Selection & Application guidelines -...

24
50 Hz R404A / R507 Low temperature refrigeration 1 CYLINDER 2 CYLINDERS 4 CYLINDERS Selection & Application guidelines RECIPROCATING COMPRESSORS LTZ Expect more from us Refrigeration and Air Conditioning

Transcript of Selection & Application guidelines -...

50 HzR404A / R507

Low temperature refrigeration

1 CYLINDER2 CYLINDERS4 CYLINDERS

Selection & Application guidelines

RECIPROCATING COMPRESSORS

LTZ

Expect morefrom us

Refrigeration andAir Conditioning

250 Hz catalogueRECIPROCATING COMPRESSORS

DANFOSS MANEUROP LTZ COMPRESSORS . . . . . . . . . . p 3

COMPRESSOR NOMENCLATURE . . . . . . . . . . . . . . . . . . . . . p 4

Order reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p 4Compressor reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p 4Motor voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p 4

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p 5

Technical specifications and versions . . . . . . . . . . . . . . . . p 5Nominal performance R404A, R507-50 HZ . . . . . . . . . p 5Operating envelope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p 5

PERFORMANCE TABLES R404A / R507 . . . . . . . . . . . . . . . . . p 6

OUTLINE DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p 7

1 cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p 72 cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p 84 cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p 9

ELECTRICAL CONNECTIONS AND WIRING . . . . . . . . . . p 10

Single phase electrical characteristics . . . . . . . . . . . . . . p 10Motor protection and suggested wiring diagrams . . . p 10Capacitor and relay selection table . . . . . . . . . . . . . . . . p 11Three phase electrical characteristics . . . . . . . . . . . . . . p 11Motor protection and suggested wiring diagram . . . . p 11

MISCELLANEOUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p 12

Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p 12Design version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p 12IP 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 19Compressor 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 ManeuropLTZ Compressors

3 50 Hz catalogueRECIPROCATING COMPRESSORS

Danfoss Maneurop LTZ compressorsare of the hermetic reciprocatingtype and are designed for low evaporating temperature applications.All components are of high qualityand precision in order to assurea long product life.The positive benefits of internalmotor protection, high efficiencycircular valve design and high torquemotors provide for a qualityinstallation.

The LTZ series is specificallydesigned for use with the HFCrefrigerants R404A, and R507, using160Z polyester oil as lubricant.These compressors can be used in new installations and also to replace Maneurop® LTE compressors in existing installations.

LTZ compressors have a largeinternal free volume that protectsagainst the risk of liquid hammeringwhen liquid refrigerant enters the compressor.

LTZ compressors are fully suction-gas cooled.This means that no additional compressor cooling is requiredand allows the compressors to beinsulated with acoustic jackets,to obtain lower sound levels,without the risk of compressoroverheating.

LTZ compressors are available in 7 different models with displacementranging from 48 to 272 cm3/rev.Six different motor voltage rangesare available for single and three phase power supplies at 50and 60 Hz.

All models are available in VE versionwith oil equalisation and oil sightglass. One cylinder models are alsoavailable without oil equalisationand oil sight glass.

50 Hz catalogue

Compressor nomenclature

ORDER REFERENCE

4RECIPROCATING COMPRESSORS

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 V4

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

Packaging type(see page 22)

Oil equalisation portand threaded sight glass

LT Z 4 V28 -

Compressor type

Motor voltage code(see below)

Polyol ester oil

Compressor size

I

Option code

Design version(see page 12)

Oil equalisation portand sight glass

LT Z 4 A28 JH

Compressor type

Motor voltage code(see below)

Polyol ester oil

Compressor size

Displacement code(see page 5)

VE -

EXAMPLE:LTZ 28 - 4I LTZ 28, individual packaging (I), motor voltage code 4, standard versionLTZ 28 - 4VI LTZ 28, individual packaging (I), motor voltage code 4,VE version (V)LTZ 28 - 4M LTZ 28, multiple packaging (M), motor voltage code 4, standard versionLTZ 28 - 4VM LTZ 28, multiple packaging (M), motor voltage code 4,VE version (V)Individual packaging: single packaging per compressorMultiple packaging: single packaging for several compressors, full pallet (number of compressors per pallet depending on compressor model).

COMPRESSOR REFERENCE (INDICATEDON THE COMPRESSOR NAMEPLATE)

NOMINAL RATINGS *R404A, R507

Compressor Cooling Power Current input COP

model capacity input (A)(W) (kW) 400V / 3 ph 230V / 1 ph 230V / 3 ph (W/W)

LTZ 22 JE 825 945 2.14 5.36 - 0.87

LTZ 28 JH 1 264 1 369 2.85 7.81 - 0.92

LTZ 40 HL 1 934 2 206 4.42 - - 0.88

LTZ 44 HM 2 115 2 578 5.72 - 13.05 0.82

LTZ 50 HP 2 917 3 401 6.29 - 13.15 0.86

LTZ 88 HU 4 002 4 810 9.62 - 15.88 0.83

LTZ 100 HW 5 545 6 017 10.28 - 16.69 0.92

Specifications

5 50 Hz catalogueRECIPROCATING COMPRESSORS

* At 2900 rpm • S: without oil sight glass and oil equalisation connection • VE: with threated oil sight glass and 3/8” flare oil equalisation connection.

Displacement Cyl. Oil Net Design versions

Compressor number charge weightmotor voltage code

model(cm3/rev) (m3/h)* (dm3) (kg) 1 3 4 5 6 9

LTZ 22 JE 48.06 8.36 1 0.95 21 S-VE S-VE S-VE S-VE - S-VE

LTZ 28 JH 67.89 11.81 1 0.95 23 S-VE S-VE S-VE S-VE - S-VE

LTZ 40 HL 96.13 16.73 2 1.8 35 - - VE - - -

LTZ 44 HM 107.71 18.74 2 1.8 35 VE VE VE - VE VE

LTZ 50 HP 135.78 23.63 2 1.8 35 VE VE VE - VE VE

LTZ 88 HU 215.44 37.49 4 3.9 62 - VE VE - VE VE

LTZ 100 HW 271.55 47.25 4 3.9 64 - VE VE - VE VE

TECHNICAL SPECIFICATIONS AND VERSIONS

NOMINAL PERFORMANCE R404A, R507- 50 HZ

OPERATING ENVELOPE

70

65

60

55

50

45

40

35

30-30-35 -25-45-50 -40 -20 -15

Co

nden

sing

tem

pera

ture

(°C

)

Evaporating temperature (°C)

S.H. = 30 K

S.H. = 11.1 K

Application Envelopefor LTZ compressors with

R404A/R507

* Ratings with R404A at dew point conditions or with R507: - 35°C evaporating temperature, 40°C condensing temperature,0 K subcooling, 10 K superheat, 50 HzCapacity and power input data ± 5%

