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Danfoss Maneurop Reciprocating Compressors, LTZ, 60Hz User guide

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RECIPROCATING COMPRESSORS
Low temperature refrigeration
Selection & Application guidelines
REFRIGERATION AND AIR CONDITIONING
www.danfoss.com
LT / LTZ - 1 / 2 / 4 CYLINDER
60 Hz - R404A / R507 / R502
2
60 Hz catalog
RECIPROCATING COMPRESSORS
DANFOSS MANEUROP LT / LTZ COMPRESSORS . . . . . . p 3
COMPRESSOR NOMENCLATURE . . . . . . . . . . . . . . . . . . . . . . p 4
Compressor reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p 4
Motor voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p 4
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p 5
Technical specifications and versions . . . . . . . . . . . . . . . . . p 5
Nominal performance R404A, R507, R502-60 Hz . . . . . p 5
Operating envelope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p 5
PERFORMANCE TABLES R404A / R507 / R502 . . . . . . . . . . p 6
OUTLINE DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p 7
1 cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p 7
2 cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p 8
4 cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p 9
ELECTRICAL CONNECTIONS AND WIRING . . . . . . . . . . p 10
Single phase electrical characteristics . . . . . . . . . . . . . . . p 10
Motor protection and suggested wiring diagrams . . . . p 10
Capacitor and relay selection table . . . . . . . . . . . . . . . . . p 11
Three-phase electrical characteristics . . . . . . . . . . . . . . . p 11
Motor protection and suggested wiring diagram . . . . . p 11
MISCELLANEOUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p 12
Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p 12
IP / NEMA rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p 12
REFRIGERANTS AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . p 13
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p 13
SYSTEM DESIGN RECOMMENDATIONS . . . . . . . . . . . . . . p 14
Piping design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p 14
Operating limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p 15
Operating voltage and cycle rate . . . . . . . . . . . . . . . . . . . p 16
Liquid refrigerant control and charge limits . . . . . . . . . p 16
Sound and vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p 18
INSTALLATION AND SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . p 19
System cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p 19
Compressor handling, mounting, and
connection to the system . . . . . . . . . . . . . . . . . . . . . . . . . . p 19
System pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p 20
Leak detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p 20
Vacuum pull-down moisture removal . . . . . . . . . . . . . . . p 21
Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p 21
Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p 22
Danfoss Maneurop types LT and LTZ are hermetic recipro-
cating compressors designed for applications with low eva-
porating temperatures.
All components are of high quality and precision in order to
assure a long product life.
The positive benefits of internal motor protection, high
efficiency circular valve design and high torque motor
design provide for a quality installation.
The LT series of compressors is
designed for use with R502, using
Maneurop 160P white mineral oil as a
lubricant.
The LTZ series is specifically
designed for use with the HFC
refrigerants R404A and R507, using
160Z polyester oil as lubricant.
These compressors can be used
in new installations, and also to
replaceManeurop
®
LTE compressors
in existing installations.
LT/LTZ compressors have a large
internal free volume that protects
against the risk of liquid hammering
when liquid refrigerant enters the
compressor.
LT /LTZ compressors are fully
suction-gas cooled. That means
no additional compressor cooling
is required and allows the compressors
to be insulated with acoustic jackets
to reduce sound levels without
risk of overheating.
LT / LTZ compressors are available in
7 different models with displacements
ranging from 3 to 16.6 in
3
/rev.
Six different motor voltage ranges are
available for single and three phase
power supplies at 60 Hz.
All models are available in VE versions
with oil equalization and an oil sight glass. One-cylinder
models are also available without oil equalization or an oil
sight glass.
3
Danfoss Maneurop
