TT 400, Applications Manual - EN

TWIN-TURBINE CENTRIFUGAL COMPRESSORS
Models: TT300, TT350, TT400, TT500 and TG310
APPLICATIONS MANUAL
Danfoss Turbocor Compressors Inc.
M-AP-001-EN Rev. J
May 2014
This Page Left Intentionally Blank
Applications Manual
Proprietary Notice
Copyright, Limitations of Liability and Revision Rights
This publication contains proprietary information to Danfoss Turbocor Compressors, Inc. (DTC). This
publication is protected under the Copyright laws of the United States of America (USA) and most other
countries. This work is owned by DTC, and was published as of the most recent revision of this publication, as
indicated on the Title page of this document. This document is for the use DTC customers and prospective
customers only. Any use beyond that is prohibited.
Tests have demonstrated that equipment produced according to the guidelines provided in this manual will
function properly, however DTC cannot guarantee the equipment to work in every physical, hardware or software
environment.
The guidelines provided in this manual are provided "AS-IS" without any warranty of any kind, either express or
implied, including, without limitation, any implied warranties of condition, uninterrupted use, merchantability,
fitness for a particular purpose.
In no event shall DTC be liable for direct, indirect, special, incidental or consequential damages arising out of the
manufacture, use, or the inability to manufacture or use information contained in this manual, even if advised of
the possibility of such damages. In particular, DTC is not responsible for any costs, including but not limited to
those incurred as a result of lost profits or revenue, loss of damage or equipment, loss of computer programs, loss
of data, the costs to substitute these, or any claims by third parties. In any event, DTC's total aggregate liability
for all damages of any kind and type (regardless of whether based in contract or tort) shall not exceed the
purchase price of this product.
DTC reserves the right to revise the publication at any time and to make changes to its contents without prior
notice or any obligation to notify former or present users of such revisions or changes.

1769 East Paul Dirac Drive
Tallahassee, Florida 32310
USA
Phone 1-850-504-4800
Fax 1-850-575-2126
www.turbocor.com
* Subject to change without notice.

* Danfoss Turbocors commitment to excellence ensures continuous product improvements.

M-AP-001-EN Rev. J

M-AP-001-EN Rev. J
Applications Manual
1 Introduction................................................................................................................................................... 7
1.1 Scope............................................................................................................................................. 7
2 Safety Summary............................................................................................................................................ 7
3 Product Certification..................................................................................................................................... 7
4 General Specifications .................................................................................................................................. 8
4.1 Maximum Pressure ....................................................................................................................... 8
4.2 Suction Pressure Limits ................................................................................................................ 9
4.3 Construction.................................................................................................................................. 9
4.4 Refrigerant Type ......................................................................................................................... 10
4.4.1 TG310 ................................................................................................................................ 10
4.5 Environment................................................................................................................................ 10
4.6 Noise ........................................................................................................................................... 10
4.7 Outdoor Installations................................................................................................................... 10
5 Accessories ................................................................................................................................................. 11
6 Product Application .................................................................................................................................... 11
6.1 TG310 ......................................................................................................................................... 11
7 Economizer Option ..................................................................................................................................... 11
8 Compressor Current Limit and Operating Range Settings ......................................................................... 12
9 Operating Envelopes................................................................................................................................... 14
10 Minimum Unloading Capacity ................................................................................................................. 19
11 Control Logic Guidelines For Multiple Compressors .............................................................................. 22
11.1 Staging of the Compressors ...................................................................................................... 22
12 Electrical Specifications............................................................................................................................ 23
12.1 Supply Voltage and Frequency................................................................................................. 23
12.2 Disconnects............................................................................................................................... 23
12.3 AC Input Line/Power Electronic Component Protection ......................................................... 24
12.4 Power Line Contactor ............................................................................................................... 25
12.5 CE Compliance and EMI/EMC Filtering ................................................................................. 25
12.6 Surge Protection........................................................................................................................ 25
12.7 Harmonic Filtering (IEEE 519) ................................................................................................ 25
12.8 Grounding (Earth) Connection Guidelines ............................................................................... 26
12.9 Equipment Panel ....................................................................................................................... 27
12.10 Mains Input Cable Specification............................................................................................. 27
13 Control Interface Wiring........................................................................................................................... 28
13.1 Control Wiring Connection Guidelines .................................................................................... 29
13.2 Interface Cable.......................................................................................................................... 30
13.3 Compressor I/O Board Mounting Details................................................................................. 31
14 Piping Considerations .............................................................................................................................. 32
15 Environmental Considerations.................................................................................................................. 33
15.1 Humidity ................................................................................................................................... 33
15.2 Vibration ................................................................................................................................... 33
16 Shipping Considerations ........................................................................................................................... 33
16.1 Vibration ................................................................................................................................... 33
17 Physical Data ............................................................................................................................................ 34
17.1 Mounting Base.......................................................................................................................... 34
17.2 Clearance .................................................................................................................................. 34
17.3 Valve Flanges ........................................................................................................................... 36
18 Guide Specifications ................................................................................................................................. 43

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18.1 General...................................................................................................................................... 43
18.2 Refrigerant ................................................................................................................................ 43
18.3 Compressor Bearings................................................................................................................ 43
18.4 Capacity Control ....................................................................................................................... 43
18.5 Compressor Motor .................................................................................................................... 43
18.6 Compressor Electronics ............................................................................................................ 43
18.6.1 Ancillary Devices ............................................................................................................ 44
19 System Design Guidelines ........................................................................................................................ 45
19.1 General Requirements............................................................................................................... 45
19.2 Economizer Option ................................................................................................................... 47
19.3 Motor/Electronics Cooling Requirements ................................................................................ 47
19.4 Electrical Requirements............................................................................................................ 47
19.5 Application-Specific Requirements.......................................................................................... 48
19.5.1 Medium Evaporating Temperature Application (TT300) ............................................... 48
19.5.2 Air-Cooled Systems/Chillers ........................................................................................... 48
19.5.3 Inverted Start ................................................................................................................... 49
19.5.4 Multiple Compressors on Common Circuit Using
One Evaporator and One Condenser ............................................................................ 49
19.5.5 Packaged Air-Side With DX-Type Evaporator and Multiple Evaporator Coils ............. 50
20 Sample Refrigeration Circuits................................................................................................................... 51
21 Sound Power Specifications ..................................................................................................................... 56
21.1 TT300 Sound Power Measurements......................................................................................... 56
21.1.1 Results ............................................................................................................................. 56
21.2 TT400 Sound Power Measurements......................................................................................... 58
21.2.1 Results ............................................................................................................................. 58
Appendix A: Acronyms ................................................................................................................................... 61

