Danfoss TT-300 User Manual

[Page 1] Danfoss TT-300

SERVICE MONITOR USER MANUAL Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1 TWIN-TURBINE CENTRIFUGAL COMPRESSOR MODEL TT-300 ...

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Contents Danfoss Turbocor Compressors Inc. i ECD-00007M Rev. 1 Introduction 1 System Requirements 2 Getting Started 3 Cable Connection 3 RS232 Connection 3 RS485 Connection 3 Monitor Program Installation 5 Starting the Monitor Program 5 User ...

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Contents ii Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1 Motor Monitoring 28 Motor Monitoring Overview 28 Motor Faults / Alarms 30 Magnetic Bearing Monitoring 31 Bearing Monitoring Overview 31 Bearing Faults 33 Electronic Valve Data / T...

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Service Monitor User Manual Danfoss Turbocor Compressors Inc. 1 ECD-00007M Rev. 1 1 Introduction The Turbocor Service Monitor program is a rich, user- friendly, graphical user interface designed to control the Turbocor compressor and to provide stat...

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System Requirements 2 Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1 2 System Requirements The monitor program must be installed on a PC that meets the minimum requirements specified in Table 1. For optimum performance, a 533 MHz Pentium or hi...

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Service Monitor User Manual Danfoss Turbocor Compressors Inc. 3 ECD-00007M Rev. 1 3 Getting Started 3.1 Cable Connection The monitoring program communicates with the compressor via the Modbus* protocol using either the RS232 or RS485 connection at ...

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Getting Started 4 Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1 Figure 2 PC to Modbus Connection (single compressor with > 10 m cable length) Figure 3 PC to Modbus Connection (multiple compressors with > 10 m cable length) ...

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Service Monitor User Manual Danfoss Turbocor Compressors Inc. 5 ECD-00007M Rev. 1 3.2 Monitor Program Installation The monitor program is installed on the PC and communicates with the compressor using the ModBus protocol over a RS-232 or RS-485 ser...

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Getting Started 6 Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1 3.4.2 Entering User Input When user input is required for the monitor program fields, perform the following sequence: 1. Double-click the variable field. (This activates the field...

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Service Monitor User Manual Danfoss Turbocor Compressors Inc. 7 ECD-00007M Rev. 1 Access Code - The access code controls access to all adjustable parameters. The default user access level on power up is read only. Enter the code that corresponds to...

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Compressor Configuration 8 Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1 • Modbus Network: the compressor receives a demand from an external computer, PLC, or building management system using the Modbus protocol on a RS-232 or RS-485 commu...

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Service Monitor User Manual Danfoss Turbocor Compressors Inc. 9 ECD-00007M Rev. 1 2. Enter the Temporary Suction Pressure Delay Time. This parameter represents time in seconds that the temporary suction pressure alarm / fault limit should be enabl...

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Compressor Configuration 10 Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1 to hold the number of steps sent to the motor as determined by the Starting Valve Position %. Value is in seconds and starts to count down when the drive is enabled. 5...

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Service Monitor User Manual Danfoss Turbocor Compressors Inc. 11 ECD-00007M Rev. 1 4.1.3 Analog Output Setup The compressor features a universal analog output for load balancing valve, IGV position, discharge pressure, etc. The operating range can ...

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Compressor Configuration 12 Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1 2. Enter the Starting Output. This value equals the percentage of maximum voltage sent to the terminals of the Chiller Interface module on compressor start-up. The ana...

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Service Monitor User Manual Danfoss Turbocor Compressors Inc. 13 ECD-00007M Rev. 1 1. Turn OFF power to the compressor. Wait at least 5 minutes, then check that the LEDs on the Backplane are OFF. 2. Turn ON power to the compressor. IMPORTANT: Recor...

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Compressor Configuration 14 Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1 4.3 Controlling User Access The access code system allows OEM customers to set their own unique pass codes thereby restricting access to company authorized personnel. T...