LT / LTZ Compressors
60 Hz catalog
RECIPROCATING COMPRESSORS
4
Compressor nomenclature
60 Hz catalog
RECIPROCATING COMPRESSORS
Option code
Design version
(see page 12)
Oil equalization port
and sight glass
LT Z 4 A28 JH
Compressor type
Motor voltage code
(see below)
Z : Polyolester oil / HFC refrigerant
– : Mineral oil / CFC refrigerant
Compressor size
Displacement code
(see page 5)
VE -
COMPRESSOR REFERENCE (INDICATED
ON THE COMPRESSOR NAMEPLATE)
Motor Code Nominal voltage Voltage application range
1 208-230 V / 1 ph / 60 Hz 187 - 253 V
3 200-230 V / 3 ph / 60 Hz 180 - 253 V
400 V / 3 ph / 50 Hz 360 - 440 V
4
460 V / 3 ph / 60 Hz 414 - 506 V
5 230 V / 1 ph / 50 Hz 207 - 253 V
6 230 V / 3 ph / 50 Hz 207 - 253 V
9 380 V / 3 ph / 60 Hz 342 - 418 V
MOTOR VOLTAGE
TECHNICAL SPECIFICATIONS AND VERSIONS
OPERATING ENVELOPE
5
Specifications
60 Hz catalog
RECIPROCATING COMPRESSORS
NOMINAL RATINGS
Compressor -10°F Evap
*
- R404A/R507 -30°F Evap
**
- R404A/R507
model Cooling capacity Power input Cooling capacity Power input
BTU/h kW BTU/h kW
LTZ 22 JE 5230 1.75 2950 1.16
LTZ 28 JH 7890 2.58 4510 1.70
LTZ 44 HM 13520 4.37 7540 3.10
LTZ 50 HP 17470 5.46 10360 3.93
LTZ 88 HU 26860 8.32 14440 5.86
LTZ 100 HW 35480 10.56 19930 7.23
Displacement
Cyl. Oil Net
Design versions
Compressor
number charge weight
motor voltage code
model
in
3
/rev ft
3
/h
*
US pints lbs 1 3 4 5 6 9
LT / LTZ 22 JE 2.93 367 1 2.0 46 VE VE VE VE - VE
LT / LTZ 28 JH 4.14 518 1 2.0 51 VE VE VE VE - VE
LT / LTZ 44 HM 6.57 822 2 3.8 77 VE VE VE - VE VE
LT / LTZ 50 HP 8.29 1036 2 3.8 77 VE VE VE - VE VE
LT / LTZ 88 HU 13.15 1643 4 8.2 137 - VE VE - VE VE
LT / LTZ 100 HW 16.57 2071 4 8.2 141 - VE VE - VE VE
NOMINAL PERFORMANCE R404A, R507- 60 HZ
-20-30 -10-50-60 -40 0 10
Evaporating temperature (°F)
160
150
140
130
120
110
100
90
80
Condensing temperature (°F)
S.H. = 54°F
S.H. = 20°F
Application Envelope
for LTZ compressors with
R404A / R507
R502
**
Rated Condition: R404A / R507, -10°F Evap, 130°F cond, 15°F subcooling, 20°F superheat
**
Rated Condition: R404A / R507, -30°F Evap, 120°F cond, 15°F subcooling, 20°F superheat
*
At 3600rpm
R404A / R507 - 60Hz
R502 - 60Hz
6
Performance tables
60 Hz catalog
RECIPROCATING COMPRESSORS
Models TE -5 -15 -20 -25 -30 -35 -40 -45
TC
BTUH KW BTUH KW BTUH KW. BTUH KW BTUH KW BTUH KW BTUH KW BTUH KW
100 9320 1.86 6690 1.55 5600 1.41 4640 1.28 3810 1.16 3080 1.04 2460 0.93 1910 0.83
LTZ 22 JE
120 6470 1.91 4550 1.58 3770 1.43 3090 1.29 2500 1.16 2000 1.04 1560 0.93 1190 0.82
140 4070 1.94 2950 1.59 2530 1.44 2170 1.29 1880 1.15
100 13310 2.68 9780 2.24 8300 2.04 6990 1.85 5840 1.67 4820 1.50 3940 1.34 3150 1.19
LTZ 28 JH
120 9590 2.80 6840 2.32 5710 2.10 4700 1.89 3830 1.70 3060 1.52 2380 1.35 1790 1.19
140 6170 2.87 4330 2.34 3590 2.10 2960 1.87 2420 1.66
100 23470 4.53 16900 3.99 14170 3.71 11780 3.43 9690 3.15 7870 2.87 6310 2.60 4950 2.33
LTZ 44 HM
120 16760 4.67 11760 4.05 9710 3.73 7940 3.42 6400 3.10 5070 2.80 3930 2.50 2940 2.20
140 10420 4.71 7210 3.98 5970 3.62 4920 3.26 4040 2.91
100 28650 5.69 21180 5.00 18050 4.66 15290 4.32 12870 3.98 10740 3.66 8890 3.33 7270 3.02
LTZ 50 HP
120 21050 5.84 15190 5.06 12770 4.67 10650 4.29 8790 3.93 7170 3.57 5760 3.22 4520 2.89
140 13510 5.88 9530 4.98 7940 4.55 6570 4.13 5410 3.71
100 43590 8.05 31490 7.16 26460 6.71 22040 6.27 18180 5.83 14820 5.40 11910 4.98 9370 4.57
LTZ 88 HU
120 32810 8.81 22930 7.58 18870 6.99 15340 6.41 12260 5.86 9600 5.32 7290 4.81 5290 4.32
140 21140 9.15 13910 7.53 11030 6.77 8570 6.03 6470 5.33
100 56530 10.27 41810 9.14 35600 8.55 30070 7.95 25180 7.35 20850 6.75 17060 6.14 13680 5.55
LTZ 100 HW
120 42650 11.16 30490 9.57 25400 8.78 20900 8.00 16920 7.23 13420 6.48 10320 5.75 7590 5.05
140 27850 11.72 18770 9.59 15050 8.56 11800 7.56 8970 6.59
LEGEND
TE evaporating temperature (°F)
TC condensing temperature (°F)
RATING CONDITIONS R404A / R507
Superheat 20°F
Subcooling 0°F
RATING CONDITIONS R502
Superheat 20°F
Subcooling 15°F
Models TE -5
*
-10
*
-15
*
-20
*
-25
**
-30
**
-35
**
-40
**
TC
BTUH KW BTUH KW BTUH KW. BTUH KW BTUH KW BTUH KW BTUH KW BTUH KW
1
00 10205 1.65 8910 1.60 7440 1.52 6550 1.40 5239 1.30 4395 1.20 3350 1.15 2620 0.95
LT 22 JE
120 8060 1.85 6885 1.75 5478 1.64 4720 1.50 3454 1.40 2720 1.20
140 6035 2.00 4990 1.85 3720 1.72 2935 1.55 1935 1.40
100 15405 2.65 13490 2.50 11360 2.37 10180 2.20 8341 2.00 7355 1.80 5890 1.69 5250 1.45
LT 28 JH
120 12925 2.80 11140 2.65 9040 2.45 8050 2.25 6212 2.10 5385 1.80
140 9995 2.95 8365 2.75 6380 2.51 5300 2.25 3823 2.10
