Emerson 450XL User's Manual
Contents
1. VILTER Since 1867 Vilter 450 XL Compressor For Industrial Refrigeration EMERSON Climate Technologies 450XL Cross Section Spring Loaded Safety Heads Protect against liquid slugging by relieving internal cylinder pressure if cylinders are subjected to an incompressible fluid Suction and Discharge Porting Maximum suction and discharge porting through the compressor achieves minimum pressure drop with valve plates that are made to exacting Vilter material and manufacturing requirements for long term service Piston and Connecting Rod The unique design of the piston and connecting rod assembly allows for movement only between the con necting rod bushing and piston pin while providing positive lubrication throughout the entire compres sion cycle Double Tapered Roller Bearings Energy efficient roller bearings enable the compressor to be used for high suction pressure applications as well as high belt drive horsepower requirements Tri MicroQ Oil Filter Removes 95 of contaminants as small as 3 microns in size Allows full flow of oil at all times resulting in reduced wear on compressor components Combines extreme filtering capacity with the convenience of a throw away recharge element Filter is enclosed in a seamless drawn carbon steel shell with cast iron cover and is equipped with a means for determining pres sure drop across the filter The versatile VMC 450XL is now even better Even though2. k GERA SR n 1000 112 185 These ratings are establised under the following conditions e 1200 RPM e Saturated suction Nosubcooling e No belt losses e All ratings are based on 60 C condensing temperature e Ratings are based on a 4 cylinder 450XL 454XL For cooling capacity and approximate kW figures of other 450XL models use a direct proportion to the number of cylinders of the 454XL For example use a 3 0 factor for determining the 12 cylin der 450XL cooling capacity and approximate kW figures 4516XL Belt Drive Recip Pak with VILTech Micro Controller Time Honored Features Vilter s attention to detail shows wherever you look Over a cen tury of experience in refrigeration compressor design goes into each and every part that comprises the 450XL We have designed our component parts to work together not just fit together That s why Vilter guarantees that all Genuine Vilter Parts will match your Vilter compressor dimensionally metallurgi cally and thermally for optimum compressor performance With Genuine Vilter Parts you can be assured of getting the engi neering design and special construction features that only Vilter can offer Consider some of the special manufacturing steps that Vilter parts go through e Select surfaces are shot peened for added strength e Mating faces are lapped for greater compressor efficiency e Many parts are ultrasonically inspected for maximum reliability
3. L B 1 th A J ol a 5 c sg fot Al eB cf ote o Bc ol 2 fios 2013 1488 sos 1514 6 1030 1410 1026 508 s67 12 2108 2013 vase 508 1514 Direct Drive Ammonia ei J L A J TATE TeTo Te Ten Ta Ts Te TA Ts Te a Hur A 4 d A d B _ l A B c p elo fale cl ole e a Bi cl De 2 12000 1047 1256 sos 740 6 zaso 1073 1026 sos 867 12 3270 1280 1486 546 1514 General Dimensions The dimensions shown above are approximate and should not be used for construction Vilter issues certified prints for construction purposes These dimensions are provided in millimeters Space needed to remove flywheel 178mm Space needed to remove crankshaft from wall to centerline of compressor 1067mm for 2 8 cylinder models and 2134mm for 12 16 cylinder models r OTH003 EN 0512 General Dimensions Maximum RPM Refrigeration Capacity at 12 C 35 C R 717 kW 686 Suction Connection inch Discharge Connection inch Unit Weight Less Motor kg Oil Charge I Standard Steps of Unloading o 50 33 66 355075100 550 15100 Vilter reserves the right to make changes in design and specifications without notice For more details see www emersonclimate eu i qi Emerson Climate Technologies GmbH European Headquarters Pascalstrasse 65 52076 Aachen Germany Tel 49 0 2408 929 0 Fax 49 0 2408 929 570 Internet www emersonc
4. 450XL compressor whether for repair work or scheduled maintenance make sure you specify Genuine Vilter Parts Look for the Genuine Vilter Part mark that is either etched or stamped directly on all major Vilter parts It s your assurance of Vilter warranty protection In some cases where a replacement part does not lend itself to stamping or etching a blue tag will identify the part as a Genuine Vilter Part Vilter re placement parts except those too big to box are shipped in boxes that have the Genuine Vilter Part mark right on the box itself Don t be misled by look alike no name imitations of Vilter com pressor parts that carry vague warranties Cheap parts can become an expensive mistake Make sure you insist on using only Genuine Vilter Parts and that you contact an Authorized Vilter Distributor or Vilter direct for all your 450XL parts requirements Capacity Reduction System Spring Loaded Safety Heads Spring loaded safety heads provide protection against liquid slugging The suction and discharge porting improve compressor efficiency e A piston operated unloading mechanism lifts the suction valve plate to unload the cylinders for reduced capacity or unloaded starts Simplified unloading piston allows easy removal for seal servicing The 6 8 12 and 16 cylinder crankshafts are shot peened for greater strength General Specifications The complete line of 450XL compressors is c
