Hanbell RC2-100AF, RC2-140AF, RC2-200AF, RC2-230AF, RC2-260AF Series Manual

0

CONTENTS

1. Compressor’s characteristics ............................................................................................................................. 2

2. Compressor specification .................................................................................................................................... 3

2.1 Design specification .................................................................................................................................... 3

2.2 Compressor outline ..................................................................................................................................... 5

2.3 Compressor construction ......................................................................................................................... 28

2.4 Capacity control system ........................................................................................................................... 30

2.5 Compressor application limits ................................................................................................................. 33

2.6 Compressor design feature ...................................................................................................................... 35

2.7 MCC and LRA ............................................................................................................................................. 37

3. Compressor handling and Installation ............................................................................................................. 41

3.1 Compressor handling ............................................................................................................................... 41

3.2 Mounting the compressor ........................................................................................................................ 41

4. Lubricant .............................................................................................................................................................. 64

4.1 Pre-cautions in changing of oil ................................................................................................................ 64

4.2 Changing of oil .......................................................................................................................................... 65

4.3 Lubricants table ......................................................................................................................................... 66

5. Electrical data and design ................................................................................................................................. 67

5.1 Motor design .............................................................................................................................................. 67

5.2 Compressor protection devices .............................................................................................................. 69

5.3 Power supply ............................................................................................................................................. 69

5.4 Selection of magnetic contactor .............................................................................................................. 71

5.5 Grounding .................................................................................................................................................. 71

6. Compressors accessories ................................................................................................................................. 72

6.1 Compressors standard and optional accessories ................................................................................. 72

6.2 Description of accessories ....................................................................................................................... 73

7. Operation and trouble shooting ........................................................................................................................ 87

7.1 Compressor start-up ................................................................................................................................. 87

7.2 System adjustment .................................................................................................................................... 89

7.3 Compressor stop ....................................................................................................................................... 91

7.4 Troubleshooting ........................................................................................................................................ 92

7.5 Compressor checking list......................................................................................................................... 95

8. System applications ........................................................................................................................................... 96

8.1 General application ................................................................................................................................... 96

8.2 Economizer application .......................................................................................................................... 109

8.3 Important notice to compressor application ........................................................................................ 112

8.4 Example of installation ........................................................................................................................... 113

Appendix 1. Compressor noise level .................................................................................................................. 116

1

Introduction

The Hanbell RC2-F series semi-hermetic twin-screw compressor inherits all the quality and experience of our RC2 series compressor. The RC2-F series compressor is developed especially for application with Freon in flooded system or refrigeration field. With a built-in high operating load design and advanced 5 to 6 Patented Screw Rotor Profile, each compressor has high efficiency and reliability in all operating condition. Each unit is carefully manufactured and inspected by high precision THREAD SCREW ROTOR GRINDING MACHINE, CNC MACHINING CENTER, and 3-D COORDINATE MEASURING MACHINE. Each compressor at HANBELL also follows the ISO 9001 certification quality system which assures the best quality control and production process to customers. RC2-F series compressor has 27 models RC2-100~RC2-1530, with displacement (50／60Hz) from 98 / 1 18 m3/hr to 1539 / 1847 m3/hr.

The RC2-F series compressors use high quality bearings which resulted in longer bearing life compare to competitors. These bearings provide strong support to screw rotors especially for the heavy duty application. Oil/Refrigerant injection port can be utilized when external cooling is needed at chamber. This can keep the compression chamber at proper discharge temperature and ensures sufficient oil viscosity for moving parts lubrication. Economizer port can be used to reach higher cooling capacity and working efficiency especially at high pressure ratio working condition or at very low evaporating temperature. All these new designs guarantee that the compressor has the best reliability, longest bearing life and easiest regular maintenance work.

This Technical Manual contains all basic information about dimensions, handling, installation, operation, trouble shooting, and system application. It is highly recommended that the content of this manual should be read carefully prior to handling, installing, and operating the RC2-F compressor in order to prevent any unwanted damage on it. For any technical issue related to RC2-F series compressor, please contact HANBELL or local distributors/agents for more information and assistance.

2

1. Compressor’s characteristics

1-1 Multi country (Taiwan, China, USA, England) patented high efficiency 5 to 6 asymmetrical rotor profile.

1-2 Precise volume control system

Steps or continuous capacity control system are available.

1-3 Economizer applications

Economizer port is a standard accessory for RC2-F series screw compressor. Floating type medium pressure (Economizer returned pressure) design, no matter if compressor work at full load or partial load condition, always can track the best medium pressure value, it means economizer could develop the maximum efficiency during the operation.

1-4 Applicable with：R-134a, R-407C, R22, R404A, R507A.

1-5 Resistant to high load condition with long life bearing design

1-6 PTC temperature thermistor for the protection of

(1) High motor coil temperature (2) High discharge temperature (3) High oil temperature (optional)

1-7 Low vibration and low noise.

1-8 High efficiency oil separator, low-pressure drop, external connection.

3

2. Compressor specification

MODEL

COMPRESSOR

MOTOR

Hydrostatic Pressure

Test

Weight

Displacement 60 /

50Hz

Rated

Speed

VI

Cap. Control (%)

Type

Nominal

Hp

Starting Voltage (V)

Insulation

Protection

m3/hr

60 / 50Hz

STEP

STEPLESS

60Hz

50Hz

60Hz

50Hz

Kg/cm2G

kg

RC2-100AF

118/98

3550/2950

2.2

2.6

3.0

3.5

4.8

33, 66, 100

33~100

3 Phase, 2 Pole, Squirrel Cage, Induction Motor

23

19

Y-△

PWS

DOL

208

220

230

380

440

460

480

575

380

400

415

Class F PTC Protection

42

260

RC2-140AF

165/137

33, 66, 100

33~100

32

26

265

RC2-180AF

216/180

33, 66, 100

33~100

42

35

365

RC2-200AF

233/193

25, 50, 75, 100

25~100

45

37

405

RC2-230AF

277/230

35, 50, 75, 100

35~100

53

44

530

RC2-260AF

309/257

25, 50, 75, 100

25~100

59

49

535

RC2-300AF

352/293

25, 50, 75, 100

25~100

67

56

580

RC2-310AF

371/308

35, 50, 75, 100

35~100

71

59

565

RC2-320AF

384/320

25, 50, 75, 100

25~100

72

60

595

RC2-340AF

407/339

35, 50, 75, 100

35~100

77

64

600

RC2-370AF

440/366

35, 50, 75, 100

35~100

84

70

610

RC2-410AF

490/407

25, 50, 75, 100

25~100

93

78

380

440

460

480

575

730

RC2-430AF

512/425

25, 50, 75, 100

25~100

100

84

735

RC2-470AF

567/471

25, 50, 75, 100

25~100

108

90

800

RC2-510AF

611/508

35, 50, 75, 100

35~100

117

98

760

RC2-550AF

660/549

25, 50, 75, 100

25~100

126

105

820

RC2-580AF

702/583

35, 50, 75, 100

35~100

131

109

805

RC2-620AF

745/619

35, 50, 75, 100

35~100

137

114

Y-△

DOL

850

RC2-710AF

858/713

35, 50, 75, 100

35~100

158

131

1050

RC2-790AF

952/791

30, 50, 75, 100

30~100

175

146

1140

RC2-830AF

993/825

30, 50, 75, 100

30~100

183

152

1150

RC2-930AF

1117/929

35, 50, 75, 100

35~100

212

176

1180

RC2-1020AF

1223/1017

25, 50, 75, 100

25~100

227

189

1500

RC2-1130AF

1350/1122

25, 50, 75, 100

25~100

248

206

1520

RC2-1270AF

1521/1268

25, 50, 75, 100

25~100

286

238

2100

RC2-1530AF

1847/1539

25, 50, 75, 100

25~100

331

275

2200

2.1 Design specification a. RC2-AF

4

MODEL

COMPRESSOR

MOTOR

Hydrostatic

Pressure Test

Weight

Displacement 60 /

50Hz

Rated

Speed

VI

Cap. Control (%)