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Applications Manual
Introduction
This Application Manual is intended to inform application data/ procedures specific to Turbocor 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.
1.1
Scope
This manual is designed for use with BMCC software, Version 3.0.0 and later.
Table 1 Application Manual Applicability
Manual
Release Date
BMCC Firmware Versions
M-AP-001-XX Rev E
September 2013
BMCv2.283x/XXv2.3.1213
M-AP-001-XX Rev J
May 2014
BMCv2.283x/CC3.0.0 and later
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.
Product Certification
The TT300, TT350, TT400 and TT500 compressors are ETL

with UL Standard 984 and CSA Standard C22.2.
The TG310 compressors are
and

M-AP-001-EN Rev. J
and CE
listed and have been tested in accordance
listed only.
General Specifications
Please refer to Section 18 for a detailed description of the specifications.
4.1
Maximum Pressure
The maximum pressure that the compressor can operate is regulated directly by two control settings: (1) Alarm Limit and (2)
Trip Limit. It is also controlled by a Pressure Ratio alarm limit monitoring the ratio between the Discharge and Suction
Pressures.
The Discharge Pressure Alarm Limit is defined in Table 4-1.
Table 4-1 Maximum Discharge Pressure Alarm Limits
Unit
TG310 HL TT300 ST*
TT300 MT
TT350 HL
TT400 ST
TT500 ST
kPa(g)
1240
1190
1190
1730
1190
1190
psig
180
172
172
250
172
172
*The TT300 ST compressor allows for adjustment of this setting.

Compressors which are placed in Air-Cooled applications can have this value
increased up to 1730 kPa(g)/250 psig.
The Discharge Pressure Trip Limit is defined in Table 4-2.

Table 4-2 Maximum Discharge Pressure Trip Limits
Unit
TG310 HL TT300 ST*
TT300 MT
TT350 HL
TT400 ST
TT500 ST
kPa(g)
1300
1240
1240
1800
1240
1240
psig
188
180
180
260
180
180
*The TT300 ST compressors allow for adjustment of this setting.

increased up to 1800 kPa(g)/260 psig.
NOTE
While the values here are represented in Gauge Pressure, the values in the registers will be defined in Absolute
Pressure. Refer to the OEM Programming Guide to identify the specific registers associated with the Discharge
Pressure Alarm and Discharge Pressure Trip Limits.
The compressor will also adjust its operation if the pressure ratio exceeds the alarm limit. The Pressure Ratio alarm limit is
defined in Table 4-3.
Table 4-3 Maximum Pressure Ratio Limits
Compressor
TT350 HL
TT400 ST
TT500 ST
Alarm
TG310 HL TT300 ST* TT300 MT

5.2
4.0
4.0
5.2
3.5
3.5
Trip
5.5
5.2
5.2
5.5
4.0
4.0
*The TT300 ST compressor allows for adjustment of this setting.

increased up to 4.8.

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Applications Manual
NOTE
Pressure ratio must be calculated using absolute pressures. Refer to the OEM Programming Guide to identify the
specific register associated with the Pressure Ratio Alarm Limit.
Beyond these control limits, the Maximum Design High-Side Pressure for the compressor is shown in Table 4-4.
Table 4-4 Maximum Design High-Side Pressure
Certification
Unit
TG310
TT300
TT350
TT400
TTT500
-NC
(UL/ETL)
kPag
N/A
2070
2070
2070
2070
psig
N/A
300
300
300
300
-CE
kPag
1300
1880
1880
1790
1790
psig
188
273
273
260
260
4.2
Suction Pressure Limits
The Suction Pressure alarm and trip limits are displayed in the table below.
Table 4-5 Suction Pressure Limits
Compressor
4.3
TG310 HL
TT300 ST*
TT300 MT
TT350 HL
TT400 ST
TT500 ST
Unit
kPa(g)
psig
kPa(g)
psig
kPa(g)
psig
kPa(g)
psig
kPa(g)
psig
kPa(g)
psig
Alarm
99
14.3
177
25.5
91
13.2
177
25.5
177
25.5
177
25.5
Trip
79
11.5
152
22
76
11
152
22
166
24
166
24
Construction
Compressor - Semi-hermetic design
Main Housing - Dimensionally-stabilized aluminum
Covers - High-impact, UV stabilized, flame-resistant polymer.
Covers - High-impact, UV stabilized, flame-resistant polymer. TG310 is identified by green cover.
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

M-AP-001-EN Rev. J
4.4
Refrigerant Type
The TT300/TT350/TT400/TT500 compressors are totally oil-free and optimized for use with refrigerant R134a.
4.4.1
TG310
The TG310 compressor is for use with R1234ze(E) refrigerant only.

ASHRAE standard 34 has classified this refrigerant as R1234ze(E) with safety classification of A2L. ASHRAE Standard
34, 2010 Addendum 1 contains the change to the standard.
ASHRAE Standard 15 (Safety Standard) has sent out an initial public review document outlining proposed changes to this
standard to address 2L refrigerants.
Table 4-6 Refrigerant Used with Turbocor Compressors
Compressor
Refrigerant
TT300/TT350/TT400/TT500
TG310
134a
R123ze(E)
NOTE
Do not use recycled refrigerant as it may contain oil, which can affect system reliability. The refrigerant should be pure
and stored in virgin containers.
4.5
Environment
The compressor should be stored and operated within the following ambient temperature ranges:
Storage: -30C to 50C (-22F to 122F).
Operation: -1C to 46C (30F to 115F).
Electronics Minimum Operating Limit: -25C (-13F)
NOTE
Contact Danfoss Turbocor for lower ambient temperature operations. Refer to Operating Envelopes, for details of
the operating conditions. These conditions are in line with the AHRI 540 Standard.
4.6
Noise
For sound power measurements, refer to Section 21.
4.7
Outdoor Installations
For outdoor installations, refer to Section 19.1.
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Accessories
Refer to the Accessories Manual for product descriptions and specifications.
Product Application
Turbocor compressors are to be used in stationary installations only. For any moving or marine applications, contact DTC.
6.1
TG310
It is the responsibiity of the OEM to ensure that proper safety protocols are in place and that the chiller system has been
designed in a manner that is compliant with all local codes and regulatory requirements governing the user of these types of
refrigerants. OEMs must also ensure compliance with the requirements stated in the manufacturers Material Safety Data
Sheet (MSDS) for R1234ze(E), and that other system components are compatible with the refrigerant, giving special
attention to elastomers and seals.
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. Refrigerant must enter the compressor in gas state into the
economizer port. Care must be taken to ensure that no liquid enters the compressor.