100 24620 4.05 21560 3.85 18100 3.63 16110 3.35 13044 3.10 11250 2.85 8812 2.65 7390 2.3
LT 44 HM
120 19430 4.10 18800 3.85 13610 3.62 12085 3.30 9170 3.10 7820 2.75 5380 2.55
140 14505 4.30 12390 4.00 9680 3.72 9225 3.40 6100 3.10
100 30850 5.15 27215 4.90 23050 4.63 20700 4.30 16900 4.00 14840 3.60 11880 3.39 10180 2.9
LT 50 HP
120 24840 5.55 21600 5.20 17640 4.90 15755 4.45 12200 4.10 10420 3.65 7460 3.41
140 19380 5.90 16610 5.45 13020 5.00 11120 4.50 8340 4.10
100 49545 7.80 42925 7.35 37500 6.88 31530 6.35 25300 5.90 21910 5.40 16930 5.02 14720 4.45
LT 88 HU
120 39390 8.10 33795 7.50 27200 7.00 24185 6.40 18300 5.90 16000 5.30 10970 4.91
140
29555 8.75 25190 8.10 19750 7.45 17030 6.80
100
63510 10.45 55325 9.70 46260 9.06 41315 8.40 33500 7.80 29580 7.15 23380 6.67 20970 8.05
LT 100 HW
120 50745 10.90 43960 10.10 35820 9.40 32395 8.50 25100 7.91 22615 7.25 16300 6.77
140 38560 11.45 34285 10.55 26600 9.75 24395 8.90 18700 8.10 15200 7.48 12034 6.83
BTUH = cooling capacity - KW = power input. For heat-rejection calculation take:THR = BTUH +
[(
KW x 1000) x 3.4 x .95
]
The duities indicated are based on following conditions: subcooling 15°F,
*
RGT: 65°F,
**
RGT: 40°F
7
Outline drawings
60 Hz catalog
RECIPROCATING COMPRESSORS
Silent block
Rotolock connection size Solder sleeve connection size Rotolock valve
Suction Discharge Suction Discharge Suction Discharge
LT / LTZ 22 JE
LT / LTZ 28 JH
1”1/4 1” 5/8” 1/2” V09 V06
3.78
10.35
2.68
0.59
0.98
3.15
2.72
Ø 8.86
13.12
Oil equalization
(VE = models only)
Models with motor
code 3, 4 & 6
with rounded off top
LP
gauge port
(schrader)
Mounting hole for PTC crankcase heater
ø 5/16"
7/8"
5/8"
Spade connectors
1/4” AMP-AWE
Ground M4-12
Knock-out
Ø 0.83”
Ø 0.83”
1 CYLINDER
Terminal box
IP / NEMA rating: 55 / 12 (with cable gland)
1.5
4.84
5.71
4.65
4.29
2.68
5.28
.676.30
Oil sight glas
(VE - models only)
55˚
2 CYLINDER
Outline drawings
8
60 Hz catalog
RECIPROCATING COMPRESSORS
2 CYLINDER
(1)
LTZ 2 cyl. Code 1-3-4-9
(2)
LTZ 2 cyl. Code 6
6.14
7.48
(1) -
7.87
(2)
2.36
.79
3.78
5.71
4.92
7.05
Mounting hole
for PTC crankcase heater
37˚
Silent block
ø 5/16"
7/8"
5/8"
Terminal box
IP / NEMA rating: 55 / 12 (with cable gland)
Spade connectors
1/4” AMP-AWE
Ground M4-12
Knock-out
Ø 0.83”
Ø 0.83”
Terminal box for motor code 6
IP / NEMA rating: 54 / 12 (with cable gland)
Screw
10-32 UNF x 9,5
Earth M4-12
Knock-out
Ø 1.14”
Ø 1.14”
Rotolock connection size Solder sleeve connection size Rotolock valve
Suction Discharge Suction Discharge Suction Discharge
LT /
LTZ 44 HM
1”3/4 1”1/4 7/8” 3/4” V07 V04
LT /
LTZ 50 HP
1”3/4 1”1/4 1”1/8 3/4” V02 V04
Outline drawings
9
60 Hz catalog
RECIPROCATING COMPRESSORS
4 CYLINDER
Silent block
20.44
3.74
9.18
4.92
Ø 13.86
.75
3.78
6.22
4.53
LP
gauge port
(schrader)
Oil sight glass
9.69
8.34
9.69
9.13
Mounting hole for
PTC crankcase heater
Oil equalization
1.2"3/4"
ø H M12
Terminal box
IP / NEMA rating: 54 / 12 (with cable gland)
Screw
10-32 UNF x 3/8”
Ground M4-12
Knock-out
Ø 1.14”
Ø 1.14”
Rotolock connection size Solder sleeve connection size Rotolock valve
Suction Discharge Suction Discharge Suction Discharge
LT /
LTZ 88 HU
LT / L
TZ 100 HW
1”3/4 1”1/4 1”1/8 3/4” V02 V04
If the motor is overloaded and the protector trips,it may
take up to three hours for the compressor to reset
and restart.
Single phase compressor motors are internally protected
by a bimetallic temperature- and current-sensing protector
that senses the main and start winding currents and
the winding temperature.
SINGLE PHASE ELECTRICAL CHARACTERISTICS
MOTOR PROTECTION AND SUGGESTED WIRING DIAGRAMS
10
Electrical connections
and wiring
60 Hz catalog
RECIPROCATING COMPRESSORS
LRA - Locked Rotor MCC - Maximum Winding resistance
Current (A) Continuous Current (A) (Ohms) (± 7%)
Motor Code 1515 1 5
Winding run start run start
LT / LTZ 22 JE 49.3 41 17 15 1.25 2.49 1.78 4.74
LT / LTZ 28 JH 81 55 25 16 0.74 1.85 1.16 3.24
LT / LTZ 44 HM 103 - 34 - 0.41 1.90 - -
LT / LTZ 50 HP 143 - 37 - 0.33 1.95 - -
230 V
CR
CS
Potential Relay
SR
C
IOL
L2L1
15 kΩ - 1 W
230 V
"A + C"
B µF
5
Start Relay
2
1
SR
C
220 kΩ - 1 W
IOL
Motor code 1: 208 - 230 V / 1ph / 60 Hz
Motor code 5: 230 V / 1ph / 50 Hz
Standard single phase CSR wiring with acces-
sory crankcase heater configuration
This system provides additional motor torque at startup
by the use of a start capacitor in combination with the
run capacitor.
This configuration can be used for refrigerant circuits
with capillary tubes or expansion valves.