Type

Nominal

Hp

Starting-Up Voltage (V)

Insulation

Protection

m3/hr

60 / 50Hz

STEP

STEPLESS

60Hz

50Hz

60Hz

50Hz

Kg/cm2G

kg

RC2-100BF

118/98

3550/2950

2.2

2.6

3.0

3.5

4.8

33, 66, 100

33~100

3 Phase, 2 Pole, Squirrel Cage, Induction Motor

38

31

Y-△

PWS

DOL

208

220

230

380

440

460

480

575

380

400

415

Class F PTC Protection

42

265

RC2-140BF

165/137

33, 66, 100

33~100

50

41

270

RC2-180BF

216/180

33, 66, 100

33~100

66

55

390

RC2-200BF

233/193

25, 50, 75, 100

25~100

70

58

415

RC2-230AF

277/230

35, 50, 75, 100

35~100

53

44

535

RC2-260BF

309/257

25, 50, 75, 100

25~100

90

75

540

RC2-300BF

352/293

25, 50, 75, 100

25~100

107

89

600

RC2-310BF

371/308

35, 50, 75, 100

35~100

110

91

570

RC2-320BF

384/320

25, 50, 75, 100

25~100

114

94

600

RC2-340BF

407/339

35, 50, 75, 100

35~100

121

101

620

RC2-370BF

440/366

35, 50, 75, 100

35~100

130

108

640

RC2-410BF

490/407

25, 50, 75, 100

25~100

146

121

380

440

460

480

575

740

RC2-470BF

567/471

25, 50, 75, 100

25~100

170

141

810

RC2-510BF

611/508

35, 50, 75, 100

35~100

183

152

780

RC2-550BF

660/549

25, 50, 75, 100

25~100

195

162

850

RC2-580BF

702/583

35, 50, 75, 100

35~100

210

175

840

RC2-620BF

745/619

35, 50, 75, 100

35~100

220

183

Y-△

DOL

880

RC2-710BF

858/713

35, 50, 75, 100

35~100

250

208

1080

RC2-790BF

952/791

30, 50, 75, 100

30~100

276

230

1180

RC2-830BF

993/825

30, 50, 75, 100

30~100

290

234

1215

RC2-930BF

1117/929

35, 50, 75, 100

35~100

334

278

1240

RC2-1020BF

1223/1017

25, 50, 75, 100

25~100

357

297

1540

RC2-1130BF

1350/1122

25, 50, 75, 100

25~100

393

327

1560

RC2-1270BF

1521/1268

25, 50, 75, 100

25~100

471

392

2200

RC2-1530BF

1847/1539

25, 50, 75, 100

25~100

534

443

2300

b. RC2-BF

Nominal Horse Power:

All above Nominal Hp are not equal to the maximum compressors Hp; Please refer to Hanbell selection software’s

output for the rated current, Maximum Continuous Current-M.C.C according to various working condition while selecting the contactor, cable, fuse and wire, etc…

5

2.2 Compressor outline

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

Note: For RC2-1020BF, RC2-1130BF, RC2-1270BF and RC2-1530BF outline drawing, please refer to those of

RC2-1020AF, RC2-1130AF, RC2-1270AF, and RC2-1530AF

28

No.

Description

No.

Description

1

Compressor casing

15

Discharge bearings

2

Motor casing

16

Discharge fixed ring

3

Discharge casing

17

Disc spring

4

Motor rotor assembly

18

Bearing slot nut

5

Motor stator assembly

19

Male rotor

6

Motor rotor washer

20

Suction bearings

7

Motor rotor spacer ring

21

Suction filter

8

Discharge connect flange

22

Suction flange

9

Piston

23

Discharge flange bushing

10

Piston ring

24

Cable box

11

Piston rod

25

Power bolt

12

Bearing seat cover plate

26

Terminal cover plate

13

Modulation slide valve

27

PTC discharge temperature sensor

14

Slide valve key

No.

Description

No.

Description

1

Compressor casing

17

Disc spring

2

Motor casing

18

Bearing slot nut

3

Discharge casing

19

Male rotor

4

Motor rotor assembly

20

Suction bearings

5

Motor stator assembly

21

Suction bearings inner/outer spacer ring

6

Motor rotor washer

22

Oil guiding ring

7

Motor rotor spacer ring

23

Suction filter

8

Piston

24

Suction flange

9

Piston ring

25

Cable box

10

Piston rod

26

Power bolt

11

Bearing seat cover plate

27

Thermostat terminals

12

Modulation solenoid valve

28

Terminal cover plate

13

Modulation slide valve

29

Discharge connect flange

14

Slide valve key

30

Discharge flange bushing

15

Discharge bearings

31

PTC discharge temperature sensor

16

Discharge fixed ring

2.3 Compressor construction

RC2-100, RC2-140, RC2-180 F type Construction

RC2-200, RC2-230, RC2-260, RC2-300, RC2-310, RC2-320, RC2-340, RC2-370, RC2-410, RC2-430, RC2-470, RC2-510, RC2-550, RC2-580, RC2-620 F type Construction

29

RC2-710, RC2-790, RC2-830, RC2-930 F type Construction

No.

Description

No.

Description

1

Compressor casing

17

Discharge fixed ring

2

Motor casing

18

Disc spring

3

Discharge casing

19

α-Balance piston

4

Motor rotor assembly

20

Bearing slot nut

5

Motor stator assembly

21

Male rotor

6

Motor rotor washer

22

Suction bearings

7

Motor rotor spacer ring

23

Suction bearings inner/outer spacer ring

8

Discharge connect flange

24

Oil guiding ring

9

Piston

25

Suction filter

10

Piston spring

26

Suction flange

11

Piston rod

27

Discharge flange bushing

12

Bearing seat cover plate

28

Cable box

13

Modulation solenoid valve

29

Power bolt

14

Modulation slide valve

30

Thermostat terminals

15

Slide valve key

31

Motor cable cover plate

16

Discharge bearings

32

PTC discharge temperature sensor

No.

Description

No.

Description

1

Compressor casing

18

Disc spring

2

Motor casing

19

Balance piston

3

Discharge casing

20

Bearing slot nut

4

Motor rotor assembly

21

Male rotor

5

Motor stator assembly

22

Suction bearings

6

Motor rotor washer

23

Suction bearings inner/outer spacer ring

7

Motor rotor spacer ring

24

Oil guiding ring

8

Muffler

25

Suction filter

9

Piston

26

Suction flange

10

Piston spring

27

Discharge flange bushing

11

Piston rod

28

Cable box

12

Bearing seat cover plate

29

Power bolt

13

Modulation solenoid valve

30

Thermostat terminals

14

Modulation slide valve

31

Motor cable cover plate

15

Slide valve key

32

PTC discharge temperature sensor

16

Discharge bearings

33

Discharge connect flange

17

Discharge fixed ring

34

Check valve

RC2-1020, RC2-1130, RC2-1270, RC2-1530 F type Construction

30

1

2

4

3

2.4 Capacity control system

The RC2-F series screw compressors are equipped with either 3-steps/4-steps or continuous (step-less) capacity control system. Both capacity control systems consist of a modulation slide valve, piston rod, cylinder, piston and piston rings. The slide valve and the piston are connected by a piston rod. The principle of operation is using the oil pressure to drive the piston in the cylinder. The lubrication oil flows from the external oil separator through the oil filter to the main oil inlet port and then fills into the cylinder due to the positive oil pressure force which is bigger than the spring force plus the force from high pressure gas. The positive pressure differential causes the piston to move toward the loading direction in the cylinder. When the slide valve moves toward the loading direction, the effective suction volume increased in the compression chamber. This means the displacement of refrigerant gas also increases, as a result the refrigeration capacity also increases. However, when any of the step solenoid valve (for 4-step capacity control system) is opened, the high pressure oil in the cylinder bypasses to the suction side, which causes the piston and the slide valve move toward the unloading direction, and then some of the refrigerant gas bypasses from the compression chamber back to the suction end. As a result, the refrigeration capacity decreases because of the reduction of displacement of refrigerant gas flowing in the system.