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11
Compressor Current Limit and Operating Range

Settings
The new compressor controller (version 3.0.0 and above; see Section 1.1 "Scope") is designed to allow a user to configure
the current setting based on the intended application. The compressor defines the Full Load Amperage (FLA) and Locked
Rotor Amperage (LRA) as a range on the nameplate. The settings for the FLA and LRA are adjustable using the Service
Monitoring Tool (SMT) or directly from the customer controller application.
The 3-Phase Over Current Alarm (FLA) cannot be set higher than the 3-Phase Over-Current Fault limit (LRA). The
maximum fault limit and alarm limit settings are dependent upon the Voltage and Model the Model type defines the range for
the FLA and LRA values.
Table 8-1 FLA and LRA Value Range
FLA
Model
LRA
Default
Voltage
Min
Max*
Min
Max
FLA
LRA
TG310
400V
50
150
55
165
50
55
TT300
400V
40
135
44
145
40
44
TT300
460V
40
135
40
135
40
40
TT300
575V
40
110
44
212
40
44
TT350
380V
50
210
55
231
50
55
TT350
400V
50
210
55
231
50
55
TT350
460V
50
180
55
198
50
55
TT400
380V
60
170
66
187
60
66
TT400
400V
60
170
66
187
60
66
TT400
460V
60
150
66
165
60
66
TT400
575V
60
120
66
132
60
66
TT500
400V
60
170
66
187
60
66
TT500
460V
60
170
66
187
60
66
* See Note.
*Refer to the OEM Programming Guide to identify specific registers associated with
the 3-Phase Over Current Alarm (FLA) and 3-Phase Over Current Fault (LRA).
12

M-AP-001-EN Rev. J
Applications Manual
NOTE
It is possible to adjust the FLA Maximum to equal the LRA Minimum, but this is not recommended. A difference
should be maintained of no less than 10% between the FLA and LRA in order to allow the compressor to adjust prior
to tripping on over current.
WARNING!
Failure to adjust the 3-Phase Current Alarm and Fault limits from the factory settings could result in limitation of the
compressor performance.
CAUTION!
Adjustment to the 3-Phase Over Current Alarm and Fault Limits cannot exceed the electrical rating for the
disconnect, fuses or wire size. Power configuration must be in accordance with applicable local, national and
international building codes (such as NEC/CEC).
TT300 compressors used in air cooled applications may also require adjustment to the Discharge Pressure trip and alarm
settings as well as the Pressure Ratio alarm setting.
See Section 4.1 "Maximum Pressure" for more information on setting these values.

M-AP-001-EN Rev. J
13
Operating Envelopes
C
Saturated Discharge Temperature (SDT)
5*
140
60
130
55
460V
400V
4*
120
3*
50
2*
45
110
40
100
35
1.5*
90
30
80
25
70
20
60
* Pressure Ratio
15
50
10
-5
20
0
30
5
40
10
50
15
60
18
64
Saturated Suction Temperature (SST)
NOTE
The maximum Saturated Discharge Temperature (SDT) of the operating envelope represents the limit for compressors
with maximum FLA settings. The SDT for a compressor with a lower maximum current rating is lower than that
shown and is related to the FLA rating of the particular compressor.
The lower limit is related to minimum pressure ratios required to effect proper motor and power electronics cooling
with standard refrigerant circuit components.
Figure 1 Operating Envelope, TT300 Design Sequence E(1)

1)
Refer to the current authorized Compressor Selection Software for more exact values and conditions.
14

M-AP-001-EN Rev. J
Applications Manual
140
60
130
55
120
4*
3*
50
2*
45
110
40
100
35
90
80
70
60
50
Medium-temperature
Application
1.5*
30
Special regulating
valve required.
See System Design
Guidelines in
Application Manual
25
20
* Pressure Ratio
15
10
-10
-5
14
23
10
15
18
32
41
50
59
64
Figure 2 Operating Envelope, TT300 Design Sequence E

(Medium Temperature Compressor)(1)
1)

M-AP-001-EN Rev. J
15
F
140
130
5*
3*
4*
60
55
2*
120
50
45
110
40
100
35
90
80
70
60
50
1.5*
30
25
20
*Pressure ratio
15
10
15
18
59
50
30 32
41
65
-1 0
10
NOTE
with maximum FLA settings.
The SDT for a compressor with a lower maximum current rating is lower than that shown and is related to the FLA
rating of the particular compressor. The lower limit is related to minimum pressure ratios required to effect proper
motor and power electronics cooling with standard refrigerant circuit components.
Figure 3 Operating Envelope, TT350 Design Sequence E and TG310(1)

(1)Refer
16
to the current authorized Compressor Selection Software for more exact values and conditions.

M-AP-001-EN Rev. J
Applications Manual
3*
120
50
2*
45
110
40
100
35
90
80
70
60
50
1.5*
30
25
20
* Pressure Ratio
15
10
-1
30
32
10
15
18
41
50
59
65
C
F
NOTE
The SDT for a compressor with a lower maximum current rating is lower than that shown and is related to the FLA
rating of the particular compressor. The lower limit is related to minimum pressure ratios required to effect proper
motor and power electronics cooling with standard refrigerant circuit components.

(1)Refer
to the current authorized Compressor Selection Software for more exact values and conditions.

M-AP-001-EN Rev. J
17
3*
120
460V
50
45
2*
110
400V
40
100
35
1.5*
90
80
70
60
30
25
20
15
*Pressure ratio
50
0
30
5
40
10
50
15
60
18
65
C
F
NOTE
The maximum SDT for compressors with an FLA less than that is lower than the upper bound of the operating
envelope and depends on the FLA rating.

(1)
18

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10 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 E


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19
Figure 7 Minimum Unloading Capacity, TT350 Design Sequence E

Figure 8 Minimum Unloading Capacity, TT400 Design Sequence of E

20

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Figure 9 Minimum Unloading Capacity TT500 Design Sequence E

Figure 10 Minimum Unloading Capacity TG310(2)

Refer to the current authorized Compressor Selection Software or DLL for more exact values and conditions.