50 Hz catalogue 6RECIPROCATING COMPRESSORS

Performance tables R404A / R507

Models TE -45 -40 -35 -30 -25 -20

TC P.F. P.A. C P.F. P.A. C P.F. P.A. C P.F. P.A. C P.F. P.A. C. P.F. P.A. C

30 470 0.62 1.7 740 0.76 2.0 1 090 0.92 2.3 1 530 1.10 2.6 2 090 1.30 2.8 2 770 1.53 3.1

LTZ 22 JE 4 40 340 0.63 1.6 550 0.78 1.8 820 0.95 2.1 1 190 1.14 2.4 1 640 1.35 2.7 2 200 1.59 3.0

50 - - - 370 0.77 1.8 550 0.95 2.1 810 1.15 2.4 1 140 1.37 2.7 1 560 1.62 3.0

60 - - - - - - 440 0.94 2.2 570 1.15 2.5 760 1.38 2.8 1 020 1.65 3.0

30 920 0.87 1.9 1 280 1.08 2.3 1 740 1.32 2.7 2 340 1.58 3.1 3 070 1.87 3.5 3 980 2.19 4.0

LTZ 28 JH 4 40 560 0.90 2.0 870 1.12 2.4 1 260 1.37 2.8 1 760 1.65 3.3 2 380 1.95 3.8 3 150 2.30 4.3

50 - - - 550 1.12 2.4 850 1.38 2.9 1 230 1.68 3.4 1 710 2.01 3.9 2 310 2.38 4.5

60 - - - - - - 560 1.35 2.8 800 1.67 3.3 1 130 2.03 3.9 1 540 2.43 4.6

30 1 200 1.45 3.2 1 720 1.78 3.7 2 420 2.14 4.3 3 340 2.54 4.9 4 510 2.97 5.5 5 950 3.43 6.1

LTZ 40 HL 4 40 950 1.50 3.2 1 360 1.83 3.8 1 930 2.21 4.4 2 690 2.61 5.0 3 660 3.05 5.7 4 880 3.52 6.3

50 - - - 910 1.84 3.8 1 310 2.22 4.4 1 870 2.64 5.1 2 600 3.09 5.7 3 550 3.57 6.4

60 - - - - - - 880 2.20 4.3 1 200 2.63 4.9 1 670 3.09 5.6 2 310 3.59 6.3

30 1 170 1.81 5.0 1 810 2.19 5.3 2 660 2.58 5.7 3 760 2.96 6.1 5 140 3.34 6.5 6 820 3.70 7.0

LTZ 44 HM 4 40 900 1.75 4.9 1 420 2.16 5.3 2 110 2.58 5.7 3 020 3.00 6.2 4 170 3.43 6.6 5 580 3.84 7.2

50 - - - 910 2.07 5.2 1 410 2.53 5.7 2 070 3.00 6.2 2 950 3.48 6.7 4 050 3.95 7.3

60 - - - - - - 930 2.37 5.5 1 330 2.90 6.0 1 880 3.44 6.6 2 630 3.98 7.3

30 1 770 2.49 5.2 2 560 2.95 5.7 3 590 3.42 6.2 4 890 3.87 6.8 6 470 4.31 7.3 8 390 4.72 7.9

LTZ 50 HP 4 40 1 370 2.37 5.1 2 050 2.88 5.7 2 920 3.40 6.3 4 010 3.93 6.9 5 370 4.45 7.6 7 020 4.95 8.3

50 - - - 1 330 2.75 5.5 1 990 3.34 6.2 2 850 3.95 7.0 3 920 4.57 7.8 5 250 5.19 8.7

60 - - - - - - 1 230 3.14 5.9 1 800 3.85 6.8 2 540 4.59 7.8 3 500 5.33 8.8

30 2 140 3.59 7.3 3 280 4.12 8.4 4 800 4.65 9.4 6 760 5.19 10.3 9 220 5.72 11.2 12 230 6.25 12.0

LTZ 88 HU 4 40 1 720 3.54 7.5 2 700 4.16 8.6 4 000 4.81 9.6 5 690 5.49 10.6 7 830 6.20 11.6 10 480 6.93 12.5

50 - - - 1 650 3.97 8.6 2 670 4.77 9.7 4 030 5.63 10.8 5 770 6.54 11.8 7 970 7.50 12.7

60 - - - - - - 1 470 4.34 9.4 2 410 5.40 10.5 3 690 6.54 11.6 5 350 7.76 12.7

30 3 370 4.50 8.0 4 880 5.27 9.2 6 830 6.03 10.4 9 290 6.77 11.6 12 300 7.47 12.8 15 940 8.11 14.0

LTZ 100 HW 4 40 2 530 4.19 7.6 3 850 5.09 8.9 5 550 6.02 10.3 7 690 6.96 11.7 10 330 7.89 13.1 13 550 8.80 14.4

50 - - - 2 340 4.74 8.7 3 710 5.87 10.3 5 450 7.05 11.9 7 650 8.27 13.5 10 340 9.49 15.1

60 - - - - - - 2 040 5.34 10.2 3 300 6.81 12.0 4 950 8.34 13.9 7 020 9.93 15.8

LEGENDTE evaporating temperature (°C)TC condensing temperature (°C)

RATING CONDITIONSSuperheat 10 KSubcooling 0 K

P.F. cooling capacity (W)P.A. power input (kW)C current consumption (A)

400 V / 3 ph / 50Hz

230 V / 1 ph / 50Hz

Models TE -45 -40 -35 -30 -25 -20

TC P.F. P.A. C P.F. P.A. C P.F. P.A. C P.F. P.A. C P.F. P.A. C. P.F. P.A. C

30 470 0.62 4.2 740 0.76 4.9 1 090 0.92 5.7 1 530 1.10 6.4 2 090 1.30 7.1 2 770 1.53 7.8

LTZ 22 JE 5 40 340 0.63 3.9 550 0.78 4.6 820 0.95 5.4 1 190 1.14 6.1 1 640 1.35 6.8 2 200 1.59 7.6

50 - - - 370 0.77 4.5 550 0.95 5.3 810 1.15 6.0 1 140 1.37 6.8 1 560 1.62 7.5

60 - - - - - - 440 0.94 5.4 570 1.15 6.2 760 1.38 6.9 1 020 1.65 7.6

30 920 0.87 5.2 1 280 1.08 6.2 1 740 1.32 7.3 2 340 1.58 8.5 3 070 1.87 9.7 3 980 2.19 11.0