The piston spring is used to push the piston back to its original position, i.e. minimum load position in order to

reduce the starting current for the next starting-up. If the compressor started at full load capacity it may result in over current start. The modulation solenoid valves are controlled by a micro controller or temperature switch to modulate the piston position smoothly with stable output of capacity.

If the oil filter cartridge or modulation solenoid valves are not working well in the capacity control system, this may result in the abnormality and ineffectiveness of the capacity control system. Before stopping the compressor, HANBELL strongly recommends that the unloading solenoid valve of step-less control system or minimum load solenoid valve of 3/4 steps control system should be kept opened for 30~60 seconds so that oil pressure in the cylinder can be released. When starting the compressor next time, the slide is at its minimum load position for a light duty start.

The capacity control solenoid valves of different models are equipped as the pictures shown below. Please refer to the pictures and description for the detail of capacity control logic.

RC2-100F/140F/180F RC2-200F~RC2-930F

31

Top view Side view

Solenoid Valve

1 2 3

4

Normal Open / Normal Close

--

NC

Standard / Optional

--

STANDARD

Control

Logic

S %

(Start)

--

ON

OFF

M1 %

(66% or 50%)

--

OFF

ON

OFF

M2 %

(75%)

--

OFF

ON

F %

(Full Load / 100%)

--

OFF

RC2-1020F ~ RC2-1530F

3 or 4 steps capacity control

Note：

ON : Solenoid valve energized

OFF: Solenoid valve not energized

Warning：If the S % ( start ) capacity is essential to be kept running for a long time, the problem of oil return, motor cooling and high discharge temperature and other problem should be considered seriously to prevent inappropriate operation of the compressor which may damage it.

32

Solenoid Valve

1 1 2 3 4

Normal Open / Normal Close

NO

NC

--

Standard / Optional

OPTIONAL

STANDARD

--

Control

Logic

Start

ON

OFF

ON

--

Loading

OFF

ON

OFF

--

Unloading

ON

OFF

ON

--

Hold /

Stable

ON

OFF

--

Stepless capacity control

Note：

ON : Solenoid valve energized OFF: Solenoid valve not energized

In continuous capacity control system, two normally close solenoid valve are equipped as standard. These two solenoid valves are controlled by the chiller temperature controller, hence refrigeration capacity can be modulated between S (start) %100% continuously. The exactness of temperature control depends on the precision of temperature sensor.

The timer resolution of control system, affects the capacity control’s speed. Hanbell recommends setting the timer resolution between 0.1~1second to have a precise capacity control. If the resolution is set more than 1 second, then it is recommended to add a flow control device to obtain a smooth capacity control.

33

2.5 Compressor application limits

Compressor Operating Limits vary significantly with the type of refrigerant used. The operating limits shown below are based on saturated suction and discharge operating conditions. For continuous operation over extended periods of time, it is important to operate the compressor within these limits to maintain proper compressor life. Operating at extra low saturated suction temperature, may cause oil management problem, and operating at extra high saturated condensing temperature may shorten the compressor life due to insufficient compressor chamber cooling or oil supply for lubrication.

a. Application limits of RC2-100F~RC2-930F are described on the respective refrigerant charts.

34

b. Application limits of of RC2-1020F~RC2-1530F are described on the respective refrigerant charts.

Note :

1. When Hanbell screw compressor operates in partial or full load within limits, temperature of motor coil and discharge will rise concurrently. In order to keep compressor running safely, Hanbell recommends using the following additional cooling methods : (1) Oil cooler. (2) Liquid injection to chamber. (3) Liquid injection to motor. Please refer to Hanbell selection software for calculation and chapter 9—application for design reference.

2. The minimum discharge superheat is recommended to be kept 10°k higher than the condensing temperature ( normally discharge superheat is around 20°K for R-134a,R404A, R507A and 30°K for R22, R407C) to avoid liquid filling back to compressor and lubrication failure. According to EN12900, the minimum suction superheat is 10°k and liquid sub-cooling is 0°k.

35

V

Pd

Pd'

V

Pd<Pd'

P

Pd, Pd'

V

Pd=Pd'

P

Pd>Pd'

Pd'

Pd

P

3. Hanbell recommends monitoring oil pressure differential by pressure differential switch passively or by

Gcmkg2/

Under compression (CR > Pi)

Over compression (CR < Pi)

CR = Pi

Loss of work

1

2 3

4

Ps

1

2 3

4

Ps

2

3

4

1

additional oil pump actively and keep it 4

over the suction pressure for adequate seal, lubrication and capacity control. This is very important especially when the condensing temperature is low and the evaporating temperature is high like the application in water-cooled flooded chillers and normally its high-low pressure differential tends to be less than 4

. In this kind of situation, installation of oil pump is

recommended to ensure sufficient oil supply.

4. All models’ motor cooling are by refrigerant returned from evaporator. If compressors run continuously at partial load below 50%, failure of motor coils might happen due to insufficient motor cooling. Therefore, Hanbell emphasizes installation of liquid injection system to motor to make sure adequate cooling at motor coils for safe running of compressors.

5. Contact with Hanbell to verify potential operating conditions outside the limits shown.

2.6 Compressor design feature

2.6.1 Compressor volume ratio

The Volume ratio (Vi) of the compressor can be defined as the ratio of suction volume of gas divided by discharge volume of gas of the compressor. The volume ratio directly affects the internal compression ratio or Pi of the compressor. A low Vi compressor corresponds to a low compression ratio compressor and high Vi compressors are used on higher compression ratio systems. In the equation below, in order to avoid over or under compression, the system compression ratio (CR) should be equal to the compressor internal compression ratio (Pi). If CR is not equal to Pi, it would cause extra compensation of work / power of compressor and also decrease C.O.P. Refer also to the P-V (pressure – volume) diagram below to show the relation.

CR = Pd/Ps

Pi = Vi

k

Vi = Vs/Vd

Where: CR: system compression ratio Pi: internal compression ratio

Vi: internal volume ratio Pd: system pressure (absolute pressure)

Pd’: discharge pressure (absolute pressure) Ps: suction pressure (absolute pressure) Vs: suction volume Vd: discharge volume K: refrigerant specific heat ratio

36

B - B' View

A - A' View

P2

P1

P2

A'

B

A

P1

PART LOAD

FULL LOAD

Vi 2.6

Vi 3.5

Note:

1. Hanbell recommends using selection program to get the suggested Vi because inappropriate Vi selection will

cause higher power consumption, vibration and discharge temperature.

2. When compressor running below 70% capacity, because the slide is partially inside the compression chamber

and results the inappropriate Vi, the system will suffer higher discharge temperature. Therefore Hanbell recommends not running compressor under partial load in a long time.

To ensure compressor performs in a high efficiency condition and prevent from additional power loss, built-in Vi is designed for all models ( Vi = 2.2, 2.6, 3.0, 3.5, 4.8 ), so the customer could select the suitable Vi according to different working condition. Please refer to Hanbell selection software to get the recommended Vi for different working condition.

