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Reciprocating
Compressors
MT/MTZ
50 - 60 Hz
RECIPROCATING COMPRESSORS
MANEUROP® RECIPROCATING COMPRESSORS
3
RECIPROCATING COMPRESSORS
COMPRESSOR MODEL DESIGNATION
Code numbers
(for ordering) MT Z 64 - 4 V I
Compressor Packaging type
type I: Single pack
M: Industrial pack
(see page 32, 33, 34)
Compressor reference
(indicated on the MT Z 64 HM 4 B VE -
compressor nameplate)
4
RECIPROCATING COMPRESSORS
SPECIFICATIONS
Technical specifications
CE
All models
(European Directive)
UL
Models with motor voltage code 3 and 4
(Underwriters Laboratories)
5
RECIPROCATING COMPRESSORS
SPECIFICATIONS
6
RECIPROCATING COMPRESSORS
SPECIFICATIONS
7
RECIPROCATING COMPRESSORS
OPERATING ENVELOPES
MT
R22 70
MTZ
R407C at DEW point 70
Condensing temperature (°C)
65
60
S.H. = 11.1 K
55
S.H. = 30 K
50
45
40
35
30
-30 -25 -20 -15 -10 -5 0 5 10 15 20
Evaporating temperature (°C)
MTZ
R134a 80
Condensing temperature (°C)
75
70
S.H. = 11.1 K
65
60
S.H. = 30 K
55
50
45
40
35
-20 -15 -10 -5 0 5 10 15 20 25
Evaporating temperature (°C)
MTZ
R404A/R507A 70
Condensing temperature (°C)
65
60 S.H. = 11.1 K
55
50
45
S.H. = 30 K
40
35
30
-35 -30 -25 -20 -15 -10 -5 0 5 10 15
Evaporating temperature (°C)
8
RECIPROCATING COMPRESSORS
OPERATING ENVELOPES
Zeotropic refrigerant Refrigerant mixtures can be either the other hand the composition of va-
zeotropic or azeotropic. pour and liquid changes during the
mixtures An azeotropic mixture (like R502 or phase transition. When the effect of
R507A) behaves like a pure refrigerant. this phase transition is very small, the
During a phase transition (from vapour mixture is often called a near-azeo-
to liquid or from liquid to vapour) the tropic mixture. R404A is such a near-
composition of vapour and liquid stays azeotropic mixture.
the same. The composition change causes phase
In a zeotropic mixture (like R407C) on shift and temperature glide.
Phase shift In system components where both gerants need some special attention.
vapour and liquid phase are present Zeotropic refrigerants must always
(evaporator, condenser, liquid recei- be charged in liquid phase. Flooded
ver), the liquid phase and vapour pha- evaporators and suction accumulators
se do not have the same composition. should not be applied in systems with
In fact both phases form two different zeotropic refrigerants. This also applies
refrigerants. Therefore zeotropic refri- to near-azeotropic mixtures.
Temperature glide During the evaporating process and These are temperatures which corres-
the condensing process at constant pond more or less with the average
pressure, the refrigerant temperature temperature during the evaporating
will decrease in the condenser and and condensing process. For the same
rise in the evaporator. Therefore when R407C cycle, mean point temperatures
speaking about evaporating and con- are typically about 2 to 3°C lower than
densing temperatures, it is important dew point temperatures. According to
to indicate whether this is a dew point Asercom recommendations, Danfoss
temperature or a mean point value. In Commercial Compressors uses dew
the figure below, the dotted lines are point temperatures for selection
lines of constant temperature. tables and application envelopes etc.
They do not correspond to the lines of To obtain exact capacity data at mean
constant pressure. point temperatures, the mean point
Points A and B are dew point values. temperatures must be converted to
These are temperatures on the satura- dew point temperatures with help of
ted vapour line. refrigerant data tables from the refri-
Points C and D are mean point values. gerant manufacturer.
Dew temperature
and
pressure (log)
mean temperature
for R407C
D B
C
A
enthalpy
9
RECIPROCATING COMPRESSORS
333(1)
356(2)
263
OUTLINE DRAWINGS 98
68 68
25
15
1 cylinder 82
39 123
Terminal box
Oil sight glass
(VE - models only)
Suction: 142(1)
147(2)
118 Discharge: 142
17
55˚
109 Spade connectors Ø 21 mm
159 1/4” AMP-AWE
Earth M4-12 Knock-out Ø 21 mm
141
IP rating: 55 (with cable gland)
68
Ø 224
Models with motor
code 3, 4, 6, 7 & 9
with rounded off top
Oil equalisation
(VE - models only)
LP
gauge port
(schrader)
333(1)
356(2)
Silent block HM8-40
263
98
68 68 23
15
25
15
82
68
10
RECIPROCATING COMPRESSORS
74 68 65
(1)
32
(2)
20
(1) (2)
15 82 / 98
OUTLINE DRAWINGS
2 cylinders 21
Mounting hole
for PTC crankcase heater Terminal box for model (1)
156
60
37˚ 96
Spade connectors Ø 21 mm
188
(1) 1/4” AMP-AWE
(2) Suction: 179 Knock-out Ø 21 mm
196 Discharge: 176 Earth M4-12
IP rating: 55 (with cable gland)
Screw
Ø 288 10-32 UNF x 9,5
Earth M4-12
Knock-out
LP Ø 29 mm
gauge port
(schrader)
Ø 29 mm
(1)
98
(2)
117
74 68 65 23
(1)
32
(2)
15
20
(1) (2)
15 82 / 98
(1) MTZ 44-1, all code 3 except 80-3 & 81-3, all code 4, 7, 9
(2) MTZ 50-1, 56-1, 64-1, 80-3, 81-3, all code 6
(1)
188 Suction: 179
196
(2)
Discharge: 176 11
RECIPROCATING COMPRESSORS
Oil sight glass
233
158
OUTLINE DRAWINGS
125
95
19
96
4 cylinders
246 Terminal box
Mounting hole for
PTC crankcase heater Oil equalisation
(VE - models only) Screw
10-32 UNF x 9,5
Earth M4-12
Knock-out
Ø 29 mm
246 Ø 29 mm
IP rating: 54
(with
cable gland)
232
212
Ø 352
H M12-50
(1) MT (Z) 144 - 160/3-4-6
(2) MT (Z) 100 - 125/3-4-6
(3) MT (Z) code 7 -LP9
gauge port
(schrader)
Silent block
HM12-50
(2)
540
(1)
519
115
Oil sight glass
30
233 19
158
125
95
19
96
246
Mounting hole for Rotolock connections size Pipe sizing Rotolock valve
PTC crankcase heater Oil equalisation
(VE - models only)
Suction Discharge Suction Discharge Suction Discharge
MT/MTZ100
MT/MTZ125
1”3/4 1”1/4 1”1/8” 3/4” V02 V04
MT/MTZ144
MT/MTZ160
246
232
12
RECIPROCATING COMPRESSORS
ELECTRICAL CONNECTIONS AND WIRING
Single phase electrical LRA - Locked Rotor MCC - Maximum Winding resistance (Ω)
