimum unloading capacity 13operating envelope 10sound power measurements 55valve flange details 41

TT350mnimum unloading capacity 14operating envelope 11

valve flange details 41TT400

minimum unloading capacity 14operating envelope 11sound power measurements 59valve flange details 41

TT500flange valve details 41minimum unloading capacity 15operating envelope 12

TXV 63UUL 63units

air-cooled 48unloading capacity

minimum 13UV 63Vvalve

flanges 31valve flange

details TT300 41valve flange details TT400 41valve flanges 31VFD 63vibration 29view

discharge side 34suction side 32

voltage rangeAC 17

Wwiring

control 23control interface 23

68 Danfoss Turbocor Compressors Inc. M-AP-001-ENG Rev. B

Copyright © 2011 Printed in USA

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