Built-in fixed type Vi

2.6.2 Floating type medium pressure ( for application with economizer)

Normally, a fix type medium pressure compressor when combine with economizer, the economizer can only develop their effect in full load condition or closed to full load condition. RC2-F series uses floating medium pressure design, the floating mechanical design is shown in the next drawing. Economizer can be functioned not only in full load condition, but also in partial load condition. The economizer can reach the best medium pressure value and develops the maximum efficiency.

Floating type medium pressure explanation

Medium pressure’s position will vary as shown in the above drawing. When the slide is at full load position, the medium pressure is P1. When the slide is at partial load position, the medium pressure is P2.

37

2.7 MCC and LRA

Model

50Hz

60Hz Unit: Ampere

380V

400V

415V

208V

220V

230V

380V

440V

460V

480V

575V

MCC

LRA

MCC

LRA

MCC

LRA

MCC

LRA

MCC

LRA

MCC

LRA

MCC

LRA

MCC

LRA

MCC

LRA

MCC

LRA

MCC

LRA

(Y/△)

RC2-100AF

53

58/175

50

60/ 180

49

55/165

115

127/380

109

117/350

104

120/360

63

70/210

55

58/175

52

60/180

50

55/165

42

48/145

RC2-140AF

73

77/230

70

80/240

67

73/220

160

175/525

151

153/460

145

160/480

88

97/290

76

77/230

72

80/240

69

73/220

58

63/190

RC2-180AF

97

103/310

92

108/325

89

98/295

213

230/690

202

198/595

193

207/620

117

125/375

101

103/310

96

108/325

92

98/295

77

85/255

RC2-200AF

103

103/310

98

108/325

94

98/295

226

230/690

214

198/595

204

207/620

124

125/375

107

103/310

102

108/325

98

98/295

82

85/255

RC2-230AF

124

160/480

117

167/500

113

155/465

270

360/1080

256

302/905

244

315/945

148

200/600

128

160/480

122

167/500

117

155/465

98

125/375

RC2-260AF

138

160/480

131

167/500

126

155/465

302

360/1080

286

302/905

273

315/945

165

200/600

143

160/480

137

167/500

131

155/465

109

125/375

RC2-300AF

155

200/600

147

208/625

142

180/540

340

462/1385

322

375/1125

308

392/1175

186

245/735

161

200/600

154

208/625

147

180/540

123

157/470

RC2-310AF

163

200/600

155

208/625

149

180/540

360

462/1385

341

375/1125

326

392/1175

197

245/735

170

200/600

163

208/625

156

180/540

130

157/470

RC2-320AF

167

200/600

158

208/625

153

180/540

366

462/1385

346

375/1125

331

392/1175

200

245/735

173

200/600

165

208/625

158

180/540

132

157/470

RC2-340AF

178

230/690

169

240/720

163

218/655

388

503/1510

367

460/1380

351

480/1440

213

270/810

184

230/690

176

240/720

168

218/655

140

182/545

RC2-370AF

194

230/690

185

240/720

178

218/655

426

503/1510

403

460/1380

386

480/1440

233

270/810

202

230/690

193

240/720

185

218/655

154

182/545

RC2-410AF

216

233/700

205

243/730

198

230/690

－－－－－

－

260

273/820

224

233/700

215

243/730

206

230/690

172

183/550

RC2-430AF

230

233/700

218

243/730

211

230/690

－－－－－

－

277

273/820

239

233/700

229

243/730

219

230/690

183

183/550

RC2-470AF

248

270/810

236

282/845

227

265/795

－－－－－

－

300

328/985

259

270/810

248

282/845

238

265/795

198

220/660

RC2-510AF

271

270/810

258

282/845

248

265/795

－－－－－

－

327

328/985

282

270/810

270

282/845

259

265/795

216

220/660

RC2-550AF

292

292/875

277

305/915

267

283/850

－－－－－

－

350

372/1115

302

292/875

289

305/915

277

283/850

231

250/750

RC2-580AF

304

292/875

288

305/915

278

283/850

－－－－－

－

365

372/1115

316

292/875

302

305/915

289

283/850

242

250/750

RC2-620AF

317

407/1220

301

428/1285

290

387/1160

－－－－－

－

381

482/1445

329

407/1220

315

428/1285

301

387/1160

252

323/970

RC2-710AF

365

447/1340

347

467/1400

334

432/1295

－－－－－

－

439

583/1750

379

447/1340

363

467/1400

348

432/1295

290

373/1120

RC2-790AF

404

477/1430

384

498/1495

370

457/1370

－－－－－

－

486

643/1930

420

477/1430

402

498/1495

385

457/1370

321

388/1165

RC2-830AF

422

522/1565

401

545/1635

387

495/1485

－－－－－

－

507

728/2185

438

522/1565

419

545/1635

402

495/1485

335

462/1385

RC2-930AF

490

663/1990

465

693/2080

448

617/1850

－－－－－

－

589

823/2470

509

663/1990

487

693/2080

466

617/1850

389

555/1665

RC2-1020AF(A1)

360

583/1750

342

613/1840

330

537/1610

434

763/2290

374

583/1750

358

613/1840

343

537/1610

287

493/1480

RC2-1020AF(A2)

536

753/2260

510

793/2380

491

690/2070

645

945/2835

557

753/2260

533

793/2380

510

690/2070

426

635/1905

RC2-1130AF(A1)

395

583/1750

375

613/1840

362

537/1610

475

763/2290

410

583/1750

393

613/1840

376

537/1610

314

493/1480

RC2-1130AF(A2)

588

753/2260

559

793/2380

538

690/2070

709

945/2835

612

753/2260

585

793/2380

561

690/2070

468

635/1905

RC2-1270AF(A1)

457

753/2260

434

793/2380

419

690/2070

550

943/2830

475

753/2260

455

793/2380

436

690/2070

364

635/1905

RC2-1270AF(A2)

682

888/2665

648

935/2805

624

782/2345

820

1168/3505

708

888/2665

677

935/2805

649

782/2345

542

717/2150

RC2-1530AF(A1)

517

753/2260

491

793/2380

474

690/2070

623

943/2830

538

753/2260

514

793/2380

493

690/2070

411

635/1905

RC2-1530AF(A2)

770

888/2665

732

935/2805

705

782/2345

927

1168/3505

800

888/2665

766

935/2805

734

782/2345

613

717/2150

Refrigerant : R134a (Y-△)

38

Model

50Hz

60Hz Unit: Ampere

380V

400V

415V

208V

220V

230V

380V

440V

460V

480V

575V

MCC

LRA

MCC

LRA

MCC

LRA

MCC

LRA

MCC

LRA

MCC

LRA

MCC

LRA

MCC

LRA

MCC

LRA

MCC

LRA

MCC

LRA

(Y/△)