LTZ 28 JH 5 40 560 0.90 5.5 870 1.12 6.6 1 260 1.37 7.8 1 760 1.65 9.1 2 380 1.95 10.4 3 150 2.30 11.8

50 - - - 550 1.12 6.6 850 1.38 7.9 1 230 1.68 9.3 1 710 2.01 10.8 2 310 2.38 12.4

60 - - - - - - 560 1.35 7.5 800 1.67 9.1 1 130 2.03 10.7 1 540 2.43 12.5

7

Outline drawings

Silent block

1 CYLINDER

Rotolock connections size Pipe sizing size Rotolock valveSuction Discharge Suction Discharge Suction Discharge

LTZ 22 JELTZ 28 JH

1”1/4 1” 5/8” 1/2” V09 V06

333

96

263

68

15 25

80

69

Ø 225

Models with motorcode 3, 4 & 9with rounded off top

LPgauge port(schrader)

Oil equalisation(VE - models only)

Mounting hole for PTC crankcase heater

38 123

145

118

109

68

134

1716

0

55˚

Oil sight glass(VE - models only)

ø H M8

22

15

Terminal box

IP rating: 55 (with cable gland)

Spade connectors1/4” AMP-AWE

Earth M4-12

Knock-outØ 21 mm

Ø 21 mm

50 Hz catalogueRECIPROCATING COMPRESSORS

8RECIPROCATING COMPRESSORS

Outline drawings

50 Hz catalogue

2 CYLINDERS

Rotolock connections size Pipe sizing size Rotolock valveSuction Discharge Suction Discharge Suction Discharge

LTZ 40 HLLTZ 44 HM

1”3/4 1”1/4 7/8” 3/4” V07 V04

LTZ 50 HP 1”3/4 1”1/4 1”1/8 3/4” V02 V04

(1) LTZ 2 cyl. Code 1-3-4-9(2) LTZ 2 cyl. Code 6

156

190(1

) - 20

0(2)

60

37˚ 96

145 125

2017

9

Mounting holefor PTC crankcase heater

415

65

266

80(1)

96(2)

Ø 288

6975 15 36(1

) - 2

4(2)

96(1

) - 11

5(2)

LPgauge port(schrader)

Oil equalisation Oil sight glass

Silent block ø H M8

22

15

Terminal box

IP rating: 55 (with cable gland)

Spade connectors1/4” AMP-AWE

Earth M4-12

Knock-outØ 21 mm

Ø 21 mm

Terminal box for motor code 6

IP rating: 54 (with cable gland)

Screw10-32 UNF x 9,5

Earth M4-12

Knock-outØ 29 mm

Ø 29 mm

9

Outline drawings

Silent block

4 CYLINDERS

(1) LTZ 4 cyl. Code 3-4-6(2) LTZ 4 cyl. Code 9

519

95

233

125

Ø 352

19

179(2)

96(1)

60(2

)

158(1

)

115(1

)

227(2

)

LPgauge port(schrader)

Oil sight glass

246

255(2

)

212

246

232(1

)

Mounting hole forPTC crankcase heater

Oil equalisation

3019

ø H M12

Terminal box

IP rating: 54 (with cable gland)

Screw10-32 UNF x 9,5

Earth M4-12

Knock-outØ 29 mm

Ø 29 mm

Terminal box for motor code 9

IP rating: 55 (with cable gland)

Screw10-32 UNF x 9,5

Transformer24 V

Protection moduleMP 12-1064

or MP 12-1069

Rotolock connections size Pipe sizing size Rotolock valvesSuction Discharge Suction Discharge Suction Discharge

LTZ 88 HULTZ 100 HW

1”3/4 1”1/4 1”1/8 3/4” V02 V04

Ø 29 mm

50 Hz catalogueRECIPROCATING COMPRESSORS

LRA - Locked Rotor MCC - Maximum Winding resistanceCurrent (A) Continuous Current (A) (Ohm) (± 7 % at 20°C)

Motor Code 1 5 1 5 1 5Winding run start run startLTZ 22 JE 49.3 41 17 15 1.25 2.49 1.78 4.74LTZ 28 JH 81 55 25 16 0.74 1.85 1.16 3.24LTZ 44 HM 103 - 34 - 0.41 1.90 - -LTZ 50 HP 143 - 37 - 0.33 1.95 - -

50 Hz catalogue 10RECIPROCATING COMPRESSORS

SINGLE PHASE ELECTRICAL CHARACTERISTICS

Electrical connectionsand wiring

Single phase CSR wiring with trickle heatcircuit configuration for LTZ 22The trickle circuit provides compressor crankcaseheating by feeding a low current to the auxiliary winding via the run capacitor during off periods.Single phase LTZ 22 compressors can be operatedwithout crankcase heater accessory when a trickleheat circuit is applied. For the larger single phase compressor models LTZ 28-50, the PTC crankcaseheater is required.

Standard single phase CSR wiring withaccessory crankcase heater configurationThis system provides additional motor torque at startup, by the use of a start capacitor in combination withthe run capacitor.This system can be used for refrigerant circuits withcapillary tubes or expansion valves.The start capacitor is only connected during the startingoperation, a potential relay is used to disconnect it afterthe start sequence.A PTC crankcase heater is required.

15 kΩ - 1 W

230 V

A µF

B µ

F

5

Start Relay

2

1S R

C220 kΩ - 1 W

C µ

F

IOL

15 kΩ - 1 W

230 V

"A + C"

B µ

F

5

Start Relay

2

1S R

C220 kΩ - 1 WIOL

MOTOR PROTECTION AND SUGGESTED WIRING DIAGRAMS

The single phase compressormotors are internally protectedby a temperature/current sensingbimetallic protector, which senses

the main and start winding currents,and also the winding temperature.If the motor is overloaded and theprotector trips, it may take up to

three hours to reset and restartthe compressor.

IOL: motor protectorA + C: run capacitorsB: start capacitorC: Common S: Start winding (auxiliary) R: Run winding (main)Capacitors A and C are replaced by a single capacitor of size A + C.

IOL: motor protectorA & C: run capacitorsB: start capacitorC: Common S: Start winding (auxiliary) R: Run winding (main)

Motor code 1: 208 - 230 V / 1ph / 60 HzMotor code 5: 230 V / 1ph / 50 Hz

Electrical connectionsand wiring

11 50 Hz catalogueRECIPROCATING COMPRESSORS

CAPACITOR AND RELAY SELECTION TABLE

Run Start 230 V / 1 ph / 50Hz capacitors capacitors StartModels (1) (2) relay

(A) µF (C) µF (B) µFLTZ 22 JE-5 20 10 100 all models

LTZ 28 JH-5 20 10 100 3ARR3J4A4

Run Start 208 - 230 V / 1 ph / 60Hz capacitors capacitors StartModels2 (1) (2) relay

(A) µF (C) µF (B) µFLTZ 22 JE-1 15 30 100LTZ 28 JH-1 25 25 135 all models

LTZ 44 HM-1 30 15 135 3ARR3J4A4

LTZ 50 HP-1 30 15 135(1) Run capacitors: 440 volts - minimum 10 000 hours.(2) Start capacitors: 330 Volts.