M-AP-001-EN Rev. J
21
11 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.
11.1
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 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.
A Load Balancing Valve (LBV) may need to be activated if the pressure ratio is not reduced to lower than 2.4. A staging
valve is recommended to be used to minimize the influence of the check valve and facilitate the smooth staging process.
However, if the pressure ratio still stays higher than 2.4, the operating compressor(s) may need to be cycled off, and then
restarted with the lag compressor(s) in parallel.
A compressor should be cycled off when insufficient load causes operating multiple compressors to go into surge so that the
remaining operating compressors can speed up to meet the demand and operate more efficiently.
To improve operating efficiency during part loads in a multiple-compressor system, maximize the number of compressors in
operation without allowing them to go into surge.
During the staging operation, it is more efficient and stable to run the compressors in full vane away from surge and choke
lines as much as possible.
NOTE
These control guidelines are specifically written for single-circuited (multiple compressors on a common refrigerant
circuit) applications. Individually circuited applications have similar staging requirements. However, the ramping
down before adding additional compressors may not be required.
NOTE
Pressure ratio is the ratio of absolute discharge to absolute suction pressure. It can be calculated as follows:
(DP + 101) / (SP + 101) (kPa) OR
(DP + 14.7) / (SP + 14.7) (psi)
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12 Electrical Specifications
12.1
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 12-1 Acceptable AC Voltage Range
Nominal Voltage
Acceptable Voltage Range
380V
342 - 418 VAC
400V
360 - 440 VAC
460V
414 - 506 VAC
575V
518 - 635 VAC
Table 12-2 Acceptable Frequency Range

Nominal
Frequency
Acceptable Frequency Range
50Hz
50Hz 5% (47Hz - 53Hz)
60Hz
60Hz 5% (57Hz - 63Hz)
NOTE
The frequency ranges in the table above apply only when generator power is being used.
12.2
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.
CAUTION!
The full-load current rating is based on the installation of a line reactor in the power line. Refer to the Accessories
Manual for specifications. Failure to use a line reactor will result in poor power factor and higher full-load current.
Refer to Figure 11 for interconnection details.

M-AP-001-EN Rev. J
23
Surge
Suppressor
(optional)
Connect power wiring ground and ground of secondary

tranformer including 24V control power to common
ground point in electrical panel.
Fuse (User-Supplied)
GND
AC Input
Voltage
L1
L2
L3
EMI/EMC
Filter
(optional)
Manual Disconnect
(see Notes)
Circuit Protection(**)
Line
Reactor
Fast actng fuses(*)
Harmonic
Filter
(optional)
User-Supplied
Notes
(*) Fast acting fuses must be installed for the TT350, TG310, TT400 and TT500 models.
The TT350, TT400 and TT500 use Class T 600VAC fast-acting fuses.
The fuses are built into the TT300.
(**) Circuit protection is required, according to local electrical requirements.
Figure 11 Typical Electrical Connections
12.3
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 compressors power electronics components.
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 compressors AC input terminals.
Use only properly rated fast-acting line fuses suitable for semiconductor protection, such as Littelfuse JLLS series, Siemens
Sitor 3NE1 series, or equivalent.
DANGER!
Fast-acting fuses are only for the purpose of reducing the accumulated energy in a compressors power electronics
caused by a short circuit event. Properly sized and selected fast acting fuses must be installed.
Sub-circuit protection must be considered separately in accordance with local electrical requirements.
User-supplied branch circuit protection must be installed in accordance with local, national, and international codes
(such as NEC/CEC). The fuses must be installed in the line before the compressors AC input terminals.
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12.4
Power Line Contactor
The power line contactor is optional. Consult local codes to determine if a contactor is necessary for your application.
12.5
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 all Turbocor 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.
12.6
Surge Protection
All Turbocor 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.
12.7
Harmonic Filtering (IEEE 519)
In order to comply with IEEE 519 requirements, DTC recommends the installation of a harmonic filter device in parallel
with the compressor as shown in Figure 11.

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12.8
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 12.9).
From an EMC standpoint, it is best to categorize different types of grounds and treat them independently (see Figure 12):
Safety ground (Protective Earth [PE]) and shields of mains cables.
Analog grounds, shielding of interface cables.
Digital grounds.
Reference ground (panel doors, backplate, etc.).
Shielding
I/O Cables
Analog 0V
Inputs
24V/5V
Circuits
Digital Ground *
Analog Ground *
Shielding
(power cables)
to motors, etc
Safety Ground (PE)
Panel
Doors
Back
Plate
110V/230V
Circuits
Reference Ground
* = Isolated from panel.
Figure 12 Typical Ground Connections
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12.9
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.
The wire-loom going to the panel door should be shielded using a metal-braided hose that is connected to ground at both
ends.
Electrical panel must have a dedicated ground conductor in accordance with relevant electrical codes.
Verify that the panel ground conductor is sized in accordance with relevant electrical codes.
NOTE
The installing electrical contractor is responsible for connecting the panel ground to the facility ground in accordance
with relevant electrical codes and standards, such as NEC Section 250 in the U.S. or its equivalent for other countries.
Special filtering and measuring may be required in installations such as hospitals that are prone to being influenced by
other electronic equipment.
12.10
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, DTC 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 90C (194F) minimum at the maximum applicable current. It is recommended that the cable be
double-jacketed, i.e., teck cable type. Refer to Table 12-3 for cable gland specifications.
Table 12-3
Main Cable Connector Plate Hole Sizes

Actual Size
50.0 mm (1.97)

M-AP-001-EN Rev. J
63.0 mm (2.48)
76.2 mm (3.00)
88.9 mm (3.50)
27
13 Control Interface Wiring

The Compressor I/O Board is the entry point for control wiring from the chiller/plant to the compressor.
RS232 Monitoring Connector (DB9)
EXV Phase 1A
J1
I/O
J6
IN
IN
STATUS
J7
OUT
OUT
OUT
OUT
OUT
I/O
DEMAND I/LOCK
EXV Phase 1B
EXV Phase 2A
EXV Phase 2B
J4
EXV #2
(Economizer or
load balancing
valve)
OUT
OUT
1A 1B 2A 2B
EXV2
EXV Phase 1A
OUT
OUT
COM NETB NETA
EXV Phase 1B
EXV Phase 2A
EXV Phase 2B
1A 1B 2A 2B
EXV1
EXV #1
(Evaporator or
load balancing
valve)
OUT
OUT
OUT
OUT
IN
IN
IN
IN
SPEED
Demand + 0-10V
Demand Interlock Contact - Safety N/C
Interlock Contact - Safety N/C
Compressor Status - N/O Contact
Compressor Status - N/O Contact
No function
No function
Liquid Temperature +
Liquid Temperature -
Compressor Running - N/O Contact

Compressor Running - N/O Contact
*Universal Analog Output +
*Universal Analog Output Entering Chilled Water
Temp. Sensor
Leaving Chilled Water
Temp. Sensor
J3
J8
IN
IN
IN
IN
LEAVE
SPARE T SPARE P
IN
OUT
OUT
IN
OUT
OUT
OUT
OUT
ANALOG ENTRY
J5
Temperature Sensor Signal, 1-5Volts