RC2-100BF

69

77/230

65

80/240

63

73/220

151

175/525

142

153/460

136

160/480

82

97/290

71

77/230

68

80/240

65

73/220

54

63/190

RC2-140BF

91

103/310

87

108/325

84

98/295

199

230/690

188

198/595

180

207/620

109

125/375

94

103/310

90

108/325

86

98/295

72

85/255

RC2-180BF

121

155/465

115

162/485

110

148/445

263

362/1085

249

310/930

238

323/970

144

192/575

124

155/465

119

162/485

114

148/445

95

127/380

RC2-200BF

128

155/465

122

162/485

117

148/445

282

362/1085

266

310/930

255

323/970

154

192/575

133

155/465

127

162/485

122

148/445

102

127/380

RC2-230BF

153

230/690

146

240/720

140

218/655

336

503/1510

318

460/1380

304

480/1440

184

270/810

159

230/690

152

240/720

146

218/655

122

182/545

RC2-260BF

171

230/690

163

240/720

157

218/655

376

503/1510

355

460/1380

340

480/1440

206

270/810

178

230/690

170

240/720

163

218/655

136

182/545

RC2-300BF

193

260/780

183

272/815

177

263/790

424

653/1960

401

520/1560

384

543/1630

232

343/1030

200

260/780

192

272/815

184

263/790

153

223/670

RC2-310BF

203

260/780

193

272/815

186

263/790

446

653/1960

421

520/1560

403

543/1630

244

343/1030

211

260/780

201

272/815

193

263/790

161

223/670

RC2-320BF

207

260/780

196

272/815

189

263/790

456

653/1960

431

520/1560

413

543/1630

250

343/1030

216

260/780

206

272/815

198

263/790

165

223/670

RC2-340BF

220

345/1035

209

360/1080

201

313/940

483

720/2160

457

662/1985

437

692/2075

264

407/1220

228

345/1035

218

360/1080

209

313/940

175

272/815

RC2-370BF

241

345/1035

229

360/1080

221

313/940

529

720/2160

500

662/1985

478

692/2075

289

407/1220

250

345/1035

239

360/1080

229

313/940

191

272/815

RC2-410BF

268

292/875

254

305/915

245

283/850

－－－－－

－

323

372/1115

279

292/875

267

305/915

256

283/850

214

250/750

RC2-470BF

310

407/1220

294

428/1285

284

387/1160

－－－－－

－

372

482/1445

321

407/1220

307

428/1285

294

387/1160

246

323/970

RC2-510BF

336

443/1330

319

463/1390

308

417/1250

－－－－－

－

406

535/1605

350

443/1330

335

463/1390

321

417/1250

268

382/1145

RC2-550BF

336

443/1330

319

463/1390

308

417/1250

－－－－－

－

406

535/1605

350

443/1330

335

463/1390

321

417/1250

268

382/1145

RC2-580BF

377

443/1330

358

463/1390

345

417/1250

－－－－－

－

454

535/1605

392

443/1330

375

463/1390

359

417/1250

300

382/1145

RC2-620BF

393

503/1510

374

527/1580

360

468/1405

－－－－－

－

473

627/1880

409

503/1510

391

527/1580

375

468/1405

313

422/1265

RC2-710BF

453

663/1990

430

693/2080

415

617/1850

－－－－－

－

545

823/2470

471

663/1990

450

693/2080

432

617/1850

360

555/1665

RC2-790BF

498

743/2230

473

777/2330

456

682/2045

－－－－－

－

598

958/2875

516

743/2230

494

777/2330

473

682/2045

395

600/800

RC2-830BF

534

785/2355

508

827/2480

489

863/2590

－－－－－

－

643

1067/3200

555

785/2355

531

827/2480

509

863/2590

425

658/1975

RC2-930BF

620

875/2625

589

915/2745

567

955/2865

－－－－－

－

746

1247/3740

644

875/2625

616

915/2745

591

955/2865

493

765/2295

RC2-1020BF(B1)

611

888/2665

580

935/2805

559

782/2345

735

1168/3505

635

888/2665

607

935/2805

582

782/2345

486

717/2150

RC2-1020BF(B2)

684

1085/3255

650

1142/3425

626

920/2760

823

1290/3870

710

1085/3255

680

1142/3425

651

920/2760

544

868/2605

RC2-1130BF(B1)

671

888/2665

637

935/2805

614

782/2345

806

1168/3505

697

888/2665

666

935/2805

638

782/2345

533

717/2150

RC2-1130BF(B2)

766

1085/3255

728

1142/3425

702

920/2760

922

1290/3870

796

1085/3255

762

1142/3425

730

920/2760

609

868/2605

RC2-1270BF(B1)

777

1085/3255

738

1142/3425

711

920/2760

934

1290/3870

807

1085/3255

772

1142/3425

740

920/2760

617

868/2605

RC2-1270BF(B2)

864

1338/4015

820

1160/3480

791

1213/3640

1038

1573/4720

896

1338/4015

857

1160/3480

821

1213/3640

686

1292/3875

RC2-1530BF(B1)

878

1085/3255

834

1142/3425

804

920/2760

1056

1290/3870

912

1085/3255

873

1142/3425

836

920/2760

698

868/2605

RC2-1530BF(B2)

996

1393/4180

946

1195/3585

912

1263/3790

1199

1633/4900

1035

1393/4180

990

1195/3585

949

1263/3790

792

957/2870

Refrigerant : R22, R407C, R404A (Y-△)

39

Refrigerant : R134a (PWS)

Model

50Hz

60Hz Unit: Ampere

380V

400V

415V

208V

220V

230V

380V

440V

460V

480V

575V

MCC

LRA

MCC

LRA

MCC

LRA

MCC

LRA

MCC

LRA

MCC

LRA

MCC

LRA

MCC

LRA

MCC

LRA

MCC

LRA

MCC

LRA

(△/△△)

RC2-100AF

53

79/165

50

84/175

49

74/155

115

170/355

109

156/325

104

166/345

63

86/190

55

79//165

52

84/175

50

74/155

42

62/130

RC2-140AF

73

108/225

70

113/235

67

101/210

160

238/495

151

211/440

145

221/460

88

125/160

76

108/225

72

110/230

69

101/210

58

79/165

RC2-180AF

97

155/310

92

163/325

89

145/290

213

338/675

202

305/610

193

320/640

117

185/370

101

155/310

96

163/325

92

145/290

77

118/235

RC2-200AF

103

155/310

98

163/325

94

145/290

226

338/675

214

305/610

204

320/640

124

185/370

107

155/310

102

163/325

98

148/295

82

118/235

RC2-230AF

124

303/505

117

285/475

113

267/445

270

645/1075

256

618/1030

244

573/955

148

360/600

128

303/505

122

285/475

117

267/445

98

237/395

RC2-260AF

138

303/505

131

285/475

126

267/445

302

645/1075

286

618/1030

273

573/955

165

360/600

143

303/505

137

285/475

131

267/445

109

237/395

RC2-300AF

155

350/565

147

329/530

142

322/520

340

822/1325

322

763/1230

308

704/1135

186

428/690

161

350/565

154

329/530

147

322/520

123

273/440

RC2-310AF

163

350/565

155

329/530

149

322/520

360

822/1325

341

763/1230

326

704/1135

197

428/690

170

350/565

163

329/530

156

322/520

130

276/445

RC2-320AF

167

350/565

158

329/530

153

322/520

366

822/1325

346

763/1230

331

704/1135

200

428/690

173

350/565

165

329/530

158

322/520

132

276/445

RC2-340AF

178

462/710

169

423/650

163

410/630

388

943/1450

367

868/1335

351

920/1415

213

546/840

184

462/710

176

423/650

168

410/630

140

358/550

RC2-370AF

194

462/710

185

423/650

178

410/630

426

943/1450

403

868/1335

386

920/1415

233

546/840

202

462/710

193

423/650

185

410/630

154

358/550

RC2-410AF

216

475/730

205

497/765

198

429/660

－－－－－

－

260

553/850

224

475/730

215

497/765

206

429/660

172

374/575

RC2-430AF

230

475/730

218

497/765

211

429/660

－－－－－

－

277

553/850

239

475/730

229

497/765

219

429/660

183

374/575

RC2-470AF

248

571/840

236

598/880

227

513/755

－－－－－

－

300

677/995

259

571/840

248

598/880

238

513/755

198

439/645

RC2-510AF

271

571/840

258

598/880

248

513/755

－－－－－

－

327

677/995

282

571/840

270

598/880

259

513/755

216

439/645

RC2-550AF

292

615/905

277

646/950

267

596/875

－－－－－

－

350

779/1145

302

615/905

289

646/950

277

595/875

231

476/700

RC2-580AF

304

615/905

288

646/950

278

595/875

－－－－－

－

365

779/1145

316

615/905

302

646/950

289

595/875

242

476/700

40

Model

50Hz

60Hz Unit: Ampere

380V

400V

415V

208V

220V

230V

380V

440V

460V

480V

575V

MCC

LRA

MCC

LRA

MCC

LRA

MCC

LRA

MCC

LRA

MCC

LRA

MCC

LRA

MCC

LRA

MCC

LRA

MCC

LRA

MCC

LRA

(△/△△)