The start capacitor is only connected during starting;
a potential relay is used to disconnect it after the start
sequence. A PTC crankcase heater is required.
Single phase Kickstart
®
wiring
Kickstart
®
is a patented two wire start kit consisting of
a potential relay and start capacitor assembly. By using
both a run and start capacitor, the Kickstart
®
kit is able to
provide maximum torque to the motor during startup.
This additional torque is required to overcome the high-
pressure differentials encountered in refrigeration systems.
Danfoss Commercial Compressors recommends use
of Kickstart
®
on all single phase LT / LTZ compressors,
particularly in hard starting applications.
Code 5 - 50 Hz version Code 1 - Kickstart
®
accessory
IOL: motor protector S: Start winding (auxiliary)
A + C: run capacitors R: Run winding (main)
B: start capacitor Capacitors A and C are replaced by
C: Common a single capacitor of size A + C.
IOL: motor protector S: Start winding (auxiliary)
CR: run capacitors R: Run winding (main)
CS: start capacitor
C: Common
Kickstart
®
kit
*
208 - 230 V
Start capacitors
1 ph / 60Hz
rated @ 220 V AC
Kickstart
®
Part
Models
CR µF CS µF
number number
LT /
LTZ 22 JE-1
45 mfd
LT /
LTZ 28 JH-1
50 mfd
LT /
LTZ 44 HM-1
45 mfd
233 - 280 mfd MP2 7302541
LT /
LTZ 50 HP-1
45 mfd
Electrical connections and wiring, continued
simultaneously. If the motor is overloaded and the
protector trips,it may take up to three hours for the pro-
tector to reset and restart the compressor.
For all three phase compressors,a PTC crankcase heater
is required.
Three-phase compressors in the LTZ series are protec-
ted by an internal motor protector connected to the
neutral point of the star-connected stator windings.
This IOL (internal overload line break) protects the
motor against overheating current overload and locked
rotor conditions. The protector cuts out all 3 phases
11
60 Hz catalog
RECIPROCATING COMPRESSORS
CAPACITOR AND RELAY SELECTION TABLE
(1)
Run capacitors: 440 volts - minimum 10, 000 hours.
(2)
Start capacitors: 330 Volts.
Run Start
230 V
capacitors capacitors Kickstart
®
Part
1 ph / 50Hz
(1) (2) number number
Models
(A) µF (C) µF (B) µF
LT /
LTZ 22 JE-5
20 10 100
LT /
LTZ 28 JH-5
20 15 100
MP2 7302541
THREE PHASE ELECTRICAL CHARACTERISTICS
MOTOR PROTECTION
AND SUGGESTED WIRING DIAGRAM
LRA - Locked Rotor MCC - Maximum Winding resistance
Current (A) Continuous Current (A) (Ohms) (± 7 % at 20°C)
Motor Code 3 4 6 9 3 4 6 9 3 4 6 9
LT / LTZ 22 JE 38 16 - 22 11 6 - 5 2.49 10.24 - 13.1
LT / LTZ 28 JH 57 23 - 29 16 7.5 - 8.5 1.37 7.11 - 9.7
LT / LTZ 44 HM 100 42 92 57 22 9.5 18 11 0.74 3.80 0.96 2.54
LT / LTZ 50 HP 117 40 92 64 23 12 18 15 0.62 3.80 0.96 2.54
LT / LTZ 88 HU 157 78.5 126 110 43 22 35 23 0.48 1.98 0.77 1.26
LT / LTZ 100 HW 210 105 170 150 54 27 43 30 0.37 1.54 0.49 0.84
Note: for three phase motors, winding resistance measured at compressor terminals is the sum of two winding resistance values shown above.
L1
L2
L3
FU FU
TR
EC
C1
EC
FD
C1
Comp.
PTC
SEC
PRI
LEGEND:
FD
..................................................................................................................................fused disconnect
FU ........................................................................................................................................................fuses
C1 .................................................................................................................... compressor contactor
EC ................................................................................................................................ external control
COMP ................................................................................................................................ compressor
PTC .......................................................................................................................... crankcase heater
TR .......................................................................................................................... control transformer
* A kit consit of a potential relay and a start capacitor
Run capacitors
440 V AC
minimum
1000 hours
The information below gives the different IP rating combinations according
to CEI 529. IP ratings of compressor terminal boxes are valid only when
correctly sized cable glands of the same IP rating are used.
APPROVALS
IP / NEMA RATING
12
Miscellaneous
60 Hz catalog
RECIPROCATING COMPRESSORS
Maneurop
®
LT / LTZ compressors
with motor code 1, 3 and 4 are UL
and cUL approved (except LTZ40-4).
All LTZ models have CE marking.
Maneurop LT / LTZ compressors
com-
ply with most international safety and
technical standards and are approved
and marked.
Refer to technical information for a
detailed list of approvals.
IP 5 5
Level of protection against contact and foreign objects
5 = Complete protection against contact
and against harmful dust deposits
Level of protection against water
4 = Protection against water splashing from any direction
5 = Protection against jets of water from any direction
First numeral:
Second numeral:
Model Rating Approximate
NEMA rating
LT / LTZ 22 IP55 12
LT / LTZ 28 IP55 12
LT / LTZ
44-1/3/4/9
IP55 12
LT / LTZ 44-6 IP54 12
LT / LTZ 50-1/3/4/9 IP55 12
LT / LTZ 50-6 IP54 12
LT / LTZ 88-3/4/6 IP54 12
LT / LTZ 88-9 IP55 12
LT / LTZ 100-3/4/6 IP54 12
LT / LTZ 100-9 IP55 12
UNDERWRITERS
LABORATORIES INC.
UL File number SA 6873 (N)
EUROPEAN
DIRECTIVE
The table below gives an overview of different refrige-
rants for low temperature applications and the corres-
ponding Maneurop
®
compressor and lubricant. Also check
local legislation and safety standards.