Current (A) Continuous Current (A) ( ± 7 % at 20° C)
characteristics Motor Code 1 5 1 5 1 5
Winding run start run start
MT/MTZ018 51 40 13 10 1.36 4.82 1.80 4.70
MT/MTZ022 49.3 41 17 15 1.25 2.49 1.78 4.74
MT/MTZ028 81 55 25 16 0.74 1.85 1.16 3.24
MT/MTZ032 84 70 26.5 20 0.64 2.85 0.90 4.30
MT/MTZ036 84 70 30 20 0.64 2.85 0.89 4.35
MT/MTZ040 99 - 34 - 0.53 2.00 - -
MT/MTZ044 97 - 31 - 0.45 1.90 - -
MT/MTZ050 114 92 36 29 0.37 1.79 0.52 2.65
MT/MTZ056 136 - 42.5 - 0.32 1.61 - -
MT/MTZ064 143 - 46 - 0.32 2.10 - -
The trickle circuit provides the facility can be operated without crankcase
Trickle circuit of heating the compressor crankcase heaters as the heater function is provi-
by feeding a small current to the auxi- ded by the trickle circuit. For the larger
liary winding and the run capacitor single phase compressor models MT/
See the drawings page 14. MTZ028-064, the use of the PTC crank-
By using PSC or CSR starting systems, case heater is recommended.
compressor models MT/MTZ018-022
PSC wiring PSC wiring may be used for refrigerant equalisation must be ensured before
circuits with capillary tubes or expan- start-up because of the low starting
sion valves with bleed ports. Pressure torque characteristics of this system.
CSR wiring CSR wiring provides additional motor are internally protected by a tem-
torque at start-up, by the use of a start perature/current sensing bimetallic
capacitor in combination with the run protector, which senses the main and
capacitor. This system can be used start winding currents, and also the
for refrigerant circuits with capillary winding temperature. Once the pro-
tubes or expansion valves. The start tector has tripped, it may take up to
capacitor is only connected during the two to four hours to reset and restart
starting operation, a potential relay is the compressor.
used to disconnect it after the start se- Check that power supply corresponds
quence. to compressor characteristics (refer to
The single phase compressor motors compressor nameplate).
13
RECIPROCATING COMPRESSORS
ELECTRICAL CONNECTIONS AND WIRING
Suggested
wiring diagrams
C
220 kW - 1 W IOL
IOL Motor protector
A&C Run capacitors
C Common
S Start winding (auxiliary)
R Run winding (main) A µF S R
C µF
Thermostat
Single phase
CSR wiring 230 V
with trickle circuit Start Relay
5
IOL Motor protector C
220 kW - 1 W IOL
A&C Run capacitors
B Start capacitor
C Common 2
S Start winding (auxiliary)
R Run winding (main) A µF S R
1
C µF
Thermostat
B µF
15 kΩ - 1 W
Single phase
CSR wiring 230 V
without trickle circuit Start Relay
5
IOL Motor protector Thermostat C
220 kW - 1 W IOL
A+C Run capacitors
B Start capacitor
C Common 2
S Start winding (auxiliary)
R Run winding (main) "A + C" S R
Capacitors A and C are replaced by a single 1
capacitor of size A + C
B µF
15 kΩ - 1 W
14
RECIPROCATING COMPRESSORS
ELECTRICAL CONNECTIONS AND WIRING
Motor protection The 3-phase compressors are protec- Note: once the overload protector has
ted by an internal motor protector, tripped it may take up to 3 hours to re-
and suggested wiring connected to the neutral point of the set and restart the compressor.
diagrams star connected stator windings, the
protector cuts out all 3-phases simul- For all 3-phase compressors, a PTC
taneously. crankcase heater is required.
Wiring diagram
with pump-down cycle CONTROL CIRCUIT
L1 L3 L2
Q1
F1 F1
KM
KA KS
KM KA KA
F2
Control device ............................................................................................. TH
Optional short cycle timer (3 min) 5 pts ........ 180 s
Control relay ................................................................................................... KA T1 T2
15
RECIPROCATING COMPRESSORS
ELECTRICAL CONNECTIONS AND WIRING
Q1
F1 F1
KM
KA KS
KA KA
F2
Soft starters Starting current of Maneurop® 3-phase ting are reduced which increases the
compressors can be reduced by using life of the internal components.
a soft starter. Two different versions are For details of the CI-tronicTM MCI soft
available: CI-tronicTM soft starters type starters, please refer to literature
MCI (recommended) and soft start kits DKACT.PD.C50.C1.02.
with statoric resistors type SCR. The For details of the SCR soft start kits,
starting current can be reduced by up please contact Danfoss.
to 50% depending on the compressor The number of starts should be limited
model and the type of soft starter. Also to 6 per hour. HP/LP pressure equalisa-
mechanical stresses that occur at star- tion is required before starting.
IP rating The compressor terminal boxes IP ra- The IP ratings are only valid when cor-
ting according to CEI 529 are shown rectly sized cable glands of the same IP
on the outline drawings section. rating are applied.
IP 5 5
First numeral, level of protection against contact
and foreign objects
5 Complete protection against contact and
against harmful dust deposits
Second numeral, level of protection against water
4 Protection against water splashing from any direction
5 Protection against jets of water from any direction
16
RECIPROCATING COMPRESSORS
REFRIGERANTS AND LUBRICANTS
General information When choosing a refrigerant, different Additional points could influence the
aspects must be taken into considera- final choice:
tion: • Environmental considerations
• Legislation (now and in the future) • Standardisation of refrigerants and
• Safety lubricants
• Application envelope in relation to • Refrigerant cost
expected running conditions • Refrigerant availability
• Compressor capacity and efficiency The table below gives an overview
• Compressor manufacturer recom- of the different refrigerant-lubricant-
mendations & guidelines compressor combinations for Maneu-
rop®‚ MT & MTZ compressors.