RC2-100BF

69

108/225

65

113/235

63

101/210

151

238/495

142

211/440

136

221/460

82

125/260

71

108/225

68

113/235

65

101/210

54

82/170

RC2-140BF

91

155/310

87

163/325

84

145/290

199

338/675

188

305/610

180

320/640

109

185/370

94

155/310

90

163/325

86

145/290

72

118/235

RC2-180BF

121

225/425

115

239/450

110

207/390

263

480/905

249

444/840

238

466/880

144

254/480

124

225/425

119

239/450

114

207/390

95

172/325

RC2-200BF

128

225/425

122

239/450

117

207/390

282

480/905

266

445/840

255

466/880

154

254/480

133

225/425

127

239/450

122

207/390

102

172/325

RC2-230BF

153

350/565

146

329/530

140

322/520

336

822/1325

318

763/1230

304

704/1135

184

428/690

159

350/565

152

329/530

146

322/520

122

273/440

RC2-260BF

171

462/710

163

423/650

157

410/630

376

943/1450

355

868/1335

340

920/1415

206

546/840

178

462/710

170

423/650

163

410/630

136

358/550

RC2-300BF

193

507/780

183

497/765

177

481/740

424

1260/1940

401

1121/1725

384

1004/1545

232

614/945

200

507/780

192

497/765

184

481/740

153

403/620

RC2-310BF

203

507/780

193

497/765

186

481/740

446

1261/1940

421

1121/1725

403

1004/1545

244

614/945

211

507/780

201

497/765

193

481/740

161

403/620

RC2-320BF

207

507/780

196

497/765

189

481/740

456

1261/1940

431

1121/1725

413

1004/1545

250

614/945

216

507/780

206

497/765

198

481/740

165

403/620

RC2-340BF

220

663/1020

209

640/985

201

608/935

483

1628/2505

457

1342/2065

437

1495/2300

264

777/1195

228

663/1020

218

640/985

209

608/935

175

527/810

RC2-370BF

241

663/1020

229

640/985

221

608/935

529

1628/2505

500

1342/2065

478

1495/2300

289

777/1195

250

663/1020

239

640/985

229

608/935

191

527/810

RC2-410BF

268

615/905

254

646/950

245

595/875

－－－－－

－

323

779/1145

279

615/905

267

646/950

256

595/875

214

476/700

RC2-470BF

310

870/1280

294

915/1345

284

826/1215

－－－－－

－

372

1030/1515

321

870/1280

307

915/1345

294

826/1215

246

690/1015

RC2-510BF

336

952/1400

319

996/1465

308

891/1310

－－－－－

－

406

1142/1680

350

952/1400

335

996/1465

321

891/1310

268

816/1200

RC2-550BF

336

952/1400

319

996/1465

308

891/1310

－－－－－

－

406

1142/1680

350

952/1400

335

996/1465

321

891/1310

268

816/1200

RC2-580BF

377

952/1400

358

996/1465

345

891/1310

－－－－－

－

454

1142/1680

392

952/1400

375

996/1465

359

891/1310

300

816/1200

Refrigerant : R22, R407C, R404A (PWS)

41

3. Compressor handling and Installation

3.1 Compressor handling

After the compressor arrives at the warehouse, check the crate if it is kept in good condition and check all the compressor accessories and the shipping documents to see if there is any discrepancy. Be noted that the compressor is charged with 0.5~1 bar nitrogen, so release the inner pressure before loosing any parts on the compressor is very important.

Each HANBELL screw compressor is fully tested at the factory where every precaution and care is taken to make sure that the compressor is in perfect condition. When lifting the compressor, it is recommended to use a steel chain or steel cable as shown in the next page. The safety rope can also be used if it is proofed to resist the compressor weight.

Make sure that the chains, cables, ropes or other lifting equipment are properly positioned to avoid possible damage to the compressor or its accessories. Keep the compressor in horizontal position when lifting, and avoid the compressor from crashing or falling on the ground, hitting the wall or any other event that may damage it or its accessories.

3.2 Mounting the compressor

The installation of the compressor in the refrigeration system should be made accessible and make sure that the chiller base or site is far enough from the heat source to prevent heat radiation. The compressor should also be installed as close as possible to the electrical power supply for easier connection and must keep good ventilation and low humidity condition in the site. Make sure that the frame or supporter is strong enough to prevent

excessive vibration and noise while the compressor are running and must reserve enough space for compressors’

future overhauling work.

42

The compressor must be installed horizontally and in order to prevent excessive vibration transferred by the structure and piping of the chiller while in operation, the cushion or anti-vibration pad should be installed. The installation of the anti-vibration pad is shown in the figure below. The screws should only be tightened until slight deformation of the rubber pad is visible.

Attention on the compressor piping works The unsuitable piping works done to the compressor could cause abnormal vibration and noise which might damage the compressor. Take notice to the following points to prevent this situation:

1. Cleanliness of the system should be kept after welding the piping to avoid any swarf or debris contained inside

the system as it may cause serious damage to the compressor during operation.

2. In order to reduce the vibration on the piping tubes, it is recommended to use copper tube to be the suction and

discharge piping tubes. Copper tubes are better to minimize the vibration in the piping while the compressor is in operation. In case steel tubes are used in piping system, then the suitable welding works are very important to avoid any stress in the piping. This inner stress can cause harmonic vibration and noise which will reduce the compressor life. If a large-caliber copper tube is not easily accessible and a steel tube is used instead in suction port, Hanbell recommends using a copper tube in discharge port to minimize abnormal vibration and noise.

3. Remove the oxidized impurities, swarf or debris caused by welding in the piping tubes. If these foreign matters

are sunk into the compressor, the oil filter might be clogged resulting in the malfunctioning of lubrication system, bearings and capacity control system.

4. Suction and discharge flanges are forged steel and it can be welded directly with piping connectors. After

welding the flanges and pipes, it must be cooled down by ambient air. Do not use water to cool it down. Water quenching is prohibited.

43

Model : RC2-100F、RC2-140F、RC2-180F

1. External oil separator

7. Oil level switch

2. Oil cooler

8. Oil temperature sensor

3. Oil filter

9. Oil heater

4. Lubricant flow switch

10. Stop valve

5. Solenoid valve

11. Compressor

6. Sight glass

(1) Installation of lubricant circuit

To obtain high oil filtering efficiency, low pressure drop and non-interruption with lubricant supply system, the oil separator is built outside the compressor. The installation of lubricant circuit is a very important issue during the installation of the compressor. So before starting, make sure to read carefully all the instructions contain inside this manual, and make sure that each step is done in accordance with the specification.

Note：Please refer to the selection software for the capacity of liquid injection or oil cooler and following recommendation to install oil cooler, oil injection system and economizer.