THREE PHASE ELECTRICAL CHARACTERISTICS

MOTOR PROTECTION AND SUGGESTED WIRING DIAGRAM

LRA - Locked Rotor MCC - Maximum Winding resistanceCurrent (A) Continuous Current (A) (Ohm) (± 7 % at 20°C)

Motor Code 3 4 6 9 3 4 6 9 3 4 6 9

LTZ 22 JE 38 16 - 22 11 6 - 5 2.49 10.24 - 13.1

LTZ 28 JH 57 23 - 29 16 7.5 - 8.5 1.37 7.11 - 9.7

LTZ 40 HL - 42 - - - 9 - - - 3.80

LTZ 44 HM 100 42 92 57 22 9.5 18 11 0.74 3.80 0.96 2.54

LTZ 50 HP 117 40 92 64 23 12 18 15 0.62 3.80 0.96 2.54

LTZ 88 HU 157 78.5 126 110 43 22 35 23 0.48 1.98 0.77 1.26

LTZ 100 HW 210 105 170 150 54 27 43 30 0.37 1.54 0.49 0.84

Note: for three phase motors, the winding resistances measured at compressor terminals is the sum of two winding resistor values shown above.

The 3-phase compressors are protected by an internalmotor protector, connected to the neutral point ofthe star connected stator windings.This IOL (internaloverload line break) protects the motor against overheating, current overload and locked rotor conditions.The protector cuts out all 3 phases

simultaneously. If the motor is overloaded and theprotector trips, it may take up to three hours to resetand restart the compressor.

For all 3-phase compressors, a PTC crankcase heateris required.

PTC

FU

FU

C1

EC

TH

N

L1L2L3

C1

MS

IOL

Comp.

LEGEND:

FU ........................................................................................................................................................fusesMS ...................................................................................................................................... main switchC1 .................................................................................................................... compressor contactorTH .......................................................................................................................................... thermostatEC .............................................................................................................................. external controlsCOMP ................................................................................................................................ compressorMP .......................................................................................................................... protection modulePTC .......................................................................................................................... crankcase heaterTR ........................................................................................................................................ transformerIOL .................................................................................................... internal overload line break

Modifications in the original com-pressor design are indicated with a design version code.This designversion code appears in the compressor reference directlyafter the motor voltage code (seepage 4).The table shows the actual designversion for LTZ compressors.When no modifications to the original design are made, no designversion code appears.This is indi-cated with a *-symbol in the table.The order reference does notinclude the design version code.

IP RATING

50 Hz catalogue 12RECIPROCATING COMPRESSORS

APPROVALS

Miscellaneous

Maneurop® LTZ compressors with motor code 1, 3 and 4 are UL approved (except LTZ40-4).All LTZ models have CE marking.

1 3 4 5 6 9

LTZ 22 A A A A * A

LTZ 28 A A A A * A

LTZ 40 - - A - - -

LTZ 44 * * A - * A

LTZ 50 * A A - * A

LTZ 88 - * * - * A

LTZ 100 - * * - * A

EX: LTZ 50 HP 4 A VE

DESIGN VERSION

All Maneurop® LTZ compressors are rated IP54 or IP55 according toCEI 529, see table below.These IP

IP 5 5

Level of protection against contact and foreign objects5 = Complete protection against contact

and against harmful dust deposits

Level of protection against water4 = Protection against water splashing from any direction5 = Protection against jets of water from any direction

First numeral:

Second numeral:

Model Rating

LTZ 22 IP55LTZ 28 IP55LTZ 40 IP55LTZ 44-1/3/4/9 IP55LTZ 44-6 IP54LTZ 50-1/3/4/9 IP55LTZ 50-6 IP54LTZ 88-3/4/6 IP54LTZ 88-9 IP55LTZ 100-3/4/6 IP54LTZ 100-9 IP55

ratings are only valid when correctly sized cable glands of the same IP rating are applied.

* no letter- model not available

13 50 Hz catalogueRECIPROCATING COMPRESSORS

Refrigerants and lubricants

Maneurop® LTZ compressors are developed for HFC refrigerantsR404A and R507 which are generally accepted as long termalternatives for CFC refrigerantR502.

Maneurop® LT compressors are still available for replacementor applications with HCFC blends.

The table below gives an overviewof different refrigerants for low

temperature applications and the corresponding Maneurop®

compressor and lubricant.Also check local legislation andsafety standards.

Refrigerant Type ODP1 GWP2 Compressor Lubricant RemarksR404A 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 andtransitional HCFC 0.03 3570 LT oil by 160 ABM. R502, should never be used in refrigerants combination with

R502 CFC 0.22 5500 LT Maneurop® mineral oil 160 P, LTZ compressors.factory charged.

Hydrocarbons HC Danfoss Maneurop does not authorise the use of hydrocarbons with their compressors.

GENERAL INFORMATION

(1) ODP: Ozone Depletion Potential - (2) GWP: Global warming Potential, time-horizon 100 years, source ARTI 1999

R404ARefrigerant R404A is a ternary mixture of R125, R143a and R134a. Its thermodynamic properties are comparable to R502. R404A has a very small temperature glide (< 1 K) between dew point and bubble pointand should therefore be charged in its liquid phase, but for most other aspects this small glide can be neglected.Because of the small glide, R404A is often called a near-azeotropic mixture. Apply the Maneurop® LTZ compressor with factory charged 160Z polyolester oil. Maneurop® LT compressors should never be used for R404A systems.

R507Refrigerant R507 is a binary mixture of R125 and R143a. Its thermodynamic properties are comparable to R502. R507 has no temperature glide and behaves as a pure refrigerant (azeotropic mixture).Apply the Maneurop® LTZ compressor with factory charged 160Z polyolester oil. Maneurop® LT compressorsshould never be used for R507 systems.

R22 based transitional refrigerantsA wide variety of R22-based transitional refrigerants (also called service refrigerants or drop-in blends) are developed as temporary R502 alternatives. Some examples are R402A, R402B, R403A and R403B.They all have a (low) ODP value. Because of the R22 component, Maneurop® LTZ compressor should not beused for these refrigerants, but Maneurop® LT compressors should be used instead.The initial mineral oil charge of the LT compressor must be replaced by Maneurop® 160ABM alkylbenzene/mineral lubricant.