Lubricant Compressor
Refrigerant Type Danfoss lubricant Application
type type
R407C HFC Polyolester MTZ Polyolester oil 160PZ Medium / High temperature
R134a HFC Polyolester MTZ Polyolester oil 160PZ Medium / High temperature
Hydrocarbons Danfoss does not authorise the use of hydrocarbons in Maneurop® MT/MTZ compressors
The Montreal protocol states that CFC these refrigerants are not published in
refrigerants such as R12 and R502 may this document. Maneurop® MT com-
no longer be applied in new installa- pressors however are suitable for use
tions in the signatory members coun- with these refrigerants and can still be
tries. used as replacements in existing ins-
Therefore capacity and other data for tallations.
R22 R22 is an HCFC refrigerant and is still a The Maneurop® MT compressor is de-
wide use today. It has a low ODP (Ozo- dicated for R22 and is supplied with an
ne Depletion Potential) and therefore initial mineral oil charge.
it will be phased out in the future.
Check local legislation. Always use mi-
neral white oil 160P.
R407C Refrigerant R407C is an HFC refrige- Always use the Maneurop® MTZ com-
rant with similar thermodynamic pro- pressors with Danfoss 160PZ polyoles-
perties to those of R22. ter oil, which is supplied with the MTZ
R407C has zero ozone depletion poten- compressor for R407C applications.
tial (ODP=0). Many installers and OEMs Maneurop® MT compressors should
consider R407C to be the standard al- never be used with R407C, even when
ternative for R22. R407C is a zeotropic the mineral oil is replaced with polyo-
mixture and has a temperature glide lester oil.
of about 6 K. For more specific infor-
mation about zeotropic refrigerants;
refer to section «zeotropic refrigerant
mixtures». R407C must be charged in
the liquid phase.
17
RECIPROCATING COMPRESSORS
REFRIGERANTS AND LUBRICANTS
R134a Refrigerant R134a is an HFC refrige- choice. R134a is a pure refrigerant and
rant with thermodynamic properties has zero temperature glide. For R134a
comparable to those of the CFC re- applications always use the Maneu-
frigerant R12. R134a has zero ozone rop® MTZ compressor with Danfoss
depletion potential (ODP = 0) and 160PZ polyolester oil which is sup-
is commonly accepted as the best plied with the MTZ compressor.
R12 alternative. For applications with Maneurop® MT compressors should
high evaporating and high conden- never be used for R134a, even when the
sing temperatures, R134a is the ideal mineral oil is replaced by polyolester oil.
R22 based transitional A wide variety of R22 based transitio- Because of the R22 component, they
nal refrigerants exist (also called servi- all have a (low) ozone depletion po-
refrigerants ce refrigerants or drop-in blends). The- tential. Maneurop® MT compressors
se were developed as temporary R12 can be applied with these transitio-
or R502 alternatives. Some examples nal refrigerants. The initial mineral oil
are R401A, R401B, R409A and R409B charge must be replaced by Maneu-
as R12 alternatives and R402A, R402B, rop®160 ABM alkylbenzene oil.
R403A and R403B as R502 alternatives.
18
RECIPROCATING COMPRESSORS
SYSTEM DESIGN RECOMMENDATIONS
Piping desing Oil in a refrigeration circuit is requi- tor efficiency. If, in a poorly designed
red to lubricate moving parts in the system, the amount of oil returning
compressor. During normal system to the compressor is lower than the
operation small oil quantities will con- amount of oil leaving the compressor,
tinuously leave the compressor, with the compressor will become starved
the discharge gas. With good system of oil and the condenser, evaporator
piping design this oil will return to the and/or refrigerant lines will become
compressor. As long as the amount of filled with oil. In such situations, addi-
oil circulating through the system is tional oil charge will only correct the
small it will contribute to good system compressor oil level for a limited pe-
operation and improved heat transfer riod of time and increase the amount
efficiency. However, too large amounts of surplus oil in the rest of the system.
of oil in the system will have a nega- Only correct piping design can ensure
tive effect on condenser and evapora- a good oil balance in the system.
Suction lines Horizontal suction line sections shall For compressors mounted in parallel,
have a slope of 0.5% in the direction the common suction riser should be
of refrigerant flow (5 mm per meter). designed as a double riser. Also refer
The cross-section of horizontal suc- to the News bulletin "Mounting ins-
tion lines shall be such that the resul- tructions for installation of Maneurop®
ting gas velocity is at least 4 m/s. In compressors in parallel " and " Parallel
vertical risers, a gas velocity of 8 to 12 application guidelines".
m/s is required to ensure proper oil re- Gas velocities higher than 12 m/s will
turn. A U-trap is required at the foot of not contribute to significantly better
each vertical riser. If the riser is higher oil return. However they will cause hi-
than 4 m, additional U-traps are requi- gher noise levels and result in higher
red for each additional 4 meters. The suction line pressure drops which will
length of each U-trap must be as short have a negative effect on the system
as possible to avoid the accumulation capacity.
of excessive quantities of oil (see fi-
gure below).
To condenser
0.5 % slope,
4 m/s or more
max. 4 m
U-trap
8 to 12 m/s
max. 4 m
0.5 % slope, Evaporator
4 m/s or more
19
RECIPROCATING COMPRESSORS
SYSTEM DESIGN RECOMMENDATIONS
Note that the suction rotolock valves, systems may differ from these recom-
which can be ordered from Danfoss as mended sizes.
accessories, are designed for average It is recommended that the suction
pipe sizes, selected for systems run- lines are insulated to limit suction gas
ning at nominal conditions. superheat.
The pipe sizes selected for specific
Discharge line When the condenser is mounted abo- compressor are required to prevent li-
ve the compressor, a loop above the quid draining from the condenser into
condenser and a U-trap close to the the discharge line during standstill.
U-trap
Oil charge and oil separator In most installations the initial com- red. In installations with the risk of slow
pressor oil charge will be sufficient. In oil return such as in multiple evapora-
installations with line runs exceeding tor or multiple condenser installations,
20 m, or with many oil traps or an oil an oil separator is recommended. Also
separator, additional oil may be requi- refer to page 29.