44

Item

Oil

cooler

Oil injection into

compression chamber

Liquid injection into

compression chamber

Liquid injection for cooling

motor winding

Economizer

A

－

－－－

O

Ci

Oi

Ei

Li

1. Check valve

8. To principal return oil port Oi

2. External oil separator

9. To medium pressure (Economizer return port) Ei

3. Stop valve

10. Oil cooler

4. Oil filter

11. Muffler

5. Lubricant flow switch

12. Suction strainer

6. Oil solenoid valve

13. Expansion valve

7. Sight glass

14. Sub-cooler

(2) Lubricant circuit, Liquid injection system and economizer connection diagram

45

Item

Oil

cooler

Oil injection into

compression chamber

Liquid injection into

compression chamber

Liquid injection for cooling

motor winding

Economizer

B

O

O － O

O

Ci

Oi

Ei

Li

46

It

Oil

cooler

Oil injection into

compression chamber

Liquid injection into

compression chamber

Liquid injection for cooling

motor winding

Economizer

C

O

－

O

1. Check valve

11. Cooling compressor’s chamber port Ci

2. External oil separator

12. To medium pressure (economizer return port) Ei

3. Stop valve

13. Liquid injection to motor winding port Li

4. Oil cooler

14. Liquid injection solenoid valve

5. Oil filter

15. Liquid injection expansion valve

6. Oil flow switch

16. Liquid line filter

7. Oil solenoid valve

17. Muffler

8. Sight glass

18. Strainer

9. To principal oil return port Oi

19. Sub-cooler

10. Adjustable flow valve

20. Expansion valve

47

Ci

Oi

Ei

Li

1. Check valve

12. To cooling down compression chamber port Ci

2. External oil separator

13. Liquid line filter

3. Stop valve

14. Liquid injection to motor winding port Li

4. Oil cooler

15. Liquid injection solenoid valve

5. Oil filter

16. Liquid injection expansion valve

6. Lubricant flow switch

17. Liquid line filter

7. Oil solenoid valve

18. To medium pressure (economizer return port) Ei

8. Sight glass

19. Muffler

9. To principal return oil port

20. Strainer

10. Liquid injection solenoid valve

21. Sub-cooler

11. Liquid injection expansion valve

22. Expansion valve

Item

Oil

cooler

Oil injection into

compression chamber

Liquid injection into

compression chamber

Liquid injection for cooling

motor winding

Economizer

D

O

－

O

48

1. Check valve

10. To medium pressure (economizer return port) Ei

2. External oil separator

11. Muffler

3. Stop valve

12. Strainer

4. Oil cooler

13. Sub-cooler

5. Oil filter

14. Expansion valve

6. Lubricant flow switch

15. Liquid injection to motor winding port Li

7. Oil solenoid valve

16. Liquid injection to expansion valve

8. Sight glass

17. Liquid injection to solenoid valve

9. To principal return oil port Oi

18. Liquid line filter

Ci

Oi

Ei

Li

49

Model : RC2-200F ~ RC2-620F

1. External oil separator

7. Oil level switch

2. Oil cooler

8. Oil temperature sensor

3. Oil filter and cartridge

9. Oil heater

4. Lubricant flow switch

10. Manually adjustable flow valve

5. Oil solenoid valve

11. Compressor

6. Sight glass

(1) Installation of lubricant circuit

50

Item

Oil

cooler

Oil injection into

compression chamber

Liquid injection into

compression chamber

Liquid injection for cooling

motor winding

Economizer

A

－

－－－

O

1. Check valve

8. To principal return oil port Oi

2. External oil separator

9. To medium pressure (Economizer return port) Ei

3. Stop valve

10. Oil cooler

4. Oil filter

11. Muffler

5. Lubricant flow switch

12. Suction strainer

6. Oil solenoid valve

13. Expansion valve

7. Sight glass

14. Sub-cooler

(2) Lubricant circuit, Liquid injection system and economizer connection diagram

51

Item

Oil

cooler

Oil injection into

compression chamber

Liquid injection into

compression chamber

Liquid injection for cooling

motor winding

Economizer

B

O

O － O

O

1. Check valve

11. Cooling compressor’s chamber port Ci

2. External oil separator

12. To medium pressure (economizer return port) Ei

3. Stop valve

13. Liquid injection to motor winding port Li

4. Oil cooler

14. Liquid injection solenoid valve

5. Oil filter

15. Liquid injection expansion valve

6. Oil flow switch

16. Liquid line filter

7. Oil solenoid valve

17. Muffler

8. Sight glass

18. Strainer

9. To principal oil return port Oi

19. Sub-cooler

10. Adjustable flow valve

20. Expansion valve

52

Item

Oil cooler

Oil injection into

compression chamber

Liquid injection into

compression chamber

Liquid injection for cooling

motor winding

Economizer

C

O － O

O

1. Check valve

12. To cooling down compression chamber port Ci

2. External oil separator

13. Liquid line filter

3. Stop valve

14. Liquid injection to motor winding port Li

4. Oil cooler

15. Liquid injection solenoid valve

5. Oil filter

16. Liquid injection expansion valve

6. Lubricant flow switch

17. Liquid line filter

7. Oil solenoid valve

18. To medium pressure (economizer return port) Ei

8. Sight glass

19. Muffler

9. To principal return oil port

20. Strainer

10. Liquid injection solenoid valve

21. Sub-cooler

11. Liquid injection expansion valve

22. Expansion valve

53

Item

Oil

cooler

Oil injection into

compression chamber

Liquid injection into

compression chamber

Liquid injection for cooling

motor winding

Economizer

D

O

－

O

1. Check valve

10. To medium pressure (economizer return port) Ei

2. External oil separator

11. Muffler

3. Stop valve

12. Strainer

4. Oil cooler

13. Sub-cooler

5. Oil filter

14. Expansion valve

6. Lubricant flow switch

15. Liquid injection to motor winding port Li

7. Oil solenoid valve

16. Liquid injection to expansion valve

8. Sight glass

17. Liquid injection to solenoid valve

9. To principal return oil port Oi

18. Liquid line filter

54

1. External oil separator

7. Oil level switch

2. Oil cooler

8. Oil temperature sensor

3. Oil filter and cartridge

9. Oil heater

4. Lubricant flow switch

10. Manually adjustable flow valve

5. Oil solenoid valve

11. Compressor

6. Sight glass

Model : RC2-710F ~ RC2-930F

(1) Installation of lubricant circuit

55

(2) Lubricant circuit, Liquid injection system and economizer connection diagram

Item

Oil

cooler

Oil injection into

compression chamber

Liquid injection into

compression chamber

Liquid injection for cooling

motor winding

Economizer

A

－

－－－

O

1. Check valve

8. To principal return oil port Oi

2. External oil separator

9. To medium pressure (Economizer return port) Ei

3. Stop valve

10. Oil cooler

4. Oil filter

11. Muffler

5. Lubricant flow switch

12. Suction strainer

6. Oil solenoid valve

13. Expansion valve

7. Sight glass

14. Sub-cooler

56

Item

Oil

cooler

Oil injection into

compression chamber

Liquid injection into

compression chamber

Liquid injection for cooling

motor winding

Economizer

B

O

O － O

O

1. Check valve

11. Cooling compressor’s chamber port Ci

2. External oil separator

12. To medium pressure (economizer return port) Ei

3. Stop valve

13. Liquid injection to motor winding port Li

4. Oil cooler

14. Liquid injection solenoid valve

5. Oil filter

15. Liquid injection expansion valve

6. Oil flow switch

16. Liquid line filter

7. Oil solenoid valve

17. Muffler

8. Sight glass

18. Strainer

9. To principal oil return port Oi

19. Sub-cooler

10. Adjustable flow valve

20. Expansion valve

57

Item

Oil cooler

Oil injection into

compression chamber

Liquid injection into

compression chamber

Liquid injection for cooling

motor winding

Economizer

C

O － O

O

1. Check valve

12. To cooling down compression chamber port Ci

2. External oil separator

13. Liquid line filter

3. Stop valve

14. Liquid injection to motor winding port Li

4. Oil cooler

15. Liquid injection solenoid valve

5. Oil filter

16. Liquid injection expansion valve

6. Lubricant flow switch

17. Liquid line filter

7. Oil solenoid valve

18. To medium pressure (economizer return port) Ei

8. Sight glass

19. Muffler

9. To principal return oil port

20. Strainer

10. Liquid injection solenoid valve

21. Sub-cooler

11. Liquid injection expansion valve

22. Expansion valve

58

Item

Oil

cooler

Oil injection into