R502The Montreal protocol states that CFC refrigerants such as R502 may no longer be applied in new installationsin the signatory member countries. For other countries or for replacement in existing installations Maneurop®

LT compressors are still available. Maneurop® LTZ compressors shall never be used for R502 systems.

HydrocarbonsHydrocarbons such as propane, isobutane etc. are extremely flammable. Danfoss Maneurop does not authorisethe use of hydrocarbons with LTZ or LT compressors in any way.

50 Hz catalogue 14RECIPROCATING COMPRESSORS

PIPING DESIGN

System designrecommendations

Suction linesHorizontal suction line sectionsshall have a slope of 0.5% in thedirection of refrigerant flow (5 mmper meter).The cross-sectionof horizontal suction lines shall besuch that the resulting gas velocityis at least 4 m/s. In vertical risers,a gas velocity of 8 to 12 m/s isrequired to ensure proper oil return.A U-trap is required at the foot ofeach vertical riser. If the riser ishigher than 4 m, additional U-trapsare required for each additional4 meters.The length of each U-trap must be as short as possible to avoid the accumulationof excessive quantities of oil.See figure below.

For compressors mounted inparallel, the common suction risershould be designed as a double riser.The cross section of the smallestriser must be designed to givea gas velocity of 8 to 12 m/s atminimum capacity (one compressorrunning).The total cross sectionof both risers must be designed togive a gas velocity of 8 to 12 m/sat full capacity (all compressorsrunning).See figure below. Also refer to theManeurop®‚ Technical Informationbulletin TI 001 "Mounting instructionsfor installation of Maneurop®‚compressors in parallel ".

Gas velocities higher than 12 m/s

will not contribute to significantlybetter oil return. However theywill cause higher noise levels andresult in higher suction line pressure drops which will have anegative effect on the system capacity. Note that the suctionrotolock valves, which can beordered from Danfoss Maneuropas accessories, are designed for average pipe sizes, selected for systems running at nominalconditions.The pipe sizes selected for specificsystems may differ from theserecommended sizes.

Suction lines must always be insulatedto limit suction gas superheat.

To compressors

From evaporators

8 to 12 m/sat minimum capacity

8 to 12 m/sat maximum capacity

U-trap, as short as possible

Evaporator

To condenser

max. 4 m

max. 4 m

U-trap, as short as possible

U-trap

8 to 12 m/s

0.5 % slope,4 m/s or more

U-trap, as short as possible

0.5 % slope,4 m/s or more

Oil in a refrigeration circuit isrequired to lubricate moving partsin the compressor. During normalsystem operation small oil quantitieswill continuously leave the compressor, with the discharge gas.Therefore the system piping shall bedesigned in a way which allows a good oil circulation, avoiding oilbeing trapped in the system andensuring a constant oil return tothe compressor.As long as the

amount of oil circulating throughthe system is small it will contribute to good system operation and improved heattransfer efficiency.However, too large amounts of oilin the system will have a negativeeffect on condenser and evaporatorefficiency. If, in a poorly designedsystem, the amount of oil returningto the compressor is lower thanthe amount of oil leaving the

compressor, the compressor willbecome starved of oil and thecondenser, evaporator and/orrefrigerant lines will become filledwith oil. In such situations,additional oil charge will only correct the compressor oil levelfor a limited period of time andincrease the amount of surplus oilin the rest of the system.Only correct piping design can ensurea good oil balance in the system.

System designrecommendations

15 50 Hz catalogueRECIPROCATING COMPRESSORS

Discharge line When the condenser is mountedat a higher position than the compressor, a suitably sized U-trapclose to the compressor may benecessary to prevent oil return tothe discharge side of the compressor during standstill.It will also help eliminate liquidrefrigerant floodback from the condenser to the compressor.

Oil charge and oil separatorIn most installations the initialcompressor oil charge will be suffi-cient. In installations with line runsexceeding 20 m, or with many oiltraps or an oil separator, additionaloil may be required. In installations

with the risk of slow oil returnsuch as in multiple evaporatoror multiple condenser installations,an oil separator is recommended.Also refer to the "Start up" section.

System componentsSystem components such as filterdriers, expansion devices and sightglasses must be specifically designed for refrigerants R404A or R507.Always refer to the component manufacturers technicaldocumentation.Apply a 100 % molecular sievesliquid line filter drier (no activatedaluminia) which is oversized ratherthan undersized.When selecting a drier, take into

account the drier capacity (watercontent capacity), the system refrigerating capacity and the system refrigerant charge.The upper limit of the applicationenvelope for LTZ compressors isat –20°C evaporating temperature.A MOP-type expansion valveor a crankcase pressure regulator(e.g. KVL) shall be used to limit thesuction pressure at a maximum of 2.7 bar effective (-15°C). Do notapply both devices in combination.A suction line heat exchanger is notrecommended for low temperatureapplications as this may cause highsuction gas superheat which can result in too high discharge temperature.

table below.The high pressureswitch can be set to lower valuesdepending on the application andambient conditions.The HP switch must either be in a lockout circuit,

or be a manual reset device toprevent compressor cycling aroundthe high pressure limit.When a discharge valve is used,the HP switch must be connectedto the service valve gauge port,which cannot be isolated.

Low pressureA low pressure safety switch isrecommended to avoid compressoroperation at too low suction pressures.

High PressureA high pressure safety switch isrequired to stop the compressor,should the discharge pressureexceed the values shown in the

protection. Depending on how thelow pressure switch and delay timerare set short cycling can occur.To avoid these problems, severalsolutions are possible, based onreducing condenser capacity;• Liquid flooding of condensers

(note: this solution requires extra refrigerant charge.A non-return valve in the discharge line is required and special care should be takenwhen designing the discharge line.)

• Reduce air flow to condensers• Alternatively the condenser

may be installed indoor.When the compressor is locatedin a low ambient temperature environment, increased refrigerantmigration will occur during shutdown periods. For such conditionsan extra belt-type crankcase heater is strongly recommended.Note that with 100% suction gascooled motors, Maneurop®

compressors can be externally insulated. Refer to section "Liquidrefrigerant migration & chargelimits" for more details.