Filter driers For new installations with MTZ com- containing activated alumina are re-
pressors Danfoss recommends using commended.
the Danfoss DML 100%-molecular sie-
The drier is to be oversized rather than
ve, solid core filter drier. Molecular sie-
undersized. When selecting a drier,
ve filter driers with loose beads from
always take into account its capacity
third party suppliers shall be avoided.
(water content capacity), the system
For servicing of existing installations refrigerating capacity and the system
where acid formation is present the refrigerant charge.
Danfoss DCL solid core filter driers
Operating limits
High Pressure A high pressure safety switch is requi- must either be in a lockout circuit, or
red to stop the compressor, should the be a manual reset device to prevent
discharge pressure exceed the values compressor cycling around the high
shown in the table below. The high pressure limit. When a discharge valve
pressure switch can be set to lower is used, the HP switch must be connec-
values depending on the application ted to the service valve gauge port,
and ambient conditions. The HP switch which cannot be isolated.
20
RECIPROCATING COMPRESSORS
SYSTEM DESIGN RECOMMENDATIONS
Low pressure A low pressure safety switch is recom- tion at too lower suction pressures.
mended to avoid compressor opera-
MT MTZ MTZ MTZ
R22 R407C R134a R404A / R507A
Test pressure low side bar (g) 25 25 25 25
Working pressure range high side bar (g) 10.9 - 27.7 12.5 - 29.4 7.9 - 22.6 13.2 - 27.7
Working pressure range low side bar (g) 1.0 - 7.0 1.4 - 6.6 0.6 - 4.7 1.0 - 7.2
Relief valve opening pressure difference bar (g) 30 30 30 30
Relief valve closing pressure difference bar (g) 8 8 8 8
Low ambient temperature At low ambient temperatures, the con- charge, which can introduce other
operation densing temperature and condensing problems. A non-return valve in the
pressure in air cooled condensers will discharge line is required and special
decrease. care should be taken when designing
This low pressure may be insufficient the discharge line.)
to supply enough liquid refrigerant to • Reduce air flow to condensers.
the evaporator. As a result the evapora- Other problems can also occur when
tor temperature will strongly decrease the compressor is operating at low
with the risk of frosting. At compressor ambient temperature. During shut
start-up, the compressor can pull a down periods, liquid refrigerant can
deep vacuum and it can be switched migrate to a cold compressor.
off by the low pressure protection. De- For such conditions a belt-type crank-
pending on the low pressure switch case heater is strongly recommended.
setting and delay timer short cycling Note that with 100% suction gas coo-
can occur. To avoid these problems, led motors, Maneurop® compressors
several solutions are possible, based can be externally insulated.
on reducing condenser capacity: Refer to section «Liquid refrigerant
• Indoor location of condensers migration & charge limits» for more
• Liquid flooding of condensers (note: details.
this solution requires extra refrigerant
Cycle rate limit There may be no more than 12 starts mended. The system must be desi-
per hour (6 when a soft start accessory gned in such a way to guarantee a
is used). A higher number reduces the minimum compressor running time in
service life of the motor-compressor order to provide proper oil return and
unit. If necessary, use an anti-short-cy- sufficient motor cooling after starting.
cle timer in the control circuit. Note that the oil return rate varies as a
A time-out of six minutes is recom- function of the system design.
21
RECIPROCATING COMPRESSORS
SYSTEM DESIGN RECOMMENDATIONS
Liquid refrigerant control Refrigeration compressors are basically be favourable to its service life. Liquid
designed as gas compressors. Depen- refrigerant can dilute the oil, wash oil
and charge limits ding on the compressor design and out of bearings and result in high oil
operating conditions, most compres- carry over, resulting in loss of oil from
sors can also handle a limited amount the sump. Good system design can li-
of liquid refrigerant. Maneurop® MT mit the amount of liquid refrigerant in
and MTZ compressors have a large the compressor, which will have a po-
internal volume and can therefore han- sitive effect on the compressor service
dle relatively large amounts of liquid life.
refrigerant without major problems. Liquid refrigerant can enter a compres-
However even when a compressor can sor in different ways, with different
handle liquid refrigerant, this will not effects on the compressor.
Off-cycle migration During system standstill and after in the crankcase decreases rapidly.
pressure equalisation, refrigerant will At lower pressures the oil holds less re-
condense in the coldest part of the frigerant, and as a result part of the re-
system. The compressor can easily be frigerant will violently evaporate from
the coldest spot, for example when it the oil, causing the oil to foam.
is placed outside in low ambient tem- This process is often called “boiling”.
peratures. After a while, the full system The negative effects from migration
refrigerant charge can condense in the on the compressor are:
compressor crankcase. A large amount • oil dilution by liquid refrigerant
will dissolve in the compressor oil un- • oil foam, transported by refrigerant
til the oil is completely saturated with gas and discharged into the system,
refrigerant. If other system compo- causing loss of oil and in extreme si-
nents are located at a higher level, this tuations risk for oil slugging
process can be even faster because • in extreme situations with high sys-
gravity will assist the liquid refrigerant tem refrigerant charge, liquid slugging
to flow back to the compressor. When could occur (liquid entering the com-
the compressor is started, the pressure pressor cylinders)
Liquid floodback during During normal and stable system ope- • evaporator fan failure or blocked air
operation ration, refrigerant will leave the evapo- filters.
rator in a superheated condition and In these situations, liquid refrigerant
enter the compressor as a superhea- will continuously enter the compres-
ted vapour. sor.
Normal superheat values at compres- The negative effects from continuous
sor suction are 5 to 30 K. However the liquid floodback are:
refrigerant leaving the evaporator can • permanent oil dilution
contain an amount of liquid refrige- • in extreme situations with high sys-
rant due to different reasons: tem refrigerant charge and large
• wrong dimensioning, wrong setting amounts of floodback, liquid slugging
or malfunction of expansion device could occur.
Liquid floodback at change In heat pumps, change over from coo- • oil dilution
over cycles in reversible ling to heating cycles, defrost and low • in extreme situations with high sys-
heat pumps load short cycles may lead to liquid tem refrigerant charge and large
refrigerant floodback or saturated re- amounts of floodback, liquid slugging
frigerant return conditions. could appear.