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Service Monitor User Manual Danfoss Turbocor Compressors Inc. 15 ECD-00007M Rev. 1 5 Starting and Stopping the Compressor The following sections describes how to start and stop the compressor. Refer to the section corresponding to the control metho...

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Starting and Stopping the Compressor 16 Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1 5.2.2 How to Stop the Compressor To stop the compressor, enter ‘0’ in the Loading Demand field. 5.3 Chiller Control The Chiller Control mode is fully aut...

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Service Monitor User Manual Danfoss Turbocor Compressors Inc. 17 ECD-00007M Rev. 1 Figure 18 Chiller Control Form ...

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Monitor Program Data and Controls 18 Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1 6 Monitor Program Data and Controls This section provides a detailed description of the forms and related data and controls that are accessible via the monitor...

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Service Monitor User Manual Danfoss Turbocor Compressors Inc. 19 ECD-00007M Rev. 1 Figure 19 General Data Page Table 4 General Data Page Parameters Parameter Description Ts [sat] Saturated suction temperature Tc [sat] Saturated discharge temperatu...

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Monitor Program Data and Controls 20 Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1 6.2 Bearing Calibration The “Calibration Data” window allows the user to view and compare the data of the latest calibration performed with the latest stor...

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Service Monitor User Manual Danfoss Turbocor Compressors Inc. 21 ECD-00007M Rev. 1 FRY Max Maximum DC voltage indicating maximum front radial y displacement. BRX Min Minimum DC voltage indicating minimum rear radial x displacement. BRX Max Maximum DC...

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Monitor Program Data and Controls 22 Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1 6.2.1 Bearing Calibration Procedure For the bearing calibration to be performed: • The shaft must be de-levitated • The interlock connection on the Chiller I...

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Service Monitor User Manual Danfoss Turbocor Compressors Inc. 23 ECD-00007M Rev. 1 the “Latest Check” and the “Stored Calibration”; see 6.2.2 "Calibration Data Interpretation": - FRX Gain - FRY Gain - BRX Gain - BRY Gain - AX Gain ...

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Monitor Program Data and Controls 24 Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1 Figure 24 Compressor Controller Form ...

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Service Monitor User Manual Danfoss Turbocor Compressors Inc. 25 ECD-00007M Rev. 1 Table 6 Compressor Controller Parameters Parameter Description Te (on title bar) Evaporation Temperature Tc (on title bar) Condensation Temperature SH (on title bar) ...

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Monitor Program Data and Controls 26 Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1 6.3.1 Compressor Control Modes Calibration In Calibration mode, the compressor prepares itself for calibration. Any external demand will be blocked from the sy...

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Service Monitor User Manual Danfoss Turbocor Compressors Inc. 27 ECD-00007M Rev. 1 NOTE: In Manual Control mode, the Chiller Interface interlock switch has no effect on the compressor state. Analog Input The Analog Input mode controls the compressor...

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Monitor Program Data and Controls 28 Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1 6.4 Motor Monitoring 6.4.1 Motor Monitoring Overview The “Variable Speed Permanent Magnet Motor Monitoring” window allows the user to: • View the actual ...

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Service Monitor User Manual Danfoss Turbocor Compressors Inc. 29 ECD-00007M Rev. 1 Figure 25 Motor Monitoring Form Table 8 Motor Monitoring Parameters Parameter Description General Motor Data: Actual Shaft Speed (RPM) Actual shaft speed in RPM. Desi...

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Monitor Program Data and Controls 30 Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1 6.4.2 Motor Faults / Alarms This section describes the possible faults displayed in the “Variable Speed Permanent Magnet Motor Monitoring” window. Table 9 ...

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Service Monitor User Manual Danfoss Turbocor Compressors Inc. 31 ECD-00007M Rev. 1 NOTE: A motor alarm will slow down the motor, whereas a motor fault will trip the motor. 6.5 Magnetic Bearing Monitoring 6.5.1 Bearing Monitoring Overview The “Ma...