Low ambient temperatureoperationAt low ambient temperatures,the condensing temperature andcondensing pressure in air cooledcondensers will decrease.This low pressure may be insufficient to supply enough liquidrefrigerant to the evaporator.As aresult the evaporating temperaturewill strongly decrease, leading tolow capacity and eventual poor oilreturn. At start up, the compressorwill pull into vacuum and it will beswitched off by the low pressure

OPERATING LIMITS

LTZR404A / R507

Test pressure low side bar (g) 25Working pressure range high side bar (g) 13.2 - 27.7Working pressure range low side bar (g) 0.1 - 2.0Relief valve opening pressure difference bar (g) 30Relief valve closing pressure difference bar (g) 8

System designrecommendations

1650 Hz catalogueRECIPROCATING COMPRESSORS

If necessary, use an anti-short-cycletimer in the control circuit.A time-out of five minutes isrecommended.The system must bedesigned in such a way to guaranteea minimum compressor running

time in order to provide proper oilreturn and sufficient motor coolingafter starting.Note that the oil return ratevaries as a function of the systemdesign.

Cycle rate limitThere may be no more than12 starts per hour (6 when a softstart accessory is used).A higher number reduces the servicelife of the motor-compressor unit.

these table limits.The maximumallowable voltage imbalance for3-phase compressors is 2%.Voltageimbalance causes high currentdraw on one or more phases,

which in turn leads to overheatingand possible motor damage.Voltage imbalance is given by the formula:

Operating voltage rangeThe operating voltage limits areshown in the table on page 4.The voltage applied to the motorterminals must always be within

Vavg = Mean voltage of phases 1, 2, 3.V1-2 = Voltage between phases 1 & 2.

V1-3 = Voltage between phases 1 & 3.V2-3 = Voltage between phases 2 & 3.

LIQUID REFRIGERANT CONTROL AND CHARGE LIMITS

amounts of liquid refrigerantwithout major problems.However even when a compressorcan handle liquid refrigerant, thiswill not be favourable to its servicelife.Liquid refrigerant will dilute the oil,wash out the bearings causingwear and eventually seizure.

Furthermore high oil carry overwill cause lack of oil in the sump.Good system design can limit theamount of liquid refrigerant inthe compressor, which will have apositive effect on the compressorservice life.

Refrigeration compressors arebasically designed as gas compressors.Depending on the compressordesign and operating conditions,most compressors can also handlea limited amount of liquid refrigerant.Maneurop®‚ LTZ compressors havea large internal volume and cantherefore handle relatively large

OPERATING VOLTAGE AND CYCLE RATE

Off-cycle migrationDuring system standstill and afterpressure equalisation, refrigerant willcondense in the coldest part of thesystem.The compressor can easilybe the coldest spot, for examplewhen it is placed outside in lowambient temperatures.After a while,the full system refrigerant chargecan condense in the compressorcrankcase.A large amount willdissolve in the compressor oil untilthe oil is completely saturated with

refrigerant. If other systemcomponents are located at a higherlevel, this process can be even fasterbecause gravity will assist the liquidrefrigerant to flow back to thecompressor.When the compressoris started, the pressure in thecrankcase decreases rapidly.At lower pressures the oil holds lessrefrigerant, and as a result partof the refrigerant will violentlyevaporate from the oil, causing theoil to foam.

This process is often called “boiling”.The negative effects frommigration on the compressor are:• oil dilution by liquid refrigerant• oil foam, transported by refrigerant

gas and discharged into thesystem, causing loss of oil andin extreme situations risk of oilslugging

• in extreme situations with highsystem refrigerant charge, liquidslugging could occur (liquidentering the compressor cylinders)

| Vavg - V1-2 | + | Vavg - V1-3 | + | Vavg - V2-3 |

2 xVavgx 100

Liquid refrigerant can enter a compressor in various ways, with different effects on the compressor as describedin the following:

System designrecommendations

17 50 Hz catalogueRECIPROCATING COMPRESSORS

However the refrigerant leavingthe evaporator can contain anamount of liquid refrigerant due todifferent reasons:• wrong dimensioning, wrong setting

or malfunction of expansion device• evaporator fan failure or frosted-

up evaporator coils.In these situations, liquid refrigerant

will continuously enter the compressor.The negative effects from continuousliquid floodback are:• permanent oil dilution• in extreme situations with high

system refrigerant charge andlarge amounts of floodback, liquidslugging could occur.

Liquid floodback duringoperationDuring normal and stable systemoperation, refrigerant will leavethe evaporator in a superheatedcondition and enter the compressoras a superheated vapour.Normal superheat values atcompressor suction are 5 to 30 K.

charge in the compressor can behandled.However, as described earlier, anylimitation of the quantity of liquidrefrigerant in the compressor will

have a positive effect on service life.If the system refrigerant chargeexceeds the table values, additionalcompressor protection is required(see below).

If the system refrigerant chargedoes not exceed the charge limitsin the table above, no additionalprecautions are required.Even the accumulation of the full

Compressor type Compressor models System refrigerant charge limit (kg)1 cylinder LTZ 22-28 2.52 cylinder LTZ 44-50 54 cylinder LTZ 88-100 10

Refrigerant charge limits

should be maintained at least 10 Kabove the saturated suction temperature.Checks must be made to insurethat the appropriate oil temperatureis maintained at all ambientconditions.A Crankcase heater is required on all systems using anLTZ compressor regardless of the system refrigerant charge.

Self-regulating PTC crankcase heaters and belt type crankcaseheaters are available as accessories.Refer to the tables below.Note: Under extreme conditionssuch as low ambient temperatureor large refrigerant charge, e.g. inmultiple evaporator systems, a belttype heater can be used in additionto the PTC heater.

Crankcase heaterA crankcase heater protectsagainst off-cycle migration ofrefrigerant by maintaining thecrankcase at a higher temperature.It will not offer protection againstcontinuous liquid floodback.The effectiveness of a crankcaseheater can be checked by measuringthe crankcase temperature, which

VoltageLTZ 22-100

designation unit ref

200 - 600 V PTC 35 W 7773001

LTZ 22-28 LTZ 40-50 LTZ 88-100Voltage

designation unit ref designation unit ref designation unit ref

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 designrecommendations

1850 Hz catalogueRECIPROCATING COMPRESSORS

Pump down cycleA pump down cycle is one of themost effective ways to protectagainst off-cycle migration of liquidrefrigerant.Pump down must always be appliedto systems with evaporators fittedwith electric defrost heaters.

Suction accumulatorA suction accumulator offersprotection against refrigerant

floodback at start-up, duringoperation or after defrost.It helps protect against off-cyclemigration by providing additionalinternal volume to the low pressureside of the system.Tests must be conducted to deter-mine the actual refrigerant holdingcapacity needed for the application.The accumulator should not besized for less than 50% of the totalsystem charge.

Liquid line solenoid valve(LLSV)An LLSV may be used to isolatethe liquid charge in the condenserside thus preventing charge transferor excessive refrigerant migrationto the compressor during off-cycles.The quantity of refrigerant in thelow pressure side of the systemcan be further reduced by usinga pump down cycle in associationwith the LLSV.