Sensor 0V
Sensor +5V
Pressure Sensor Signal, 1-5Volts
ModBus RS-485 NetB

ModBus RS-485 NetA
J2
IN
OUT
RUN
Level Sensor +15V

Sensor Signal , 1-5Volts
Level Sensor 0V
LIQDT
Level
Sensor
#2 (Economizer)
OUT
IN
OUT
OUT
Float
Level Sensor +15V

Sensor Signal , 1-5Volts
Level Sensor 0V
Float
Level
Sensor
#1 (Evaporator)
ModBus Common (Shield)
* Universal output can be used for :

output manual control
0-5VDC or 0-10VDC
**Level sensor circuit can be configured

for two types of sensors using humpers
JP5 abd JP6. Refer to the Installation and
Operations Manual for details.
Figure 13 Typical Control Wiring
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Table 13-1 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.
Liquid Temperature
Optional input for monitoring temperature. The temperature sensor must be an NTC type 10K @ 25C
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 output manual control, set to 0-5V or 0-10V via onboard jumpers.
13.1
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 instance, all external contractors/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.

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13.2
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 highdensity 44-pin connectors (female at one end and male at the other end). An extension cable is available from your local
supplier.
NOTE
If an I/O extension cable is used, heat-shrink tubing should be applied to the mating cable connectors to maintain good
conductivity and protect the connection from heat and humidity.
For RS-485 communication, the maximum cable length should not exceed 100 meters (328 feet). If using RS-232
communication, the cable length should not exceed 15 meters (50 feet) between the PC and the compressor (refer to Figure
14).
Figure 14 I/O Wiring Specifications
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13.3
Compressor I/O Board Mounting Details
The Compressor I/O Board (Figure 15) must be installed in a UL-approved electrical enclosure equipped with DIN EN
50022, 50035, or 50045 mounting rails.
Figure 15 Compressor I/O Board

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14
Piping Considerations
Care should be exercised when selecting pipe sizes as they will vary according to their application. Section 19, System
Design Guidelines, 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 19.2 for more information. DTC requires
the installation of a sight glass and full-flow liquid dryer in the motor-cooling line.
NOTE
Some applications may require alternative arrangements. Contact DTC 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.
Discharge piping should contain a caution label from system manufacturers or compressor installers that the surface is hot.
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15 Environmental Considerations
15.1
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.
15.2
Vibration
External copper piping should be braced to minimize the transfer of vibration to the compressor.
16 Shipping Considerations
16.1
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 compressors isolation mounts, compressor
vibration during transit can fracture the motor cooling lines rigid piping. DTC suggests the temporary installation of an antivibration bracket between the compressors base frame and mounting rail during transit, as shown in Figure 16.
Figure 16 Anti-Vibration Bracket

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33
17 Physical Data
This section contains data relative to compressor mounting, service clearance, and piping connections.
See Figure 18 and Figure 19. Note: The dimensions in Figure 17, Figure 18, Figure 19 show measurements in metric with
imperial in parenthesis.
17.1
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 17-1). 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.
17.2
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.
Figure 17 Suction/Front View All Models
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Figure 18 Service Side View All Models
Discharge Port 229.7 (9.04) (TT300)

220.2 (8.67) (TT350, TT400, TT500)
787.6 (31.00)
87.3 (3.43)
290.4 (11.43)
O-RING GROOVE
OD: 88.9 (3.499)
WIDTH: 4.1 (0.614)
ID: 80.7 (3.177)
150 (5.91)
(TT350, TT400, TT500, TG310)
174.0 (6.57 (TT300)
O-RING GROOVE
OD: 33.3 (1.311) (TT300)
41.3 (1.659) (TT350, TT400, TT500, TG310)
WIDTH: 4.1 (0.614)
ID: 25.1 (0.988) (TT300)
33.1 (1.30) (TT350, TT400, TT500, TG310)
Figure 19 Discharge Side View

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17.3
Valve Flanges
!
CAUTION!
The discharge line must be fitted with a check valve to prevent reverse flow into the discharge port, which can cause damage
to compressor components.
Compressor valve flange details are shown in Figure 28 and Figure 29. Refer to the product specifications in the Accessories
Manual for further details
Gas Flow
Figure 20 Discharge Port Details (TT300)
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Gas Flow
Figure 21 Discharge Port Details (TT350 and TG310)
Gas Flow
Figure 22 Discharge Port Detail (TT400)
M-AP-001-EN Rev. J
37
Gas Flow
Figure 23 Discharge Port Detail (TT500)
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Figure 24 Suction Port (All Models)

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39
Gas Flow
Figure 25 Suction Port Detail DD (All Models)
Gas Flow
Figure 26 Suction Port Detail DD (TT500)
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Figure 27 Mounting Base Mounting Base (TT300, TT350, TT400, TT500 and TG310)
Table 17-1 Physical Dimensions
Length
31.02" (788 mm)
Width
20.4" (518 mm)

M-AP-001-EN Rev. J
Height
9.17" (487 mm)
Shipping weight
TT300: 265 lbs. (120 kg)
TT350: 290 lbs. (132 kg)
TG310: 290 lbs. (132 kg)
TT400: 290 lbs. (132 kg)
TT500: 306 lbs. (139 kg)
41
Figure 28 TT300 Flange Footprint Details
Figure 29 TT350, TG310 and TT400 Flange Footprint Details
Figure 30 TT500 Flange Footprint Details
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18 Guide Specifications
This section contains written specifications for the TT300/TT350/TT400/TT500/TG310 compressors for use in system
design specifications.
18.1
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.
18.2
Refrigerant
Compressors shall be designed for use with R134a with the exception of the TG310 which is designed for use with
R1234ze(E).
18.3
Compressor Bearings
The compressor shall be provided with radial and axial magnetic bearings to levitate the shaft, thereby eliminating metal-tometal 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.
18.4
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. 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. 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.
18.5
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.
18.6
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.

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18.6.1
Ancillary Devices
A check valve shall be installed on the discharge port of the compressor to protect against backflow of refrigerant during
coast down. 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.
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19 System Design Guidelines

In addition to the instructions detailed in the TT300, TT350, TT40, TT500 and TG310 technical documentation set, this
section provides basic guidelines and requirements for the design and manufacture of R134a systems equipped with DTC
compressors.
Refer to the applicable DTC technical manual for applications, operating, installation and commissioning instructions.
NOTE
The compressor internal safety control settings are designed to provide protection for the compressor only. Designers
MUST provide SYSTEM protection within their control design. DTC will not be responsible for system protection
other than the compressor.
19.1
General Requirements
1.
Check for compliance with all installation, operating, commissioning and service steps, as outlined in the
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. Compatibility to suit R1234ze(E) refrigerant is
required for TG310.
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, a 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. To take advantage of low pressure ratio operation to improve low load
performance and efficiency, EXV capacity should be selected accordingly. 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.
6.
The refrigeration piping system must be clean and free of all debris in accordance with 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 with vents is recommended to house the compressor.