Maneurop
®
LTZ compressors were developed for HFC
refrigerants R404A and R507, which are generally accep-
ted as long term alternatives for CFC refrigerant R502.
Maneurop
®
LT compressors are still available for repla-
cement or applications with HCFC blends.
GENERAL INFORMATION
13
Refrigerants and lubricants
60 Hz catalog
RECIPROCATING COMPRESSORS
Refrigerant Type ODP
1
GWP
2
Compressor Lubricant Remarks
R404A HFC 0 3260 LTZ POE 160Z, factory charged -
R507 HFC 0 3300 LTZ POE 160Z, factory charged -
R22 based
0.02 1960 Replace factory charged mineral
Transitional refrigerants and R502
transitional HCFC
0.03 3570
LT
oil by 160 ABM.
should never be used
refrigerants in combination with
R502 CFC 0.22 5500 LT
Maneurop
®
mineral oil 160 P,
LTZ compressors.
factory charged.
Hydrocarbons
HC Danfoss Commercial Compressors does not authorize the use of hydrocarbons with their compressors.
(1)
ODP: Ozone Depletion Potential -
(2)
GWP: Global warming Potential, time-horizon 100 years, source ARTI 1999
R404A
Refrigerant R404A is a ternary mixture of R125, R143a and R134a. Its thermodynamic properties are comparable to
those of R502. R404A has a very small temperature glide (< 2°F) between dew point and bubble point and should
therefore be charged in its liquid phase,but in most other aspects the small glide can be neglected. Because of the small
glide, R404A is often called a near-azeotropic mixture.Use the Maneurop
®
LTZ compressor with factory charged 160Z
polyolester oil. Use Maneurop LTZ compressors, and not type LT in all R404A applications.
R507
Refrigerant R507 is a binary mixture of R125 and R143a,with thermodynamic properties comparable to those of R502.
R507 is an azeotropic mixture, exhibits no temperature glide, and behaves as a pure refrigerant. In R507 systems,
use the Maneurop LTZ compressor with factory charged 160Z polyolester oil. Use Maneurop type LTZ compressors,
and not type LT with R507.
R22 based transitional refrigerants
A wide variety of R22-based transitional refrigerants (also called service refrigerants or drop-in blends) have been deve-
loped as temporary R502 alternatives. Some examples are R402A, R402B, R403A and R403B. All of these have low
ODP value. Because of the R22 component in these refrigerants, Maneurop LTZ compressors should not be used for
them. Instead, use Maneurop LT compressors with R22, the factory mineral oil charge of the LT compressor must be
replaced with Maneurop
®
160ABM alkylbenzene mineral lubricant.
R502
The Montreal protocol states that CFC refrigerants such as R502 may no longer be used in new installations in the
signatory member countries. Maneurop LTZ compressors can not be used in R502 systems. But, for countries that
have not signed the Montreal protocol, and for replacement in existing installations, Maneurop LT compressors are still
available.
Hydrocarbons
Hydrocarbons such as propane, isobutane, etc., are extremely flammable. Danfoss Commercial Compressors does not
in any way authorize or recommend the use of hydrocarbon refrigerants with LTZ or LT compressors.
lines must be such that the gas velocity is at least 13 ft/s.
In vertical risers,a gas velocity of 26 to 40 ft/s is required
to insure proper oil return. A U-trap is required at the foot
of each vertical riser. If the riser is higher than 13 feet,
additional U-traps are required for each additional 13 feet.
Keep U-traps as short as possible to avoid excessive
accumulation of oil. See figure below. For compressors
mounted in parallel, the common suction riser should be
a double riser. The cross section of the smallest riser
must be designed for 26 to 40 ft/s gas velocity at minimum
capacity (one compressor running).The total cross section
of both risers must be such as to give a gas velocity of
26 to 40 ft/s at full capacity (all compressors running).
See figure below. Gas velocities higher than 40 ft/s will
not contribute to significantly better oil return, but they
will cause higher noise levels and result in higher suction
line pressure drops which will have a negative effect on
the system capacity. Note that the suction rotolock
valves,which can be ordered from Danfoss Maneurop as
accessories, are designed for average pipe sizes, selected
for systems running at nominal conditions.The pipe sizes
selected for specific systems may differ from these
recommended sizes. It is recommended that the suction
lines be insulated to limit suction gas superheat.
Refrigeration circuits require oil to lubricate the com-
pressor’s moving parts. During normal system operation
small amounts of oil will continually leave the compressor
with the discharge gas. As long as the amount of oil cir-
culating through the system is small it improves both sys-
tem efficiency and heat transfer.When system piping is
well designed, almost all of the oil returns to the com-
pressor. Too much oil outside the compressor has a
negative effect on heat transfer efficiency in both conden-
ser and evaporator.In a poorly designed system,with less
than optimal oil return, the compressor becomes oil-
starved, and the condenser, evaporator, and refrigerant
lines contain too much oil.Adding oil in such a situation
only corrects the compressor oil level for a limited time
and increases the amount of surplus oil in the rest of the
system.
Only correct piping design can insure good oil balance
in the system.
Suction lines
Horizontal suction line sections must have a slope of
0.5% in the direction of refrigerant flow (5/8” for every
10 feet of pipe).The cross section of horizontal suction
PIPING DESIGN
14
System design
recommendations
60 Hz catalog
RECIPROCATING COMPRESSORS
To compressors
From evaporators
26 to 40 ft/s
at minimum capacity
26 to 40 ft/s
at maximum capacity
U-trap, as short as possible
Evaporator
To condenser
max. 13 ft
max. 13 ft
U-trap, as short as possible
U-trap
26 to 40 ft/s
0.5 % slope,
13 ft/s or more
U-trap, as short as possible
0.5 % slope,
13 ft/s or more
System design recommendations, continued
devices,and sight glasses must always be selected for the
particular refrigerant used.This is especially important in
installations using HFC refrigerants.Always refer to the
component manufacturer’s technical documentation.