5. atios too from 8 1 for am monia to 14 1 for R404A In V belt configurations all the way up to 224 kW or direct drive setups up to 285 kW And it s usable for both 50Hz and 60Hz applications up to 1200 RPM The graph Figure 2 on the next page depicts the broad range of applications that the 450XL covers Cooling Capacity kW Nominal High Stage Capacities Complete detailed ratings for all 450XL high stage models plus rat With its 114 mm bore and stroke the 450XL provides up to 30 ings for 450XL booster compressors special high suction pressure more capacity than similar size compressor units all while main compressors and even integral two stage compressors are avail taining a favorable COP ratio able for all major refrigerants either from the Vilter Sales Offices Nominal high stage ratings for the 450XL are shown in Figure 1 below Figure 2 Broad Applications 27 58 Figure 1 High Stage capacities 450XL ratings Max Discharge 24 1 barg R 404a R 507 Absorbed Power kW Discharge Pressure barg 10 5 barg Max Suction Minimum Allowable 0 83 0 0 83 1 65 2 48 3 31 4 14 4 96 5 79 5 79 6 62 7 44 8 27 9 10 9 92 Suction Pressure barg 0 8 barg Suction Pressure barg Saturated Suction Temperature C E Max 14 1 R 404a amp R507 lexi NOON ax 14 2 a 2 E Max 12 1 R 22 RPM 452XL 458XL_ 4512XL 4516XL El Max 10 1 R 134a amp R 290 1200 150 225 El Max 8 1 R 717 et
6. de capacity control The piston and connecting rods shall be assembled with a shrink fit wrist pin for higher load carrying capabilities and superior wearing qualities The compressor shall come complete with structural steel base and be equipped with the additional following standard equip ments crankcase oil thermometer and heater oil filter pressure gauge with manual 3 way valve oil failure switch high and low pressure cutout capacity control switches and unloader solenoid valves based on the number of steps of capacity reduction water or refrigerant cooled oil cooler suction discharge and oil pressure gauges complete with Stedy Mounts and shut off valves water or refrigerant cooled cylinder covers following your need The parameters for the motors selection shall be Required power kW Frequency Hz and Rotational speed RPM Voltage Volt and phasing Direct coupling or V belt drive The compressor minimal cooling capacity kW shall be defined for given Suction temperature C or pressure barg Condensing temperature C or pressure barg Compressors are to be manufactured by Vilter Manufacturing Corporation Cudahy Wisconsin or equal as approved Vil Tech i Bi 4512XL Direct Drive Recip Pak with Superseparator and VILTech Micro Controller 2 amp 4 Cylinder Units 6 amp 8 Cylinder Units 12 amp 16 Cylinder Units V Belt Drive Ammonia B J L A J L B i A
7. e The steels used are of special alloys for durable performance e Exacting tolerances are measured in light bands rather than in hundredths of millimetres Piston Pin and Ring Assembly Connecting Rod Bearing and Bushing e A shrink fit wrist pin is used to increase bearing load Capacity Replaceable insert bearing improves lubrication and load carrying capacity Hardened steel wrist pins Forged connecting rods are ground and polished to back the precision made size steel backed Babbitt insert Three cast iron compression bearing rings and one oil ring provide a Grooved wrist pin bushings positive seal while wiping oil are fed with pressurized back to the crankcase lubricating oil surface cycle Ductile Iron Crankshaft e Designed with a bigger crankpin diameter for greater load bearing and bearing e All crankshafts are statically and dynamically balanced for reduced vibration Precision drilled crankshaft ensures proper lubrication through the compression The Vilter 450XL Full Two Year Warranty The 450XL compressor is fully warranted against defects of materi als and workmanship under normal use and service for a period of two years from date of shipment regardless of startup date For example if startup occurs one month from shipping date the customer will have a full twentythree 23 months of warranty coverage after startup Genuine Vilter Parts When you need parts for your