The negative effects are:
Liquid floodback Liquid floodback in systems working liquid has a different composition than
and zeotropic refrigerants with a zeotropic refrigerant such as the vapour.
R407C introduces additional negative This new refrigerant composition may
effects. A part of the refrigerant leaves result in different compressor opera-
the evaporator in liquid phase and this ting pressures and temperatures.
22
RECIPROCATING COMPRESSORS
SYSTEM DESIGN RECOMMENDATIONS
Crankcase heater A crankcase heater protects against to the oil sump to ensure good heat
the off-cycle migration of refrigerant transfer to the oil.
and proves effective if oil temperature Belt crankcase heaters are not self-re-
is maintained 10 K above the satura- gulating. Control must be applied to
ted LP temperature of the refrigerant. energise the belt heater once the com-
Tests must thereby be conducted to pressor has been stopped and then to
ensure that the appropriate oil tempe- de-energise it while the compressor is
rature is maintained under all ambient running. The belt heater must be ener-
conditions. A PTC crankcase heater gised 12 hours before restarting the
is recommended on all stand-alone compressor following an extended
compressors and split systems. PTC down period.
crankcase heaters are self-regulating. If the crankcase heater is not able to
Under extreme conditions such as very maintain the oil temperature at 10 K
low ambient temperature a belt type above the saturated LP temperature
crankcase heater could be used in ad- of the refrigerant during off cycles or
dition to the PTC heater, although this if repetitive floodback is present a the
is not a preferred solution for 1 and 2 Liquid Line Solenoid Valve (LLSV) +
cylinder compressors. The belt crank- pump-down cycle is required, even-
case heater must be positioned on the tually in conjunction with a suction
compressor shell as close as possible accumulator.
Liquid line solenoid valve In refrigeration applications, the Li- a LLSV in conjunction with a pump-
& pump-down quid Line Solenoid Valve (LLSV) is hi- down cycle, the quantity of refrigerant
ghly recommended. During the off-cy- in the low-pressure side of the system
cle, the LLSV isolates the liquid charge will be reduced.
in the condenser side, thus preventing A pump-down cycle design is required
against refrigerant transfer or exces- when evaporators are fitted with elec-
sive migration of refrigerant into the tric defrost heaters.
compressor. Furthermore, when using
23
RECIPROCATING COMPRESSORS
SOUND AND VIBRATION MANAGEMENT
Sound Running compressors cause sound no body cooling, they can be insula-
and vibration. Both phenomena are ted. Values for the sound reduction
closely related. achieved with acoustic hoods are
Sound produced by a compressor is shown also in the table on the right.
transmitted in every direction by the For inside mounted compressors,
ambient air, the mounting feet, the sound insulation of the plantroom is
pipework and the refrigerant in the an alternative to sound insulation of
pipework. the compressor.
The easiest way to reduce the sound Sound transmitted by mounting feet,
transmitted through ambient air is to pipework and refrigerant should be
fit a Danfoss acoustic hood accessory. treated the same way as for vibration.
Because Maneurop® compressors are Please refer to the next section.
100% suction gas cooled, and require
Sound power level for MTZ Sound power level at 50 Hz Sound power level at 60 Hz
with R404A, motor code 4 dB(A) dB(A)
Te = -10°C,
TC = 45°C without with without with
hood hood* hood hood*
MTZ018 73 65 73 66
MTZ022 74 68 77 71
MTZ028 71 64 73 66
MTZ032 71 64 73 66
MTZ036 70 64 76 69
MTZ040 70 65 72 67
MTZ044 80 74 82 76
MTZ045 80 74 82 76
MTZ050 83 76 84 78
MTZ051 83 76 84 78
MTZ056 81 74 81 74
MTZ057 81 74 81 74
MTZ064 80 74 84 78
MTZ065 80 74 84 78
MTZ072 79 72 82 75
MTZ073 79 72 82 75
MTZ080 79 73 84 78
MTZ081 79 73 84 78
MTZ100 85 79 87 81
MTZ125 84 78 86 80
MTZ144 83 77 86 80
* Sound data with hood are valid for
MTZ160 83 77 86 80
the Danfoss acoustic hood accessory.
24
RECIPROCATING COMPRESSORS
SOUND AND VIBRATION MANAGEMENT
Vibration The mounting grommets delivered Care must be taken to avoid tubing
with the compressor should always be having resonant frequencies close to
used. They reduce the vibration trans- those of the compressor frequency.
mitted by the compressor mounting Vibration is also transmitted by the
feet to the base frame. refrigerant gas. Maneurop®‚ compres-
The base on which the compressor sors have built in mufflers to reduce
is mounted should be sufficiently ri- this vibration.
gid and of adequate mass to ensure To further reduce vibration an extra
the full effectiveness of the mounting muffler can be installed.
grommets.
The compressor should never be di- Note: Maneurop® MT & MTZ compres-
rectly mounted to the base frame wi- sors have been designed and qualified
thout the grommets, otherwise high for stationary equipment used in A/C
vibration transmission would occur and Refrigeration applications.
and the compressor service life redu- Danfoss doesn’t warrant these com-
ced. Suction and discharge lines must pressors for use in mobile applications,
have adequate flexibility in 3 planes. such as trucks, railways, subways, etc...
Eventually vibration absorbers may be
required.
25
RECIPROCATING COMPRESSORS
INSTALLATION AND SERVICE
System cleanliness System contamination is one of the nitrogen or CO2 through the pipes du-
main factors affecting equipment re- ring brazing to prevent oxidation. If
liability and compressor service life. flux is used, take every precaution to
Therefore it is important to ensure sys- prevent leakage into the piping. Do
tem cleanliness when manufacturing not drill holes (e.g. for schräder valves)
a refrigeration system. During the ma- in parts of the installation that are
nufacturing process, system contami- already completed, when filings and
nation can be caused by: burrs can not be removed. Carefully
• Brazing and welding oxides follow the instructions below regar-
• Filings and particles from ding brazing, mounting, leak detec-
removing burrs from pipe-work tion, pressure test and moisture remo-
• Brazing flux val. All installation and service work
• Moisture and air. shall only be done by qualified per-
Only use clean and dehydrated re- sonnel respecting all procedures and
frigeration grade copper tubes and using tools (charging systems, tubes,
silver alloy brazing material. Clean all vacuum pump, etc.) dedicated for the
parts before brazing and always purge refrigerant that will be used.