When selecting a liquid line filter drier, take into account
the drier’s water content capacity, system cooling
capacity, and the refrigerant charge. Use a drier
containing 100 % molecular sieves (no activated alumina)
and that is oversized rather than undersized.
The upper limit of the application envelope for LTZ com-
pressors is at - 4°F evaporating temperature.
A MOP-type expansion valve or a crankcase pressure
regulator (Danfoss KVL) must be used to limit the suction
pressure to a maximum of 39 psig (5°F). Do not apply
both devices in combination.
A suction line heat exchanger is not recommended for
low temperature applications as it may cause high suction
gas superheat, which can result in a discharge temperature
that is too high.
Discharge line
In applications with the condenser mounted above the
compressor, a suitably sized U-trap may be necessary to
prevent oil return to the discharge side of the
compressor when the compressor is idle.The U-trap will
also help eliminate liquid refrigerant floodback from the
condenser to the compressor.
Oil charge and oil separator
In most installations the compressor’s initial factory oil
charge will be sufficient. If, however, there are line runs
exceeding 65 feet, many oil traps, or an oil separator,
additional oil may be needed.When an installation has
multiple evaporators, multiple condensers, or other
elements increasing the risk of slow oil return, an oil
separator is recommended. Find additional information
in the "Start up" section.
System components
System components such as filter driers, expansion
decreases.The lower pressure may be insufficient to sup-
ply enough liquid refrigerant to the evaporator. As a result,
the evaporating temperature
will greatly decrease, leading to low capacity,
and eventually to poor oil return. At start up,
the compressor will pull into a vacuum and will be cut out
by the low pressure protection. Depending on how the
low pressure switch and delay timer are set, short cycling
can occur.
To avoid these problems,use one of several solutions that
can reduce condenser capacity:
• Flood condensers with liquid. This solution requires
extra refrigerant charge, which can introduce other
problems. A non-return valve in the discharge line is
required, and special care should be taken when desi-
gning the discharge piping.
• Reduce air flow to the condenser.
• Install the condenser indoors.
When the compressor is located in an environment with
low ambient temperature,increased refrigerant migration
will occur when the compressor is not running. In such
conditions an extra belt-type crankcase heater is strongly
recommended. Note that with their 100% suction gas
cooled motors, Maneurop
®
compressors can be externally
insulated. Refer to the section titled "Liquid refrigerant
migration & charge limits" for more details.
High Pressure
A high pressure safety switch is required to stop the
compressor if discharge pressure exceeds the values
shown in the table below.
The high pressure switch can be set lower depending on
the application and ambient conditions, but to prevent
compressor cycling around the high pressure limit, the
switch must be either in a lockout circuit or have a
manual reset device.When a discharge valve is used, the
high pressure switch must be connected to the valve’s
service gauge port, which cannot be isolated.
Low pressure
To avoid compressor operation at suction pressures that
are too low,a low pressure safety switch is recommended.
Low ambient temperature operation
At low ambient temperatures, the condensing tempera-
ture and condensing pressure in air cooled condensers
OPERATING LIMITS
15
60 Hz catalog
RECIPROCATING COMPRESSORS
LT / LTZ
psi(g)
pressure limits
Working pressure range high side 191.5 – 401.8
Relief valve opening pressure difference 435.1
Relief valve closing pressure difference 116.0
Maximum test pressure high side 400
Working pressure range low side 1.5 – 29
Maximum test pressure low side 362.6
System design recommendations, continued
Voltage imbalance causes high current draw on one or
more phases, which in turn leads to overheating and
possible motor damage.Voltage imbalance is given by
the formula:
Operating voltage range
The voltage applied to the motor terminals must always
be within the limits specified in the table on page 4. The
maximum voltage imbalance for 3-phase compressors is
2%.
The system must be designed in such way as to guarantee
that compressor run time is at least sufficient to allow
proper oil return and sufficient motor cooling after starting.
Note that the oil return rate is a function of system design.
Cycle rate limit
There must be no more than 12 starts per hour (6 when
a soft start accessory is used).A higher number reduces
the service life of the motor-compressor unit.If necessary,
use an anti-short-cycle timer in the control circuit;
a time-out of five minutes is recommended.
OPERATING VOLTAGE AND CYCLE RATE
LIQUID REFRIGERANT CONTROL AND CHARGE LIMITS
That can easily be the compressor (for example, when it
is placed outside in low ambient temperatures). After
a while, the entire system refrigerant charge can condense
in the compressor crankcase. A large amount will dissolve
in the compressor oil until the oil is completely saturated
with refrigerant.If other system components are located
at a higher level, this process can be even faster because
gravity will favor the flow of liquid refrigerant back to
the compressor. When the compressor is started,
crankcase pressure decreases rapidly. At lower pressures
the oil holds less refrigerant, and as a result part of
the refrigerant will violently evaporate from the oil,
causing the oil to foam. This process is often called
“boiling.” The negative effects on the compressor of oil
migration include:
• oil dilution by liquid refrigerant;
• oil foam, transported by refrigerant gas and discharged
into the system,in turn causing loss of oil,and in extreme
situations, a risk of oil slugging;
• in extreme situations with a high refrigerant charge,
liquid can enter the compressor cylinders (liquid slugging).
Refrigeration compressors are designed as gas compres-
sors.Depending on the compressor design and operating
conditions, most compressors can also handle a limited
amount of liquid refrigerant. Liquid refrigerant can enter
a compressor in different ways, with different effects on
the compressor. Maneurop LT and LTZ compressors
have a large internal free volume and can therefore hand-
le relatively large amounts of liquid refrigerant without
major problems. But even when a compressor can handle
liquid refrigerant, doing so is not favorable to its service
life. Liquid refrigerant can dilute the oil, wash oil out of
the bearings, and result in high oil carryover, causing loss
of oil from the sump. Good system design will limit the
amount of liquid refrigerant in the compressor and have
a positive effect on the
compressor service life.