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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 pumped down due to
the surge characteristics of centrifugal compressors.
12.
Use the table below for recommended minimum pipe sizes.

Table 19-1 Recommended Minimum Copper Tube Size
TT300
TT350
TT400
TT500
TG310
Suction
Discharge
2 5/8
3 1/8
3 1/8
NOTE
If steel pipe is used, the pipe must be selected to give the equivalent inside diameter to copper pipe.
Properly tapered trumpets with smooth transitions must be used to connect the compressor flanges to the pipework.
The discharge line exit transition should not be at an angle greater than eight degrees inclusive. The suction line length
should be straight for 1.5 times the pipe diameter before entry into the compressor.
13.
46
In humid environments, the bell housing of the compressor should be insulated. A bell housing cover thermal
insulator is available as an accessory.

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19.2
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. Refrigerant must enter the compressor through the economizer port in a
gas state. 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 Selection
Software on the Customer Service and Support - Performance Tools section of the DTC web page (www.turbocor.com). 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.
19.3
Motor/Electronics Cooling Requirements

NOTES
Sub-cooled liquid must be fed to the motor/electronics cooling port of the compressor.
It must be solid liquid with a minimum of 6 F (3.5C) sub cooled at the connection point to the motor/
electronics cooling port of the compressor.
NOTE
Filter dryer, sight glass and service valve must be fitted in the motor-cooling liquid line.
To ensure sub-cooled liquid, it is important that the condenser is fitted with a sub-cooler (integrated or separate).
It is essential that compressor motor and power electronics cooling is available immediately at start up. The compressor
motor cooling liquid feed line must be configured and located so that this occurs. Recommended minimum pipe size is 1/2
for all models. A larger size may be necessary in some situations such as systems with low subcooling on start or extended
piping runs. A full flow filter / drier must be installed and a liquid sight glass must be installed adjacent to each compressor.
19.4
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.
DTC recommends the use of a properly selected surge suppressor on the power supply to the compressor in
installations susceptible to lightning (refer to Figure 11).
3.
Fast Acting fuses with an appropriate CAT and current rating must be supplied and fitted externally for the TT350,
TG310, 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 the compressor and the line reactor must be either a fully shielded and sheathed type or
carried in a properly grounded metal conduit.

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19.5
Application-Specific Requirements
19.5.1
Medium Evaporating Temperature Application (TT300)

NOTE
Medium Evaporating Temperature is defined as between 0 and -10 degrees C (between 32 and 14 degrees F).
1.
Check the 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 motor/electronics cooling outlet port adjacent to the inter stage
port. The recommended valve is Sporlan ORIT-10 7/8, set at 200 kPa (30 psi) for R134a. The motor/electronics
cooling outlet port is fitted with a 5/8 flare adapter.
19.5.2
Air-Cooled Systems/Chillers
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 avoided.
Internal controls will limit compressor speed if compressor choke is encountered, particularly during start up where pressure
ratio is low. It may be necessary to raise condensing pressure to allow the compressor to speed up. In any event, the pressure
ratio should be raised above 1.5 at start-up and should not drop below 1.3 during operation with the 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. The minimum unloaded speed will
be higher due to surge.
NOTE
In air-cooled systems/chillers, a staging valve must be installed with each compressor.
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19.5.3
Inverted Start
Inverted Start, commonly called Monday Morning Start Up, can be a situation containing a 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

This performance chart (Figure 31) is representative of a maximum capacity curve that you would see with Turbocor
centrifugal compressors. At point A, a low pressure ratio due to high evaporator load conditions, such as hot building startup, can limit the maximum capacity of the centrifugal compressor.
If more capacity is desired, it is advisable to raise the discharge pressure temporarily to increase the pressure ratio (point B)
until the sensible heat in the building is dissipated.
19.5.4
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 19.2.
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.

M-AP-001-EN Rev. J
49
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.
Staging valves are required for staging lag compressors. The take-off point from the discharge line should be
upstream of the non-return valve.
8.
The maximum start-up pressure ratio is about 2.4. If the pressure ratio is higher than 2.4, an LBV is required to reduce
the pressure ratio before starting the compressor.
NOTE
Contact Danfoss Turbocor for compressor selection and technical advice.
19.5.5
Packaged Air-Side With DX-Type Evaporator and Multiple Evaporator Coils
1.
Each evaporator must be controlled by an independent EXV, 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 pressuredrop differences.
4.
It is recommended to install a suction line accumulator.
5.
Motor-cooling liquid should be fed from the common liquid line Follow the instructions in Section 19.2.
50

M-AP-001-EN Rev. J
Applications Manual
20 Sample Refrigeration Circuits
Figure 32 Typical Refrigeration Piping Schematic

M-AP-001-EN Rev. J
51
Figure 33 Typical Refrigeration Piping Schematic

With Staging and Load Balancing Valve
Figure 34 Typical Refrigeration Piping Schematic With Flash Tank Economizer

52

M-AP-001-EN Rev. J
Applications Manual
Figure 35 Typical Refrigeration Piping Schematic With Sub-Cooler Circuit Economizer

M-AP-001-EN Rev. J
53
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
54

M-AP-001-EN Rev. J
Applications Manual
Figure 38 Typical Refrigeration Piping Schematic Using Multiple Compressors

on a Common Circuit With a Flooded Evaporator
NOTE
Contact DTC for compressor selection and further technical advice.