Compressor handling,
mounting and
connection to the system
Compressor handling Maneurop® MT and MTZ compressors never be used to lift the complete ins-
are provided with a lifting lug. This lug tallation.
should always be used to lift the com- Keep the compressor in an upright po-
pressor. Once the compressor is instal- sition during handling.
led, the compressor lifting lug should
Compressor mounting Mount the compressor on a horizon- These grommets largely attenuate the
tal plane with a maximum slope of 3 compressor vibration transmitted to
degrees. All compressors are supplied the base frame. The compressor must
with three or four rubber mounting always be mounted with these grom-
grommets, each complete with metal mets. Refer to the table below for tor-
sleeves and nuts and bolts. Refer to the que values.
outline drawings on page 18 to 21.
Recommended torque
Designation
(Nm)
Cable screw of T connector
screw 10/32 - UNF x 3 3
in electrical box
1" 80
Rotolock valves and solder sleeves 1"1/4 90
1"3/4 110
Mounting grommet bolts 1 - 2 - 4 cylinder 15
Oil sight glass - 50
Oil equalisation connection 1 - 2 - 4 cylinder 30
Compressor connection New compressors have a protective Whenever possible the compressor
to the system nitrogen holding charge. The suction must be the last component to be
and discharge caps should only be integrated in the system. It is advi-
removed just before connecting the sable to braze the solder sleeves or
compressor to the installation to avoid service valves to the pipework before
air and moisture entering the com- the compressor is mounted. When all
pressor. brazing is finished and when the total
26
RECIPROCATING COMPRESSORS
INSTALLATION AND SERVICE
system is ready, the compressor caps the compressor, they shall be closed
can be removed and the compressor immediately after mounting, thus
can be connected to the system with a keeping the compressor isolated from
minimum exposure to ambient air. atmosphere or from a not yet dehydra-
If this procedure is not possible, the ted system.
sleeves or valves may be brazed to the Note: When the compressor is built
pipes when mounted on the compres- into a ”pack” or “rack” configuration
sor. which is not installed immediately on
In this situation nitrogen or CO2 must its final location, a vacuum pull-down
be purged through the compressor via and moisture removal must be perfor-
the schräder valve to prevent air and med to this pack (rack) as if it were a
moisture ingress. Purging must start complete system (see below). The pack
when the caps are removed and pro- must be charged with nitrogen or CO2
ceeded during the brazing process. and open tubes must be blocked with
When rotolock valves are used on caps or plugs.
Schrader
N2
System pressure test It is recommended that an inert gas pressure test, the maximum allowed
such as nitrogen be used for pressure pressure for the different components
testing. Dry air may also be used but should not be exceeded.
care should be taken since it can form For MT/MTZ compressors the maxi-
an inflammable mixture with the com- mum test pressures are shown in the
pressor oil. When performing a system table below.
1-2-4 cylinder compressors
Maximum compressor test pressure, low side 25 bar(g)
Maximum compressor test pressure, high side 30 bar(g)
Do not exceed 30 bar pressure diffe- because this will open the internal
rence between high pressure side and compressor relief valve.
low pressure side of the compressor
Leak detection Whenever possible (if valves are pre- metric detection system using helium
sent) the compressor must be kept iso- can also be applied.
lated from the system. Perform a leak Eventual leaks shall be repaired res-
detection using the final refrigerant. pecting the instructions written
Pressurise with nitrogen or another above. It is not recommended to use
neutral gas and use a leak detector for other gasses such as oxygen, dry air or
the applied refrigerant. Any spectro- acetylene as these gasses can form an
27
RECIPROCATING COMPRESSORS
INSTALLATION AND SERVICE
inflammable mixture. Never use CFC Note 2 : Leak detecting additives shall
or HCFC refrigerants for leak detection not be used as they may affect the
of HFC systems. lubricant properties.
Note 1 : Leak detection with refri- Warranty may be voided if leak detec-
gerant may not be allowed in some ting additives have been used.
countries. Check local regulations.
Vacuum pull-down Moisture obstructs the proper functio- isolated from the vacuum pump. Wait
moisture removal ning of the compressor and the refri- 30 minutes during which the system
geration system. pressure should not rise. When the
Air and moisture reduce service life pressure rapidly increases, the system
and increase condensing pressure, is not leak tight.
and cause excessively high discharge A new leak detection must be per-
temperatures, which can destroy the formed and the vacuum pull-down
lubricating properties of the oil. Air procedure should be restarted from
and moisture also increase the risk of step 1. When the pressure slowly in-
acid formation, giving rise to copper creases, this indicates the presence
platting. All these phenomena can of moisture. In this case step 2 and 3
cause mechanical and electrical com- should be repeated.
pressor failure.
4. Connect the compressor to the sys-
To eliminate these factors, a vacuum
tem by opening the valves. Repeat
pull-down according to the procedure
step 2 and 3.
below is recommended:
5. Break the vacuum with nitrogen or
1. Whenever possible (if valves are
the final refrigerant.
present) the compressor must be kept
isolated from the system. 6. Repeat step 2 and 3 on the total sys-
tem.
2. After the leak detection, the system
At commissioning, system moisture
must be pulled-down under a vacuum
content may be up to 100 ppm. Du-
of 500 microns (0.67 mbar). A two sta-
ring operation the filter drier must re-
ge vacuum pump shall be used with a
duce this to a level < 20 ppm.
capacity appropriate to the system vo-
Warning :
lume. It is recommended to use con-
Do not use a megohmmeter or apply
nection lines with a large diameter and
power to the compressor while it is un-
to connect these to the service valves
der vacuum, as this may cause motor
and not to the schrader connection to
winding damage.
avoid too high pressure losses.
Never run the compressor under va-
3. When the vacuum level of 500 mi- cuum as it may cause compressor mo-
cron is reached, the system must be tor burn-out.
Start-up Before initial start-up or after a prolon- prior to start-up, or turn on power for
ged shut down period, energise the single phase compressors with trickle
crankcase heater (if fitted) 12 hours circuit.
Refrigerant charging Zeotropic and «near-azeotropic» re- from the running compressor.
frigerant mixtures such as R407C and The refrigerant charge quantity must
R404A must always be charged in the be suitable for both winter and sum-
liquid phase. For the initial charge, the mer operation. Refer also to section
compressor must not run and service «Protection against flooded starts
valves must be closed. Charge refrige- and liquid floodback» for information
rant as close as possible to the nomi- about refrigerant charge limits.
nal system charge before starting the Warning: when a liquid line solenoid
compressor. Then slowly add refrige- valve is used, the vacuum in the low
rant in the liquid phase, on the low pressure side must be broken before
pressure side as far away as possible applying power to the system.