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Monitor Program Data and Controls 32 Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1 Figure 26 Magnetic Bearing Monitoring Form Table 10 Bearing Monitoring Parameters Parameter Description Shaft Levitation State Shaft state control. When in the ...

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Service Monitor User Manual Danfoss Turbocor Compressors Inc. 33 ECD-00007M Rev. 1 6.5.2 Bearing Faults This section describes the possible faults displayed in the “Magnetic Bearing Monitoring” window. Table 11 provides a description of the pos...

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Monitor Program Data and Controls 34 Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1 Chiller Interface module. Similarly, the “EXV#2 Control Settings” controls the stepper motor connected to “EXV2” on the Chiller Interface module. Table...

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Service Monitor User Manual Danfoss Turbocor Compressors Inc. 35 ECD-00007M Rev. 1 Table 12 Electronic Valve Data / Tuning Parameters (Stepper Motors) Parameter Description Control Mode Selects which control variable will be maintained by the stepper...

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Monitor Program Data and Controls 36 Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1 6.7 Chiller Control The “Chiller Control” window allows the user to control one of the following: • Leaving chiller water or air temperature • Entering ...

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Service Monitor User Manual Danfoss Turbocor Compressors Inc. 37 ECD-00007M Rev. 1 To view the “Chiller Control” window, select “Window”→ “Chiller Control” from the menu bar, or click on the “Chiller Control” icon located below th...

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Monitor Program Data and Controls 38 Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1 6.8 System Information To access the “System Information” window, select “Advanced”→ “System Information” from the menu bar. The “System Info...

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Service Monitor User Manual Danfoss Turbocor Compressors Inc. 39 ECD-00007M Rev. 1 6.8.1 Compressor Info Selecting the “Compressor Info” tab allows the user to view the system information. Specifically, it allows the user to view the: • Compr...

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Monitor Program Data and Controls 40 Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1 6.9.1 Compressor Controller Settings Select the “CC_Control” tab to view the following: • Monitor program measurement unit selected • Compressor Control ...

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Service Monitor User Manual Danfoss Turbocor Compressors Inc. 41 ECD-00007M Rev. 1 6.9.2 Compressor Controller Alarms Select the “CC Alarm Limits” tab to view the compressor general alarm limits. Table 16 describes the general alarm limits. The...

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Monitor Program Data and Controls 42 Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1 Figure 31 EEPROM Settings - Compressor Controller Alarm Limits Table 16 EEPROM Settings - Compressor Controller Alarm Limit Parameters Parameter Description Dis...

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Service Monitor User Manual Danfoss Turbocor Compressors Inc. 43 ECD-00007M Rev. 1 6.9.3 Compressor Controller Fault Limits Select the “CC Trip Limits” tab to view the compressor general fault limits. Table 17 describes the general trip limits....

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Monitor Program Data and Controls 44 Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1 6.9.4 Compressor Stepper Motor Settings Select the “Stepper Motor Controls” tab to view and change the compressor’s stepper motor settings. Specificall...

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Service Monitor User Manual Danfoss Turbocor Compressors Inc. 45 ECD-00007M Rev. 1 6.9.5 Stepper Motor Valve Controls Select the “EXV#1 Settings” tab to view the control settings for the electronic expansion valve #1 (EXV#1). EXV#1 refers to th...

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Monitor Program Data and Controls 46 Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1 Figure 34 EEPROM Settings - Stepper Motor Valve #1 Controls ...

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Service Monitor User Manual Danfoss Turbocor Compressors Inc. 47 ECD-00007M Rev. 1 6.9.6 Analog Output Controls Select the “Analog Output” tab to view the analog output control settings. The Analog Output Control Settings control the output lab...

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Monitor Program Data and Controls 48 Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1 . Figure 35 EEPROM Settings - Analog Output Controls ...