M-AP-001-EN Rev. J
55
21 Sound Power Specifications

21.1
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
21.1.1
Results
The sound power measured under each operational mode is presented in Table 21-1. Table 21-2 presents the results of sound
pressure calculations for various distances while the compressor is installed on top of a building
Disclaimer
The sound data below should be used as a guide only.
The following sound measurements are based on a specific physical setup, such as suction/discharge piping, evaporator
and condensers, as well as specific pressure ratios. Any OEM system design would not necessarily match these
conditions.
OEMs are responsible for their system sound level measurements and their published data.
Below are the results from Sound Power Measurements on a Turbocor TT300 Compressor.
Table 21-1 Sound Power Measurements
Operation Mode
Sound Power
(A-Scale)
dBA
Sound Power
(Linear Scale)
dB
Dominant Frequency
250 kW
81.5
81.5
1070 Hz
315 kW
86.0
85.5
1180 Hz
Table 21-2
56
Sound Pressure Calculation
Distance in
Relation to Compressor
(meters)
Operational Mode of Compressor (Capacity)

250 kW (70 Ton) dBA
315 kW (90 Ton) dBA
73.5
78.0
1.5
70.0
70.0
64
68.5

M-AP-001-EN Rev. J
Applications Manual
Table 21-2
Sound Pressure Calculation (Continued)
Distance in
Relation to Compressor
(meters)
Operational Mode of Compressor (Capacity)

250 kW (70 Ton) dBA
315 kW (90 Ton) dBA
59.5
64.0
55.5
60.0
Table 21-3 Sound Power at Third Octave Band, TT300 Compressor

Sound Power, 250kW (70 Ton)
Third octave band

(Hz)
Linear scale (dB)
A-weighted (dBA)
Third octave band

(Hz)
Linear scale (dB))
A-weighted (dBA)
160
55.5
41.8
160
59.6
45.8
200
62.0
51.7
200
64.9
54.9
250
63.9
55.6
250
67.7
59.5
315
68.7
62.0
315
69.9
63.4
400
66.9
62.3
400
66.6
62.2
500
71.5
68.6
500
65.7
62.6
630
60.2
58.4
630
71.8
69.8
800
65.1
64.5
800
67.7
67.2
1000
76.5
76.7
1000
70.5
70.6
1250
66.2
66.9
1250
82.3
83.0
1600
69.9
71.0
1600
72.6
73.9
2000
69.6
70.9
2000
73.3
74.7
2500
68.6
69.9
2500
72.8
74.3
3150
72.3
73.6
3150
75.3
76.7
4000
71.3
72.3
4000
74.6
75.8

M-AP-001-EN Rev. J
57
21.2
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
21.2.1
Results
The sound power measured with the discrete point method under two operational modes is presented in Table 21-4. Table
21-5 presents the results of sound pressure calculations for various distances while the compressor is installed on top of a
building.
Disclaimer
The sound data below should be used as a guide only.
The following sound measurements are based on a specific physical setup, such as suction/discharge piping, evaporator
and condensers, as well as specific pressure ratios. Any OEM system design would not necessarily match these
conditions.
OEMs are responsible for their system sound level measurements and their published data.
Below are the results from Sound Power Measurements on a Turbocor TT400 Compressor.
Table 21-4 Sound Power Measurements
Operation Mode
Sound Power
(A-Scale)
dB(A)
Sound Power
(Linear Scale)
dB
420 kW (120 Ton)
88.4
89.1
525 kW (150 Ton)
88.1
89.2
Table 21-5 Sound Pressure Calculation

Distance in
Relation to
Compressor
(meters)
58
Operational Mode of
Compressor
(Capacity)
420 kW
(120 Ton)
dBA
525 kW
(150 Ton)
dBA
80.5
80
1.5
77
76.5
71
70.5

M-AP-001-EN Rev. J
Applications Manual
Table 21-5 Sound Pressure Calculation
Distance in
Relation to
Compressor
(meters)
Table 21-6
Operational Mode of
Compressor
(Capacity)
420 kW
(120 Ton)
dBA
525 kW
(150 Ton)
dBA
66.5
66
62.3
62
Sound Power at Third Octave Band of TT400 Compressor
Sound Power, 420kW (120 Ton

Third octave band
(Hz)
Linear scale (dB)
160
A-weighted (dBA)
Third octave band

(Hz)
Linear scale (dB)
A-weighted (dBA)
51
65
160
55
70
200
49
61
200
50
62
250
60
70
250
61
70
315
60
68
315
62
69
400
64
71
400
65
75
500
63
65
500
62
66
630
78
79
630
76
79
800
80
81
800
78
80
1000
83
82
1000
82
83
1250
82
81
1250
81
81
1600
77
76
1600
75
74
2000
77
76
2000
75
74
2500
75
74
2500
76
76
3150
75
75
3150
75
76
4000
72
71
4000
73
73

M-AP-001-EN Rev. J
59
60

M-AP-001-EN Rev. J
Applications Manual
Appendix A: Acronyms
Acronym
Definition
AC
Alternating Current
AHRI
Air-Conditioning, Heating and Refrigeration Institute
CE
Conformance European
CSA
Canadian Standards Association
DC
Direct Current
DTC
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