8. limate eu M RSO N The Emerson Climate Technologies logo is a trademark and service mark of Emerson Electric Co Emerson Climate Technologies Inc is a subsidiary of Emerson Electric Co CI i m ate Tech n O og ies Copeland is a registered trademark and Copeland Scroll is a trademark of Emerson Climate Technologies Inc All other trademarks are property of their respective owners Information contained in this brochure is subject to change without notification 2012 Emerson Climate Technologies Inc EMERSON CONSIDER IT SOLVED
9. mum Heavy Duty Crankshaft An over sized crankshaft pin diameter provides years of rugged dependable duty while the larger bearing surface allows for higher pressure differential capabi lities Connecting Rod Bearings Vilter s unique oil circuit drilling arrangement ensures proper hydrodynamic lubrication of insert bearings throughout the entire compression process Rod bearings are specially designed to supply lubrication to the piston pin bushing at all times Double Bellows Shaft Seal The 450XL shaft seal designed to specific Vilter specifications is manufactured from materials strictly used for industrial refrigeration applications Seal unit assembly consists of two opposed seals one sealing from the atmosphere and the other from the crank case Mating seal surfaces are lubricated and cooled by circulated oil Single Casting Frame The single casting frame incorporates suction and discharge manifolds plus bearing supports It s cast to exacting tolerances from a high grade of cast iron to withstand extreme changes in heat and pressure The castings are notably free from porosity and internal strains and display excellent wearing qualities Patented Design Far Reaching Applications The 450XL is so versatile it can handle almost any refrigeration system conditions Up to 24 1 bar maximum discharge and up to 10 3 bar maximum suction with a maximum 17 2 bar pressure differential At different compression r
10. omprised of six models ranging from a nominal 88 kW cooling capacity 2 cylinder machine all the way to the high end of the scale a nominal 704 kW cooling capacity 16 cylinder model In between are the 4 6 8 and 12 cylinder mid size units All 450XL compressors run at a maximum of 1200 RPM and all are provided with built in capacity reduction steps for economical operation at reduced loads V belt and direct connected motor operation are also available through out the entire range of 450XL models We have tried to make every centimetre count in designing the 450XL to fit into even the tightest space requirements The 450XL is amachine that provides displacement of 84 5 m3 h per cylinder giving you maximum capacity in a minimum amount of space There s sure to be a 450XL model that s a perfect match to your refrigeration application Engineering Specifications The compressor shall have double shaft seal double tapered roller main shaft bearings Tri Micro oil filter and oil strainer that removes 95 of contami nants as small as 3 microns in size dynamically and statically bal anced heavy duty crankshaft of ductile iron also shot peened on 6 8 12 and 16 cylinder models spring safety heads die forged steel connecting rods with replaceable bearing halves aluminum type heat treated pistons with three compression rings and one oil ring piston operated suction valve lifters to unload the compressor for starting and to provi
11. we ve made these specific changes we ve retained While retaining all of the features that are exclusive to Vilter com all of the exclusive Vilter features including provisions for fast and pressors we ve made several design improvements easy servicing with components that are easy to access e Piston The 450XL can operate with ammonia halocarbon and even some e Connecting road and bearing insert hydrocarbon refrigerants It works in extreme applications with up e Crankshaft to a 17 2 bar pressure differential It can be belt driven up to 224 e Safety head kW or direct driven all the way up to 285 kW And it can run at high e Capacity reduction system compression ratios all the way up to 12 1 with certain halocarbon refrigerants Even with all these built in features you ll still find the 450XL to be extremely cost efficient This compressor has a whopping cylinder displacement of 84 5 m h while running at 1200 RPM And the high isentropic efficiency of the 450XL means its COP is second to none when compared to other compression systems The 450XL can be installed almost anywhere even on an upper floor if necessary since vibration is kept to a minimum Noise level is low too due to the use of quickacting precise ring plate suction and discharge valves Compression and Oil Rings The 450XL piston ring set consists of three compres sion rings and a single special oil scraper ring for keeping oil consumption to an absolute mini
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