Off-cycle migration
When the compressor is idle and pressure equalizes,
refrigerant will condense in the coldest part of the system.
16
60 Hz catalog
RECIPROCATING COMPRESSORS
Vavg = Mean voltage of phases 1, 2, 3.
V
1-2
=Voltage between phases 1 & 2.
V
1-3
=Voltage between phases 1 & 3.
V
2-3
=Voltage between phases 2 & 3.
|
V
avg
-
V
1-2
|
+
|
V
avg
-
V
1-3
|
+
|
V
avg
-
V
2-3
|
2 x
V
avg
x 100
System design recommendations, continued
• evaporator fan failure or blocked air filters.
In these situations, liquid refrigerant will continuously
enter the compressor. The negative effects from conti-
nuous liquid floodback are:
• permanent oil dilution; or
• in extreme situations with high system refrigerant char-
ge and large amounts of floodback, liquid slugging.
Liquid floodback during operation
During normal and stable system operation, refrigerant
will leave the evaporator in a superheated condition and
enter the compressor as a superheated vapor. Normal
superheat values in the suction line at compressor suc-
tion fitting are 10 to 55°F but the refrigerant leaving the
evaporator can contain some liquid refrigerant for diffe-
rent reasons:
• incorrect dimensioning, incorrect setting, or malfunction
of the expansion device;
Even accumulation of the full charge in the compressor
can be handled.But as described earlier,limiting the entry
of liquid refrigerant into the compressor will have a posi-
tive effect on service life.
If the system refrigerant charge exceeds the table values,
additional compressor protection is required (see below).
If the system refrigerant charge does not exceed the
charge limits in the table, no additional precautions are
required.
temperature,or a large refrigerant charge as used in mul-
tiple evaporator systems, a belt type heater can be used
in addition to a PTC heater.
A heater will not offer protection against continuous
liquid floodback.
Crankcase heater
A crankcase heater is required on all systems with LT /
LTZ compressors regardless of the refrigerant charge.
The effectiveness of a crankcase heater can be checked by
measuring the crankcase temperature, which should be
maintained at least 18°F above the saturated suction
temperature.
Checks must be made to insure that the appropriate oil
temperature is maintained under all ambient conditions.
Both self-regulating PTC crankcase heaters and belt type
crankcase heaters are available as accessories, as shown
in the tables.
Note: Under extreme conditions such as low ambient
17
60 Hz catalog
RECIPROCATING COMPRESSORS
Compressor types Compressor models System refrigerant charge limit (lbs)
1 cylinder LT / LTZ 22-28 5
2 cylinder LT / LTZ 44-50 10
4 cylinder LT / LTZ 88-100 20
Refrigerant charge limits
Voltage
LT / LTZ 22-100
designation part number
200 - 600 V PTC 35 W PTC
Voltage LT / LTZ 22-28 LT / LTZ 44-50 LT / LTZ 88-100
designation part number designation part number designation part number
110 V - - 50 W - 110 V 7773010 - -
230 V 54 W - 230 V 7773002 50 W - 230 V 7773003 75 W - 230 V 7773004
400 V 54 W - 400 V 7773013 50 W - 400 V 7773009 75 W - 400 V 7773014
575 V ----75 W - 575 V 7773105
Note: Belt type crankcase heaters are not self-regulating.
They must be switched on when the compressor stops and switched off when the compressor runs.
PTC crankcase heater
Belt type crankcase heaters
System design recommendations, continued
Suction accumulator
A suction accumulator offers protection against refrige-
rant floodback at start-up, during operation, and after
defrost. The accumulator provides additional internal
volume on the low pressure side of the system. Tests
must be conducted to determine the actual refrigerant
capacity each application requires. The accumulator
should be sized for not less than 50% of the total system
charge.A suction line accumulator should not be used in
systems with zeotropic refrigerants.
Liquid line solenoid valve (LLSV)
An LLSV may be used to isolate the refrigerant charge in
the condenser side of the system, thereby preventing
transfer or excessive migration to the compressor during
off cycles. Using a pumpdown cycle with the LLSV can
further reduce the amount of refrigerant in the low
pressure side of the system.
Pumpdown cycle
A pumpdown cycle is one of the most effective ways to
protect against off-cycle migration of liquid refrigerant.
Pumpdown must always be used when evaporators are
fitted with defrost heaters.
insulation of the compressor. Sound transmitted by
mounting feet, pipework, and refrigerant should be
treated the same way as vibration, which is covered in
the next section.
Running compressors cause sound and vibration, which
are closely related phenomena.
Sound
The table at right shows the sound power levels
produced by Maneurop compressors. Note that sound
power levels are not the same as sound pressure levels
often seen in documentation.The sound that a compres-
sor produces is transmitted in every direction by the
ambient air, the mounting feet, the pipework and the
refrigerant.The easiest way to reduce the sound level in
ambient air is to fit an acoustic hood available as acces-
sory. Because Maneurop compressors are 100% suction
gas cooled,and require no body cooling,they can be insu-
lated. Values for the sound reduction achieved with
Maneurop
®
acoustic hoods are shown also in the table at
right. For compressors mounted indoors, sound insula-
tion of the machine room is an alternative to sound
Suction and discharge lines must have adequate flexibili-
ty in every direction. Eventually vibration absorbers may
be required. Care must be taken to avoid tubing that
has resonant frequencies close to those of the com-
pressor.The refrigerant gas also transmits vibration,
which is reduced by the Maneurop compressor’s built-
in mufflers.To further reduce vibration transmission by
the refrigerant, an additional muffler can be installed.