28
RECIPROCATING COMPRESSORS
INSTALLATION AND SERVICE
Oil charge and oil level The oil charge must be checked before into account oil contained in accesso-
commissioning (1/4 to 3/4 of the oil ries such as oil separators or oil traps).
sight glass). Check the oil level again If this amount has already been added
after a minimum of 2 hours operation and the oil level in the compressor
at nominal conditions. In most instal- keeps decreasing, the oil return in the
lations the initial compressor oil char- installation is insufficient. Refer also to
ge will be sufficient. In installations section "Piping design".
with line runs exceeding 20 m or with In installations where slow oil return
many oil traps or an oil separator, ad- is likely such as in multiple evaporator
ditional oil may be required. Normally or multiple condenser installations, an
the quantity of oil added should be no oil separator is recommended. Refer
more than 2% of the total refrigerant to the table on page 17 to select the
charge (this percentage does not take correct oil.
Suction gas superheat The optimum suction gas superheat is The maximum allowable superheat is
8 K. A lower superheat value will con- about 30 K. Higher values can be ac-
tribute to better system performance cepted but in these cases, tests have
(higher mass flow and more efficient to be performed to check that the
use of evaporator surface). Low super- maximum discharge temperature of
heat values however increase the risk 130°C will not be exceeded. Note that
of unwanted liquid floodback to the high superheat values decrease the
compressor. compressor application envelope and
For very low superheat values an elec- system performance.
tronically controlled expansion valve
is recommended.
29
RECIPROCATING COMPRESSORS
ACCESSORIES AND SPAREPARTS
The below tables show an extract of the sors. For an exhaustive list please refer
available accessories and spareparts to Accessories & Spareparts catalogue,
for Maneurop® reciprocating compres- ref. FRCC.EK.002.A1.02
Rotolock accessories
Type Code no. Description Application Packaging Pack size
V06-V01 7703004 Valve set, V06 (1"~1/2"), V01 (1"~3/8") MT/MTZ018-028 (exept 028 code 1) Multipack 4
V09-V06 7703005 Valve set, V09 (1-1/4"~5/8"), V06 (1"~1/2") MT/MTZ032-040 (& 028 code 1) Multipack 4
V07-V04 7703006 Valve set, V07 (1-3/4"~7/8"), V04 (1-1/4"~3/4") MT/MTZ044-072 Multipack 6
V02-V04 7703009 Valve set, V02 (1-3/4"~1-1/8"), V04 (1-1/4"~3/4") MT/MTZ080-160 Multipack 6
C06-C01 7703011 Angle adapter set, C06 (1"~1/2"), C01 (1"~3/8") MT/MTZ018-028 (exept 028 code 1) Multipack 4
C09-C06 7703012 Angle adapter set, C09 (1-1/4"~5/8"), C06 (1"~1/2") MT/MTZ032-040 (& 028 code 1) Multipack 4
C07-C04 7703013 Angle adapter set, C07 (1-3/4"~7/8"), C04 (1-1/4"~3/4") MT/MTZ044-072 Multipack 6
C02-C04 7703014 Angle adapter set, C02 (1-3/4"~1-1/8"), C04 (1-1/4"~3/4") MT/MTZ080-160 Multipack 6
G01 8156130 Gasket, 1" Models with 1" rotolock connection Multipack 10
G01 7956001 Gasket, 1" Models with 1" rotolock connection Industry pack 50
G09 8156131 Gasket, 1-1/4" Models with 1-1/4" rotolock connection Multipack 10
G09 7956002 Gasket, 1-1/4" Models with 1-1/4" rotolock connection Industry pack 50
G07 8156132 Gasket, 1-3/4" Models with 1-3/4" rotolock connection Multipack 10
G07 7956003 Gasket, 1-3/4" Models with 1-3/4" rotolock connection Industry pack 50
Gasket set, 1", 1-1/4", 1-3/4", Oil sight glass gaskets
8156009 All 1-2-4 cylinder models Multipack 10
black & white
Crankcase heaters
Type Code no. Description Application Packaging Pack size
PTC35W 7773001 PTC crankcase heater, 35 W, incl. heat transfer paste All models Multipack 10
PTC35W 7973009 PTC crankcase heater, 35 W, incl. heat transfer paste All models Industry pack 50
PTC35W 7773125 PTC crankcase heater, 35 W, mounting without paste All models Multipack 10
PTC35W 7973011 PTC crankcase heater, 35 W, mounting without paste All models Industry pack 50
7773106 Belt type crankcase heater, 55 W, 230 V, CE mark, UL MT/MTZ018-040 Multipack 4
7773002 Belt type crankcase heater, 54 W, 240 V, UL MT/MTZ018-040 Multipack 4
7773013 Belt type crankcase heater, 54 W, 400 V, UL MT/MTZ018-040 Multipack 4
7773111 Belt type crankcase heater, 54 W, 460 V, UL MT/MTZ018-040 Multipack 4
7773109 Belt type crankcase heater, 65 W, 110 V, CE mark, UL MT/MTZ044-081 Multipack 6
7973001 Belt type crankcase heater, 65 W, 110 V, CE mark, UL MT/MTZ044-081 Industry pack 50
7773107 Belt type crankcase heater, 65 W, 230 V, CE mark, UL MT/MTZ044-081 Multipack 6
7973002 Belt type crankcase heater, 65 W, 230 V, CE mark, UL MT/MTZ044-081 Industry pack 50
7773117 Belt type crankcase heater, 65 W, 400 V, CE mark, UL MT/MTZ044-081 Multipack 6
7773010 Belt type crankcase heater, 50 W, 110 V, UL MT/MTZ044-081 Multipack 6
7773003 Belt type crankcase heater, 50 W, 240 V, UL MT/MTZ044-081 Multipack 6
7773009 Belt type crankcase heater, 50 W, 400 V, UL MT/MTZ044-081 Multipack 6