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Service Monitor User Manual Danfoss Turbocor Compressors Inc. 49 ECD-00007M Rev. 1 6.9.7 Compressor Controller Impeller Specific Settings Select the “Impeller Settings” tab to view the compressor controller impeller specific settings. The param...

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Monitor Program Data and Controls 50 Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1 6.9.8 Compressor Controller (CC) Critical Fault Lock Outs Select the “CC LockOuts” tab to view the setup for the CC critical fault lock outs. The “Numbe...

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Service Monitor User Manual Danfoss Turbocor Compressors Inc. 51 ECD-00007M Rev. 1 6.9.9 Refrigerant TBD 6.10 Compressor Event Log The compressor event log provides the user with details about the compressor events and faults. To view the “Compre...

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Monitor Program Data and Controls 52 Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1 Fault” parameter box indicates the current event being displayed. 6.11 History Data The “Compressor History Data” window provides the user with informati...

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Service Monitor User Manual Danfoss Turbocor Compressors Inc. 53 ECD-00007M Rev. 1 6.12 Trending 6.12.1 Graphs The trending graphs allow the user to view the individual “trends” of the parameters listed in Table 21 with respect to time. The tim...

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Monitor Program Data and Controls 54 Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1 down menu. All graphs may be cleared simultaneously by clicking on “Reset Graphs” located on the menu bar. When the “Graphs” window is closed, all param...

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Service Monitor User Manual Danfoss Turbocor Compressors Inc. 55 ECD-00007M Rev. 1 Discharge Pressure The actual discharge gauge pressure at the compressor flange as measured by the discharge pressure transducer. Suction Temperature The actual sucti...

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Monitor Program Data and Controls 56 Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1 6.12.2 Trending & Data Acquisition The “Trending & Data Acquisition” window allows the user to view and compare the trends of: • Multiple temperat...

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Service Monitor User Manual Danfoss Turbocor Compressors Inc. 57 ECD-00007M Rev. 1 For each parameter, check the checkbox next to the parameter to plot the parameter. Uncheck the checkbox to stop plotting the parameter. To clear the graphs, click o...

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Monitor Program Data and Controls 58 Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1 The graph, as shown in Figure 43, displays the saturated discharge temperature (SDT) versus the evaporator capacity. For a given evaporator capacity, the red l...

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Service Monitor User Manual Danfoss Turbocor Compressors Inc. 59 ECD-00007M Rev. 1 6.14 Fault Captures The “Fault Captures” window allows the user to view all the compressor faults, and the state of the compressor at the time the fault occurred...

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Monitor Program Data and Controls 60 Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1 6.15 Data Capture The “Compressor Data Capture Screen” allows the user to view the compressor data, listed in Table 22, at a particular instant in time. T...

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Service Monitor User Manual Danfoss Turbocor Compressors Inc. 61 ECD-00007M Rev. 1 Figure 46 Compressor Data Capture Screen ...

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Monitor Program Data and Controls 62 Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1 Table 22 List of Compressor Data Captured Data Parameter Description 0 Compressor Control Faults Displays the compressor’s most recent active critical fault. ...

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Service Monitor User Manual Danfoss Turbocor Compressors Inc. 63 ECD-00007M Rev. 1 24 Actual Shaft Speed (RPM) Actual rotational shaft speed. 25 Desired Shaft Speed (RPM) Desired rotational shaft speed. 26 Inverter Side Motor Amps Current outputted f...

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Service Monitor User Manual Danfoss Turbocor Compressors Inc. A-1 ECD-00007M Rev. 1 Appendix A: Determination of Actual Power Setting The BMC\CC holds four variables in the EPROM that determine the input power capability of the compressor based on ...

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A-2 Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1 For a reference pressure of 356kPa at 283ºK: The referred power is determined to be: PWR ref = 24.783*2.80-14.06 = 55.32 kW The actual maximum power is: PWRmax= 55.32 * (340 / 356) = 52.83 kW ...