Vibration
Always use the mounting grommets delivered with the
compressor.The grommets reduce the vibration trans-
mitted to the base frame by the compressor mounting
feet.
The compressor’s mounting base should be sufficiently
rigid and of adequate mass to insure full effectiveness of
the mounting grommets.The compressor should never
be directly mounted on the base frame without using
the grommets; to do so will cause high vibration trans-
mission and will shorten compressor service life.
SOUND AND VIBRATION
18
60 Hz catalog
RECIPROCATING COMPRESSORS
Sound power level
Acoustic
Compressor
dB(A)
hood
model
without with part number
hood hood
LT / LTZ 22 75 69
7755001
LT / LTZ 28 70 65
LT / LTZ 44 86 81
7755002
LT / LTZ 50 82 76
LT / LTZ 88 86 81
7755003
LT / LTZ 100 86 81
tems,tubes,vacuum pumps,etc.) dedicated to the system
refrigerant.
• Use only clean and dehydrated refrigeration grade cop-
per tubes and silver alloy brazing material.
• Clean all parts before brazing and always have nitrogen
or CO
2
flowing through the pipes during brazing to pre-
vent oxidation.
• If flux is used, take every precaution to prevent leakage
into the piping.
• Do not drill holes (e.g. for schrader valves) in parts of
the installation that are already completed, if filings and
burrs can not be removed.
Carefully follow the instructions in the next section when
brazing, mounting, detecting leaks, pressure testing and
moisture removal.
System contamination is one of the main factors affecting
equipment reliability and service life. It is therefore
important to insure system cleanliness when assembling
a refrigeration system.
During the assembly, system contamination can be cau-
sed by:
• Filings and particles created while removing burrs from
pipe-work;
• Brazing and welding oxides;
• Brazing flux;
• Moisture and air.
All installation and service work must be done only by
qualified and certified personnel, who must follow the
procedures described below using tools (charging sys-
compressor lifting lug should never be used to lift the
complete installation. Keep the compressor in an upright
position when handling it.
Compressor handling
Maneurop
®
LT / LTZ compressors are provided with a lif-
ting lug.This lug should always be used to lift the com-
pressor. Once the compressor is installed, the
SYSTEM CLEANLINESS
19
60 Hz catalog
RECIPROCATING COMPRESSORS
Installation and service
COMPRESSOR HANDLING, MOUNTING
AND CONNECTION TO THE SYSTEM
torque
lb ft
Cable screw of T connector in electrical box 2
1" 59
Rotolock valves and solder sleeves 1"1/4 66
1"3/4 81
Mounting grommet bolts 11
Oil sight glass 37
Oil equalization connection 22
LP Service port (schrader) cap nut 11
Connecting the compressor to the system
Whenever possible the compressor must be the last
component to be integrated into the system. New
compressors have a protective nitrogen holding charge.
Only the suction and discharge caps should be removed
just before connecting the compressor to the installation.
To avoid air and moisture entering the compressor,
it is advisable to braze the solder sleeves or service valves
to the pipework before the compressor is mounted.
When all brazing is finished and the total system is ready,
the compressor caps can be removed and the compres-
sor connected to the system with minimum exposure to
ambient air. If this procedure is not possible, the sleeves
or valves may be brazed to the pipes when mounted on
the compressor making certain that
Compressor mounting
Mount the compressor with the base plate horizontal,
with a maximum slope of 3 degrees.All compressors are
supplied with three or four rubber mounting grommets,
each complete with metal sleeves, nuts and bolts. Refer
to the outline drawings on pages 7 to 9.
The mounting grommets largely attenuate compressor
vibration transmitted to the base frame.The compressor
must always be mounted with these grommets.
Refer to the right table for torque values.
Note 1: Leak detection with refrigerant may not be allowed in some countries. Check local regulations.
Note 2: Leak detecting additives can not be used because they may affect the properties of the system lubricant.The warranty may be voided if leak detecting
additives are used.
1-2-4 cylinder compressors
Maximum compressor test pressure, low side 363 psi(g)
Maximum compressor test pressure, high side 435 psi(g)
Installation and service
nitrogen or CO2 is flowing through the com-
pressor via the schrader valve to prevent the
entrance of air and moisture. Nitrogen or CO
2
flow must start when the caps are removed and
must continue throughout the brazing process.
When rotolock valves are used on the com-
pressor, they must be closed immediately after
mounting, thus keeping the compressor isolated
from the atmosphere or from a system that is
not yet dehydrated.
Note:
When the compressor is built into a multiple-
compressor “rack” which is not installed imme-
diately in its final location,vacuum pull-down and
moisture removal must be performed on the
rack as if it were a complete system (see the fol-
lowing sections).The rack must be charged with
nitrogen or CO
2
and open tubes must be bloc-
ked with caps or plugs.
SYSTEM PRESSURE TEST
LEAK DETECTION
The maximum test pressures for LT / LTZ compressors
are shown in the table below.
Do not exceed a pressure difference of 435 psi between
the high pressure side and the low pressure side of the
compressor; higher pressure differentials will cause the
internal compressor relief valve to open.
It is recommended that an inert gas such as nitrogen be
used for pressure testing. Dry air may also be used but
care should be taken since it can form a flammable mix-
ture with the compressor oil.
When performing a system pressure test, do not exceed
the maximum allowed pressure of any of the components.
repairing leaks, observe the procedures described in the
sections above.The use of other gases such as oxygen,
dry air, or acetylene is not recommended, because these
gases can form a flammable mixture. Never use CFC or
HCFC refrigerants for leak detection in HFC systems.
During leak detection,if valves are present, the compres-
sor must be kept isolated from the system whenever
possible. Use the final system refrigerant.Pressurize with
nitrogen or another neutral gas and use a leak detector
designed for the system refrigerant. A spectrometric
detection system using helium can also be used.When
20
60 Hz catalog
RECIPROCATING COMPRESSORS
N
2
Schrader
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