7773006 Belt type crankcase heater, 50 W, 460 V, UL MT/MTZ044-081 Multipack 6
7773119 Belt type crankcase heater, 75 W, 575 V, UL MT/MTZ044-081 Multipack 6
7773110 Belt type crankcase heater, 75 W, 110 V, CE mark, UL MT/MTZ100-160 Multipack 6
7773108 Belt type crankcase heater, 75 W, 230 V, CE mark, UL MT/MTZ100-160 Multipack 6
7973005 Belt type crankcase heater, 75 W, 230 V, CE mark, UL MT/MTZ100-160 Industry pack 50
7773118 Belt type crankcase heater, 75 W, 400 V, CE mark, UL MT/MTZ100-160 Multipack 6
7773004 Belt type crankcase heater, 75 W, 240 V, UL MT/MTZ100-160 Multipack 6
7773014 Belt type crankcase heater, 75 W, 400 V, UL MT/MTZ100-160 Multipack 6
7773008 Belt type crankcase heater, 75 W, 460 V, UL MT/MTZ100-160 Multipack 6
7773105 Belt type crankcase heater, 75 W, 575 V, UL MT/MTZ100-160 Multipack 6
Acoustic hoods
Type Code no. Description Application Packaging Pack size
7755001 Acoustic hood for 1 cylinder compressor MT/MTZ018-040 Single pack 1
7755002 Acoustic hood for 2 cylinder compressor MT/MTZ044-081 Single pack 1
7755003 Acoustic hood for 4 cylinder compressor MT/MTZ100-160 Single pack 1
30
RECIPROCATING COMPRESSORS
ACCESSORIES AND SPAREPARTS
Single phase CSR starting kits & starting kits in prewired box
Type Code no. Description Application Packaging Pack size
CSR 7701022 CSR starting kit, 20 µF, 10 µF, 100 µF MT/MTZ018-028 code 5 Multipack 4
CSR 7701023 CSR starting kit, 25 µF, 10 µF, 135 µF MT/MTZ032-036 code 5 Multipack 4
CSR 7701021 CSR starting kit, 15 µF, 10 µF MT/MTZ018 code 1 Multipack 4
CSR 7701038 CSR starting kit, 15 µF, 30 µF, 100 µF MT/MTZ022 code 1 Multipack 4
CSR 7701154 CSR starting kit, 25 µF, 25 µF, 135 µF MT/MTZ028 code 1 Multipack 4
CSR 7701155 CSR starting kit, 25 µF, 20 µF, 100 µF MT/MTZ032-036 code 1 Multipack 4
CSR 7701156 CSR starting kit, 35 µF, 20 µF, 100 µF MT/MTZ040 code 1 Multipack 4
CSR 7701042 CSR starting kit, 30 µF, 15 µF, 135 µF MT/MTZ044-051 code 1 Multipack 6
CSR 7701043 CSR starting kit, 30 µF, 20 µF, 200 µF MT/MTZ057 code 1 Multipack 6
CSR 7701044 CSR starting kit, 30 µF, 25 µF, 235 µF MT/MTZ064-065 code 1 Multipack 6
CSR 7701028 CSR starting kit, prewired box, 20 µF, 10 µF, 100 µF MT/MTZ018-028 code 5 Single pack 1
CSR 7701029 CSR starting kit, prewired box, 25 µF, 10 µF, 135 µF MT/MTZ032-036 code 5 Single pack 1
CSR 7701147 CSR starting kit, prewired box, 15 µF, 30 µF, 100 µF MT/MTZ022 code 1 Single pack 1
CSR 7701148 CSR starting kit, prewired box, 25 µF, 25 µF, 135 µF MT/MTZ028 code 1 Single pack 1
CSR 7701149 CSR starting kit, prewired box, 25 µF, 20 µF, 100 µF MT/MTZ032-036 code 1 Single pack 1
CSR 7701150 CSR starting kit, prewired box, 35 µF, 20 µF, 100 µF MT/MTZ040 code 1 Single pack 1
CSR 7701049 CSR starting kit, prewired box, 30 µF, 15 µF, 135 µF MT/MTZ044-051 code 1 Single pack 1
Kickstart kits
Type Code no. Description Application Packaging Pack size
7701060 Kickstart kit; relay + start capacitor 227 µF MT/MTZ018 code 1 & 5 Single pack 1
7701059 Kickstart kit; relay + start capacitor 280 µF MT/MTZ022-064 code 1 & 5 excl 050-5 Single pack 1
Lubricants
Type Code no. Description Application Packaging Pack size
160PZ 7754019 POE lubricant, 160PZ, 1 litre can MTZ with R404A, R507A, R134a, R407C Multipack 12
160PZ 7754020 POE lubricant, 160PZ, 2 litre can MTZ with R404A, R507A, R134a, R407C Multipack 8
160P 7754001 Mineral oil, 160P, 2 litre can MT or LT with R22 or R502 Multipack 8
160P 7754002 Mineral oil, 160P, 5 litre can MT or LT with R22 or R502 Multipack 4
160ABM 7754009 Alkylbenzene oil 160ABM, 2 litre can MT or LT with transitional refrigerants Multipack 8
31
RECIPROCATING COMPRESSORS
ORDERING INFORMATION AND PACKAGING
Ordering information Maneurop® MT & MTZ reciprocating The code numbers ending on "M" in
compressors can be ordered from below tables represent the compres-
Danfoss Commercial Compressors sors in industrial packs. For ordering
in either industrial packs (also called single packs, please replace the last
multiple packaging) or in single packs letter "M" by letter "I".
(also called individual packaging).
32
RECIPROCATING COMPRESSORS
ORDERING INFORMATION AND PACKAGING
33
RECIPROCATING COMPRESSORS
ORDERING INFORMATION AND PACKAGING
Packaging
Single pack Multipack Industrial pack
1 cylinder
MT/MTZ018 21 142 279
34
RECIPROCATING COMPRESSORS
Danfoss Commercial Compressors http://cc.danfoss.com
Danfoss can accept no responsibility for possible errors in catalogues, brochures and other printed material. Danfoss reserves the right to alter its products without notice. This also
applies to products already on order provided that such alterations can be made without subsequential changes being necessary in specifications already agreed. All trademarks
in this material are property of the respective companies. Maneurop® Danfoss and the Danfoss logotype are trademarks of Danfoss A/S. All rights reserved.
FRCC.PC.004.A1.02 - May 2005 - Replace GA 035 - 06/01 GB www.kraft.fr