Emerson Vilter 450XL User manual

Vilter 450 XL® Compressor
For Industrial Refrigeration

450XL Cross Section
2
The versatile VMC 450XL is now even better!
While retaining all of the features that are exclusive to Vilter com-
pressors, we’ve made several design improvements:
• Piston
• Connecting road and bearing insert
• Crankshaft
• Safety head
• Capacity reduction system
Even though we’ve made these specific changes, we’ve retained
all of the exclusive Vilter features, including provisions for fast and
easy servicing with components that are easy to access.
The 450XL can operate with ammonia, halocarbon and even some
hydrocarbon refrigerants. It works in extreme applications with up
to a 17,2 bar pressure differential. It can be belt-driven up to 224
kW or direct driven all the way up to 285 kW. And it can run at high
compression ratios all the way up to 12:1 with certain halocarbon
refrigerants.
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-Micro® 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.

3
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 m3/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.
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 ratios, 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.
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 minimum.
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

4
Nominal High-Stage Capacities
With its 114 mm bore and stroke, the 450XL provides up to 30%
more capacity than similar size compressor units, all while main-
taining a favorable COP ratio.
Nominal high-stage ratings for the 450XL are shown in Figure 1
below.
Complete detailed ratings for all 450XL high-stage models, plus rat-
ings for 450XL booster compressors, special high suction pressure
compressors, and even integral two-stage compressors, are avail-
able for all major refrigerants either from the Vilter Sales Offices.
These ratings are establised under the following conditions:
•1200 RPM
•Saturated suction
•No subcooling
•No belt losses
•All ratings are based on 60°C condensing temperature
•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
Figure 1 | High Stage capacities 450XL ratings
Figure 2 | Broad Applications
Cooling Capacity (kW)
Absorbed Power (kW)
Saturated Suction Temperature °C
Suction Pressure (barg)
Discharge Pressure (barg)
Minimum
Allowable
Suction
Pressure (barg)
-0.8 barg
Max. Discharge 24.1 barg
10.5 barg Max. Suction
17.2 Bar ΔP Max
2.07 Bar ΔP Minimum for Gas Unloading
0 Bar ΔP Minimum for Oil Unloading
Maximum Motor kW

5
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:
•Select surfaces are shot-peened for added strength
•Mating faces are lapped for greater compressor efficiency
•Many parts are ultrasonically inspected for maximum reliability
•The steels used are of special alloys for durable performance
•Exacting tolerances are measured in light bands rather than in
hundredths of millimetres
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 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.
Piston, Pin and Ring
Assembly
Connecting Rod,
Bearing and Bushing
Capacity Reduction System
Ductile Iron Crankshaft Spring Loaded Safety
Heads
•A shrink-fit wrist pin is used
to increase bearing load
capacity.
• Hardened steel wrist pins
are ground and polished to
size.
• Three cast iron compression
rings and one oil ring provide a
positive seal while wiping oil
back to the crankcase.
•Replaceable insert bearing
improves lubrication and
load carrying capacity.
• Forged connecting rods
back the precision-made,
steel-backed Babbitt insert
bearing.
• Grooved wrist pin bushings
are fed with pressurized
lubricating oil.
•Designed with a bigger
crankpin diameter for greater
load bearing and bearing
surface.
• All crankshafts are statically
and dynamically balanced for
reduced vibration.
• Precision drilled crankshaft
ensures proper lubrication
through the compression
cycle.
• The 6, 8, 12, and 16-cylinder
crankshafts are shot-peened
for greater strength.
•Spring loaded safety heads
provide protection against
liquid slugging.
• The suction and discharge
porting improve compressor
efficiency.
•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.

6
General Specifications
The complete line of 450XL compressors is comprised 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 a machine 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 provide 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.
4512XL Direct Drive Recip Pak with
Superseparator and VILTech Micro-
Controller

7
2 & 4 Cylinder Units 6 & 8 Cylinder Units 12 & 16 Cylinder Units
V-Belt Drive Ammonia
Cyl. A B C D E Cyl. A B C D E Cyl. A B C D E
12 2108 2013 1486 508 1514 6 1930 1410 1026 508 867 12 2108 2013 1486 508 1514
16 2108 2013 1581 508 1514 8 1930 1422 991 508 883 16 2108 2013 1581 508 1514
Direct Drive Ammonia
Cyl. A B C D E Cyl. A B C D E Cyl. A B C D E
2 2000 1041 1259 508 740 12 2356 1073 1026 508 867 12 3258 1280 1524 546 1514
4 2203 1054 1310 508 802 16 2419 1140 991 508 883 16 3258 1280 1616 546 1514
V-Belt Drive Halocarbon
Cyl. A B C D E Cyl. A B C D E Cyl. A B C D E
2 1753 1241 1256 508 740 6 1930 1435 1026 508 867 12 2108 2038 1448 508 1514
4 1880 1271 1310 508 802 8 1930 1448 991 508 883 16 2108 2038 1527 508 1514
Direct Drive Halocarbon
Cyl. A B C D E Cyl. A B C D E Cyl. A B C D E
2 2000 1041 1256 508 740 6 2369 1073 1026 508 867 12 3270 1280 1486 546 1514
4 2203 1054 1310 508 802 8 2432 1140 991 508 883 16 3270 1280 1565 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.

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452XL 454XL 456XL 458XL 4512XL 4516XL
Number of Cylinders 24681216
Maximum RPM 1200 1200 1200 1200 1200 1200
Bore & Stroke (mm) 114 x 114 114 x 114 114 x 114 114 x 114 114 x 114 114 x 114
CFM @ Maximum RPM (m3/h) 169 336 507 676 1014 1352
Refrigeration Capacity at -12°C/+35°C, R-717 (kW) 84 172 257 341 514 686
Suction Connection (inch) 2 1/2 34456
Discharge Connection (inch) 2 2 1/2 3 3 2 x 3 2 x 3
Unit Weight Less Motor (kg) 862 1225 1406 1542 2404 2630
Oil Charge (l) 19 27 27 27 53 53
Standard Steps of Unloading (%) 0 50 33/66 24/50 33/66 25/50
Option 1 Steps of Unloading (%) 50 25/50/75 - 25/50/75 - 25/50/75
Option 2 Steps of Unloading (%) 100 50/100 33/66/100 25/50/75/100 33/66/100 25/50/75/100
Maximum Discharge Temperature (°C) 149 149 149 149 149 149
Crankcase Oil Temperature Range (°C) 43-54 43-54 43-54 43-54 43-54 43-54
Vilter reserves the right to make changes in design and specifications without notice.
General Dimensions