SOUND AND VIBRATION

Compressors in operation are oneof the sources of sound and vibration in a refrigeration system.Both phenomena are closely related.

SoundSound produced by a compressoris transmitted in every direction bythe ambient air, the mounting feet,the pipework and the refrigerant inthe pipework.The easiest way to reduce thesound transmitted through ambientair is to fit a Maneurop®‚ acoustichood accessory.Because Maneurop®‚ compressorsare 100% suction gas cooled, andrequire no external cooling, theycan be insulated or enclosed in

Sound power levelAcousticCompressor dB(A)*

hoodmodel without with unit ref.

hood hood

LTZ 22 71 647755001

LTZ 28 69 62

LTZ 40 86 80

LTZ 44 85 79 7755002

LTZ 50 83 77

LTZ 88 86 807755003

LTZ 100 86 80

the base frame otherwise highvibration transmission would occurand the service life reduced.Suction and discharge lines musthave adequate flexibility in 3 planes.Eventually vibration absorbers maybe required.Vibration is also transmittedby the refrigerant gas.Maneurop®‚ compressors have builtin mufflers to reduce pulsation.To further reduce vibration

an extra discharge line muffler canbe installed.

Nota: Maneurop® hermetic compressors (MT and LT series),have been designed and qualifiedfor stationary equipment used inA/C and Refrigeration applications.Danfoss Maneurop doesn't warrantits compressors for use in mobileapplications, such as trucks, railways,subways, etc…

VibrationThe mounting grommets deliveredwith the compressor should alwaysbe used.They reduce the vibrationtransmitted by the compressormounting feet to the base frame.The base on which the compressoris mounted should be sufficientlyrigid and of adequate mass toensure the full effectiveness of themounting grommets.The compressorshould never be rigidly mounted to

*Measured at TE = -32°C,TC = 40°C, 50 Hz, 400 V

a sound proofing material linedcompartment. Sound transmittedby mounting feet, pipework andrefrigerant should be treated

the same way as vibration.Please refer to the next section.

Installation and service

COMPRESSOR HANDLING, MOUNTING AND CONNECTION TO THE SYSTEM

compressor. Once the compressoris installed, the compressor liftinglug should never be used to lift the complete installation.

Keep the compressor in an uprightposition during handling.

Compressor handlingManeurop®‚ LTZ compressors areprovided with a lifting lug.This lugshould always be used to lift the

Recommended torqueNm

Cable screw of T connector in electrical box 31" 80

Rotolock valves and solder sleeves 1"1/4 901"3/4 110

Mounting grommet bolts 15Oil sight glass 50Oil equalisation connection 30

• Brazing flux• Moisture and air.Only use clean and dehydratedrefrigeration grade copper tubesand silver alloy brazing material.Clean all parts before brazing andalways purge nitrogen or CO2

through the pipes during brazing toprevent oxidation. If flux is used,take every precaution to preventleakage into the piping. Do not drillholes (e.g. for schräder valves) in parts of the installation that are

already completed, when filings andburrs can not be removed.Carefully follow the instructionsbelow regarding brazing, mounting,leak detection, pressure test andmoisture removal.All installation and service workshall only be done by qualified personnel respecting all proceduresand using tools (charging systems,tubes, vacuum pump, etc.) dedicated for R404A and R507.

System contamination is one of the main factors affecting equipment reliability and compressorservice life.Therefore it is important to ensuresystem cleanliness when manufacturing a refrigeration system.During the manufacturing process,system contamination can becaused by:• Brazing and welding oxides• Filings and particles from

removing burrs from pipe-work

SYSTEM CLEANLINESS

Compressor mountingMount the compressor on a horizontal plane with a maximumslope of 3 degrees.All compressors are supplied withthree or four rubber mounting

grommets, each complete withmetal sleeves and nuts and bolts.Refer to the outline drawings onpage 7 to 9.These grommets largely attenuatethe compressor vibration transmit-

ted to the base frame.The compressor must always be mounted with these grommets.Refer to the table below fortorque values.

19 50 Hz catalogueRECIPROCATING COMPRESSORS

Compressor connection to the systemNew compressors have a protective nitrogen holding charge.The suction and discharge capsshould only be removed justbefore connecting the compressor

to the installation to avoid air andmoisture entering the compressor.

Whenever possible the compressormust be the last component to beintegrated in the system.It is advisable to braze the solder

sleeves or service valves to thepipework before the compressor is mounted.When all brazing isfinished and when the total systemis ready, the compressor caps canbe removed and the compressorcan be connected to the system

2050 Hz catalogueRECIPROCATING COMPRESSORS

Installation and service

LEAK DETECTION

a leak detector for the applied refrigerant.Any spectrometricdetection system using helium can also be applied. Eventual leaksshall be repaired respecting the instructions written above.It is not recommended to use

other gasses such as oxygen, dryair or acetylene as these gassescan form an inflammable mixture.Never use CFC or HCFC refrigerants for leak detection ofHFC systems.

Whenever possible (if valves arepresent) the compressor must bekept isolated from the system.Perform a leak detection using thefinal refrigerant (R404A or R507)or R134a. Pressurise with nitrogenor another neutral gas and use

Note 1 : Leak detection with refrigerant may not be allowed in some countries. Check local regulations.Note 2 : Leak detecting additives shall not be used as they may affect the lubricant properties.Warranty may be voided if leak detecting additives have

been used.

1-2-4 cylinder compressorsMaximum compressor test pressure, low side 25 bar(g)Maximum compressor test pressure, high side 30 bar(g)

mixture with the compressor oil.When performing a system pressuretest, the maximum allowed pressurefor the different componentsshould not be exceeded.

For LTZ compressors the maximumtest pressures are shown in thetable below.

It is recommended that an inertgas such as nitrogen be used forpressure testing. Dry air may alsobe used but care should be takensince it can form an inflammable

Do not exceed 30 bar pressuredifference between high pressure

side and low pressure side of thecompressor because this will open

the internal compressor reliefvalve.

SYSTEM PRESSURE TEST

with a minimum exposure toambient air. If this procedure is notpossible, the sleeves or valves may be brazed to the pipes whenmounted on the compressor.In this situation nitrogen or CO2

must be purged through the compressor via the schräder valveto prevent air and moisture ingress.Purging must start when the capsare removed and proceeded duringthe brazing process.When rotolock valves are used on the compressor, they shall beclosed immediately after mounting,thus keeping the compressor isolated from atmosphere or froma not yet dehydrated system.