M-AP-001-EN Rev. J
61
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62

M-AP-001-EN Rev. J
Applications Manual
A
AC 61
voltage range 23
accessories 11
acronyms 61
AHRI 61
air-cooled units 48
ancillary devices 44
application
temperature 48
B
base
mounting 34
bearings 43
C
cable
AC input - see specification, cable
interface 30
capacity control 43
CE 61
compliance 25
CE Certification
TG310 7
TT300 7
TT350 7
TT400 7
CE Certification TT500 7
CE compliance 25
certification 7
clearance 34
compliance
CE 25
compressor
bearings 43
discharge side view 35
electronics 43
I/O board mounting 31
motor 43
multiple on common circuit 49
service side view 35
compressor bearings 43
considerations
environmental 33
piping 32
shipping 33
M-AP-001-EN Rev. J
construction 9
contactor
power line 25
control
capacity 43
parallel 22
staged 22
Control Interface Wiring 28
control logic
multiple compressors 22
control logic guidelines
multiple compressors 22
parallel control 22
staged control 22
control wiring 28
connection guidelines 29
details 29
typical 28
CSA 61
D
data
physical 34
DC 61
design guidelines 45
application-specific requirements 48
electrical requirements 47
general requirements 45
dimensions
flanges 42, 43
mounting base 36
Discharge Port Detail
TT300 36
TT400 37
TT500 38
discharge side
view 35
Discharge Side View
TG310 35
TT300 35
TT350 35
TT400 35
TT500 35
disconnects 23
DTC 61
63
E
electrical
requirements 47
electrical connections
typical 24
electrical specifications 23
disconnects 23
electronics 43
EMC 61
EMI 61
EMI/EMC filtering 25
environment 10
environmental considerations 33
EPC 61
equipment panel 27
ETL 61
ETL certification
TG310 7
TT300 7
TT350
ETL certification
TT400 7
TT500 7
evaporator
requirements 50
EXV 61
F
filter
EMI/EMC 25
harmonic 25
filtering
EMI/EMC 25
harmonic 25
FLA 61
Flange Details
TT400 42
flange details
TG310 42
TT300 42
TT350 42
TT400 42
TT500 42
flanges
valve 36
FLC 61
64
frequency range 23
G
general specifications 8
grounding
connection guidelines 26
Earth connection guidelines 26
grounding connections
typical 26
GUI 61
guidelines
control wiring 29
control wiring connections 29
grounding
connection 26
system design 45
H
harmonic filtering 25
HFC 61
humidity 33
I
I/O board
mounting details 31
ID 61
IEEE 61
IGBT 61
IGV 61
interface cable 30
IP 61
L
LBV 61
line protection 24
LLS 61
LRA 61
M
Mains Input Cable
specification 27
Maximum Pressure
TG310 8
TT300 8
TT350 8
TT400 8
TT500 8
maximum pressure 8
measurements
sound power 58
M-AP-001-EN Rev. J
Applications Manual
sound power (TT300) 56
Minimum Unloading Capacity
TG310 21
TT300 19
TT350 20
TT400 20
TT500 21
motor
compressor 43
cooling line 32
Mounting Base
TG310 41
TT300 41
TT350, Mounting Base
TT400 41
TT500 41
mounting base 34
dimensions 36
mounting details
I/O board 31
multiple compressors
common circuit 49
control logic 22
N
noise 10
NTC 61
O
OD 61
Operating Envelope
TG310 16
TT300 15
TT350 16
TT400 17
TT500 18
operating range 14
extended performance compressor 14
medium temperature compressor 15
P
panel
equipment 27
parallel control 22
PE 61
physical data 34
piping
considerations 32
M-AP-001-EN Rev. J
piping considerations 32
PLC 61
power line
contactor 25
pressure
maximum 8
protection
surge 25
PWM 61
R
range
AC voltage 23
frequency 23
operating 14
refrigerant 43
TG310 43
type 10
refrigerant type 10
refrigeration
sample circuits 51
typical piping schematic 54, 55
Refrigeration Piping
schematic using motor-cooling pressure regulating valve 54
schematic using multiple compressors on a
common circuit 55
schematic with flash tank economizer 52
schematic with load balancing valve 52
schematic with multiple DX evaporators 54
schematic with sub-cooler circuit economizer
53
typical schematic 51
requirements
application-specific 48
electrical 47
evaporator 50
general 45
S
safety summary 7
SDT 61
Service Side View
TG310 35
TT300 35
TT350 35
TT400 35
65
TT500 35
shipping considerations 33
sound 56
sound power
measurements 56
TT40) 58
sound pressure
calculation 56
sound pressure calculation 58
specification
accessories 56
cable 27
supply voltage 23
specifications
ancillary devices 44
capacity control 43
compressor bearings 43
compressor electronics 43
compressor motor 43
electrical 23
general 8
refrigerant 43
TG310 43
TT300 43
TT350 43
TT400 43
TT500 43
SST 61
staged control 22
Suction Front View
TG310 34
TT300 34
TT350 34
TT400 34
TT500 34
Suction Port
T300 39
TG310 39
TT350 39
TT400 39
TT500 39
Suction Port Detail
TG310 39
TT300 39
TT350 39
66
TT400, 39
TT500 39
supply voltage
specification 23
surge protection 25
system design
general requirements 45
guidelines 45
T
temperature
application 48
TG310
flange details 42
minimum unloading capacity 21
operating envelope 16
TT 61
TT300
sound power measurements 56
valve flange details 42
TT350
mnimum unloading capacity 20
TT400
sound power measurements 58
TT500
flange valve details 42
TXV 61
U
UL 61
units
air-cooled 48
unloading capacity
minimum 19
UV 61
V
valve
flanges 36
M-AP-001-EN Rev. J
Applications Manual
valve flange
details TT300 42
valve flange details TT400 42
VFD 61
vibration 33
view
discharge side 35

M-AP-001-EN Rev. J
voltage range
AC 23
W
wiring
control 28
control interface 28
67
68

M-AP-001-EN Rev. J
This Page Left Intentionally Blank
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
M-AP-001-EN Rev. J

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TWIN-TURBINE CENTRIFUGAL COMPRESSORS

Models: TT300, TT350, TT400, TT500 and TG310

This Page Left Intentionally Blank

Danfoss Turbocor Compressors Inc.

* Subject to change without notice.

Danfoss Turbocor Compressors Inc.

Danfoss Turbocor Compressors Inc.

Danfoss Turbocor Compressors Inc.

Danfoss Turbocor Compressors Inc.

BMCC Firmware Versions

BMCv2.283x/CC3.0.0 and later

The TT300, TT350, TT400 and TT500 compressors are ETL

Danfoss Turbocor Compressors Inc.

listed and have been tested in accordance

Please refer to Section 18 for a detailed description of the specifications.

TG310 HL TT300 ST*

*The TT300 ST compressor allows for adjustment of this setting.

The Discharge Pressure Trip Limit is defined in Table 4-2.

TG310 HL TT300 ST*

*The TT300 ST compressors allow for adjustment of this setting.

TG310 HL TT300 ST* TT300 MT

*The TT300 ST compressor allows for adjustment of this setting.

Danfoss Turbocor Compressors Inc.

Suction Pressure Limits

Compressor - Semi-hermetic design

Main Housing - Dimensionally-stabilized aluminum

Covers - High-impact, UV stabilized, flame-resistant polymer.

Covers - High-impact, UV stabilized, flame-resistant polymer. TG310 is identified by green cover.

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

Danfoss Turbocor Compressors Inc.

The TG310 compressor is for use with R1234ze(E) refrigerant only.

Storage: -30C to 50C (-22F to 122F).

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

Electronics Minimum Operating Limit: -25C (-13F)

For sound power measurements, refer to Section 21.

For outdoor installations, refer to Section 19.1.

Danfoss Turbocor Compressors Inc.

Refer to the Accessories Manual for product descriptions and specifications.

Danfoss Turbocor Compressors Inc.

Compressor Current Limit and Operating Range

Danfoss Turbocor Compressors Inc.

Danfoss Turbocor Compressors Inc.

Saturated Discharge Temperature (SDT)

Saturated Suction Temperature (SST)

Figure 1 Operating Envelope, TT300 Design Sequence E(1)

Danfoss Turbocor Compressors Inc.

Saturated Suction Temperature (SST)

Figure 2 Operating Envelope, TT300 Design Sequence E

Danfoss Turbocor Compressors Inc.

Saturated Discharge Temperature (SDT)

Figure 3 Operating Envelope, TT350 Design Sequence E and TG310(1)

Danfoss Turbocor Compressors Inc.

Saturated Discharge Temperature (SDT)

Saturated Suction Temperature (SST)

Figure 4 Operating Envelope, TT400 Design Sequence E(1)

Danfoss Turbocor Compressors Inc.

Saturated Discharge Temperature (SDT)

Saturated Suction Temperature (SST)