Note: When the compressor is built into a ”pack” or“rack”-configuration which is not installed

system (see below).The pack mustbe charged with nitrogen or CO2

and open tubes must be blockedwith caps or plugs.

immediately on its final location,a vacuum pull-down and moistureremoval must be performed to thispack (rack) as if it were a complete

N2

Schrader

21 50 Hz catalogueRECIPROCATING COMPRESSORS

START UP

VACUUM PULL-DOWN MOISTURE REMOVAL

(0.67 mbar).A two stage vacuumpump shall be used with a capacity appropriate to the system volume. It is recommendedto use connection lines with a large diameter and to connectthese to the service valves andnot to the schraeder connectionto avoid too high pressure losses.

3.When the vacuum level of 500 micron is reached, the systemmust be isolated from thevacuum pump.Wait 30 minutesduring which the system pressureshould not rise.When the pressure rapidly increases, thesystem is not leak tight.A new leak detection must beperformed and the vacuum pull-down procedure should be restarted from step 1.When thepressure slowly increases, this

indicates the presence of moisture. In this case step 2 and 3should be repeated.

4. Connect the compressor to thesystem by opening the valves.Repeat step 2 and 3.

5. Break the vacuum with nitrogenor the final refrigerant.

6. Repeat step 2 and 3 on the totalsystem.

At commissioning, system moisturecontent may be up to 100 ppm.During operation the filter driermust reduce this to a level < 20 ppm.Warning :Do not use a megohmmeter orapply powerto the compressorwhile it is under vacuum, as thismay cause motor winding damage.Never run the compressor undervacuum as it may cause compressormotor burn-out.

Moisture obstructs the properfunctioning of the compressor andthe refrigeration system.Air and moisture reduce servicelife and increase condensing pressure,and cause excessively high dischargetemperatures, which can destroythe lubricating properties of theoil.Air and moisture also increasethe risk of acid formation, givingrise to copper platting.All thesephenomena can cause mechanicaland electrical compressor failure.To eliminate these factors, avacuum pull-down according to theprocedure below is recommended:1.Whenever possible (if valves are

present) the compressor must bekept isolated from the system.

2.After the leak detection, the system must be pulled-downunder a vacuum of 500 microns

Note: R507 is an azeotropic mixture and can be charged eitherin liquid or gas phase.The refrigerant charge quantitymust be suitable for both winterand summer operation.Refer also to section "Protectionagainst flooded starts and liquidfloodback" for information aboutrefrigerant charge limits.

Oil charge and oil levelThe oil charge must be checkedbefore commissioning (1/4 to 3/4of the oil sight glass). Check the oillevel again after a minimum of2 hours operation at nominalconditions. In most installationsthe initial compressor oil chargewill be sufficient. In installationswith line runs exceeding 20 mor with many oil traps or an oilseparator, additional oil may berequired. Normally the quantity ofoil added should be no more than2 % of the total refrigerant charge(this percentage does not take into

account oil contained in accessoriessuch as oil separators or oil traps).If this amount has already beenadded and the oil level in the compressor keeps decreasing,the oil return in the installation is insufficient. Refer also to section "Piping design".In installations where slow oilreturn is likely such as in multipleevaporator or multiple condenserinstallations, an oil separator isrecommended.Always use Maneurop 160Z lubricant.

Installation checksAfter a few running hours, all systemparameters must be verified.Basically these are:• Power and current consumption.These must be verified with thevalues on page 6.• Thermodynamic parameters

• evaporating temperature• evaporator outlet temperature• suction temperature

Before initial start up or after aprolonged shut down period, energisethe crankcase heater 12 hoursprior to start up, or turn on powerfor single phase compressors withtrickle heat circuit.

Refrigerant chargingR404A is a “near-azeotropic” refrigerant mixture and must therefore be charged in the liquidphase. For the initial charge, thecompressor must not run and service valves must be closed.Charge refrigerant as close as possible to the nominal systemcharge before starting the compressor.Then slowly add refrigerant in the liquid phase onthe low pressure side as far awayas possible from the running compressor inlet.Warning: when a liquid line solenoid valve is used, the vacuumin the low pressure side must be broken before applying power to the system.

Installation and service

2250 Hz catalogueRECIPROCATING COMPRESSORS

PACKAGING

Individual packaging

Net Gross Compressor Full palletModelsweight weight Nbr Packed dim. Stacking(kg) (kg) (mm) (mm)

LTZ 22 21 1426 330x295x385 1000x600x510 4

LTZ 28 23 151

LTZ 40 35 221

LTZ 44 35 221 6 395x365x455 1115x800x500 4

LTZ 50 35 227

LTZ 88 62 3966 485x395x600 1200x1000x730 4

LTZ 100 64 420

Multiple packaging

Gross Totalweight Nbr dim. Stacking(kg) (mm)

27912 1200x800x500 4

295

302

302 8 1200x800x550 4

302

3986 1200x800x650 4

410

• condensing temperature• discharge temperature

These different parameters giveinformation about the runningconditions of different systemcomponents.They may indicatewhich components must be adjusted.• The evaporating temperature forexample, is related to the refrigerant conditions in theevaporator.• The superheat at the evaporatoroutlet must be adjusted to optimisethe evaporator performance.Generally a value of 5 to 6 K isrecommended.• The compressor suction temperature gives informationabout the suction gas superheat atthe compressor.This value shouldbe kept as low as possible because

it will substantially increase thecompressor performance and alsohave a positive effect on compressor service life.Note however that extreme lowsuperheat values can increase therisk of unwanted liquid floodbackto the compressor.To maintain lowand stable superheat, an electronically controlled expansionvalve is recommended.The maximum allowable superheatis about 30 K.When a too highsuperheat (> 30 K) is noted, whilethe setting of the expansion valueis correct, the insulation of the suction line between evaporatorand compressor should be checkedand eventually replaced by a higherquality insulation.• The discharge temperature cangenerally indicate several

malfunctions.A too high dischargetemperature is the result of otherparameters, such as a malfunctioning condenser, presenceof non-condensable gasses,too high suction gas superheat,refrigerant overcharging, etc…The maximum allowable dischargetemperature is 130°C.• When after commissioning the liquid sight glass indicatesmoisture, the filter drier mustimmediately be replaced.

RECIPROCATING COMPRESSORS

Certified Quality System

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LawrencevilleGeorgia - USA

TrévouxFrance

The Danfoss Maneuropfacilities

AnseFrance

Danfoss ManeuropCommercial Compressors

BP 331 F-01603 Trévoux FranceTél. 04 74 00 28 29 - (33) 4 74 00 28 29Fax 04 74 00 52 44 - (33) 4 74 00 52 44www.danfoss-maneurop.comEvery effort has been made to provide accurate descriptions and data.However, due to the continuing process of product improvement and evolvement, all information in this brochure is subject to change without notification.Bluestar is a trademark of Danfoss.