compression chamber

Liquid injection into

compression chamber

Liquid injection for cooling

motor winding

Economizer

D

O

－

O

1. Check valve

10. To medium pressure (economizer return port) Ei

2. External oil separator

11. Muffler

3. Stop valve

12. Strainer

4. Oil cooler

13. Sub-cooler

5. Oil filter

14. Expansion valve

6. Lubricant flow switch

15. Liquid injection to motor winding port Li

7. Oil solenoid valve

16. Liquid injection to expansion valve

8. Sight glass

17. Liquid injection to solenoid valve

9. To principal return oil port Oi

18. Liquid line filter

59

Model : RC2-1020F ~ RC2-1530F

1. External oil separator

7. Oil level switch

2. Oil cooler

8. Oil temperature sensor

3. Oil filter and cartridge

9. Oil heater

4. Lubricant flow switch

10. Manually adjustable flow valve

5. Oil solenoid valve

11. Compressor

6. Sight glass

(1) Installation of lubricant circuit

60

Item

Oil

cooler

Oil injection into

compression chamber

Liquid injection into

compression chamber

Liquid injection for cooling

motor winding

Economizer

A

－

－－－

O

1. Check valve

7. To principal return oil port Oi

2. External oil separator

8. To medium pressure (Economizer return port) Ei

3. Stop valve

9. Oil cooler

4. Oil filter

10. Muffler

5. Lubricant flow switch

11. Suction strainer

6. Oil solenoid valve

12. Expansion valve

7. Sight glass

13. Sub-cooler

(2) Lubricant circuit, Liquid injection system and economizer connection diagram

61

Item

Oil

cooler

Oil injection into

compression chamber

Liquid injection into

compression chamber

Liquid injection for cooling

motor winding

Economizer

B

O

O － O

O

1. Check valve

11. Cooling compressor’s chamber port Ci

2. External oil separator

12. To medium pressure (economizer return port) Ei

3. Stop valve

13. Liquid injection to motor winding port Li

4. Oil cooler

14. Liquid injection solenoid valve

5. Oil filter

15. Liquid injection expansion valve

6. Oil flow switch

16. Liquid line filter

7. Oil solenoid valve

17. Muffler

8. Sight glass

18. Strainer

9. To principal oil return port Oi

19. Sub-cooler

10. Adjustable flow valve

20. Expansion valve

62

Item

Oil cooler

Oil injection into

compression chamber

Liquid injection into

compression chamber

Liquid injection for cooling

motor winding

Economizer

C

O

－

O

1. Check valve

12. To cooling down compression chamber port Ci

2. External oil separator

13. Liquid line filter

3. Stop valve

14. Liquid injection to motor winding port Li

4. Oil cooler

15. Liquid injection solenoid valve

5. Oil filter

16. Liquid injection expansion valve

6. Lubricant flow switch

17. Liquid line filter

7. Oil solenoid valve

18. To medium pressure (economizer return port) Ei

8. Sight glass

19. Muffler

9. To principal return oil port

20. Strainer

10. Liquid injection solenoid valve

21. Sub-cooler

11. Liquid injection expansion valve

22. Expansion valve

63

Item

Oil

cooler

Oil injection into

compression chamber

Liquid injection into

compression chamber

Liquid injection for cooling

motor winding

Economizer

D

O

－

O

1. Check valve

10. To medium pressure (economizer return port) Ei

2. External oil separator

11. Muffler

3. Stop valve

12. Strainer

4. Oil cooler

13. Sub-cooler

5. Oil filter

14. Expansion valve

6. Lubricant flow switch

15. Liquid injection to motor winding port Li

7. Oil solenoid valve

16. Liquid injection to expansion valve

8. Sight glass

17. Liquid injection to solenoid valve

9. To principal return oil port Oi

18. Liquid line filter

64

smm /

2

4. Lubricant

The main functions of the lubrication oil in the screw compressor are lubrication, internal sealing, cooling, silencing and capacity control. The positive oil pressure in the cylinder pushes the piston and the slide valve which are connected by a piston rod to move forward and backward in the compression chamber. The design with positive pressure differential lubrication system in the RC2-F series is available to omit an extra oil pump in most of applications. However, in some special applications (Pd-Ps<4 bar), it is still necessary to install an extra oil pump to the compressor for safety.

Bearings used in RC2-F compressor require a small but steady quantity of oil for lubrication; the oil injection into the compression chamber creates an oil sealing film between screw rotors which secures the volumetric efficiency and absorbs a part of compression heat. In order to separate the oil from the refrigerant or gas, an oil separator is required to ensure the least amount of oil carried into system. High oil carryover to the system will reduce the heat exchanger performance or simply block the pipe. For synthetic oil, it has high tendency to react with water, acid and metal particle and generates slurry. Compressor operates without sufficient oil supply will lead to high discharge temperature, bearing failure or screw rotor jam. Pay more attention to the oil temperature, which has a very significant factor to the compressor’s bearing life. High oil temperature will reduce the oil viscosity and cause the poor lubrication and heat absorption in the compressor as well. Too much refrigerant dissolved in the oil will also reduce the oil viscosity which might become the root cause of bearing failure in the future. The oil viscosity is

recommended at 10 condition(low evaporating temperature/high condensing temperature), an extra oil cooler will be needed.

High viscosity oil is recommended to be applied in the strict working condition (heat pump/ air-cooled). User should take notice on the oil level in the oil separator because if the oil return from the evaporator is less than the oil carryover to the system from oil separator, the oil separator will loss oil gradually and comes to the system stop in the end. Therefore, when users find oil return problem in the system, a fine oil separator is highly recommended to be installed between the oil separator discharge port and condenser. Flooded chiller or DX type chiller with long distance piping is also recommended to be installed with a fine oil separator to reduce the oil carryover into system.

Low viscosity oil is recommended to be applied in the low evaporating temperature (SST< -20℃). Selecting an oil which can maintain at least 10 cSt for its viscosity under operating. Miscibility of oil with refrigerant is usually an important index for the selection of oil. The oil with good miscibility with refrigerant should have low miscibility

at any temperature. If the compressor operates under the critical working

value at high working temperature and high miscibility value at low working temperature to ensure the oil viscosity not declined too much at different working condition.

4.1 Pre-cautions in changing of oil

The following points should be noted to ensure good oil characteristics:

1. Use only qualified oil and do not mix different brand of oil together. Different kinds of refrigerant should match different kinds of oil, note that some synthetic oil are incompatible with mineral oil.

65

2. For the chiller system using synthetic oil, make sure not to expose the oil to atmosphere for a long time. It is necessary to vacuum the system completely when installing the compressor.

3. If the customer wants to use special type of oil, confirm with the compressor manufacturer is necessary.

4. In order to vaporize the water in the system, it is suggested to heat the system and vacuum the system as long as possible after changing of new oil in the system

5. If the system encounters a compressor motor burned, the acidity debris will remain inside the system, so follow the procedures mentioned above to overhaul the system is necessary. It is also important to check the oil acidity after 72 hours operation and change it again until the oil acidity is within the standard value.

4.2 Changing of oil

Lubrication oil is one of the most important factor to the compressor system in order to maintain the good operation, lubrication, cooling, sealing and capacity control. The following points should be taken into consideration to ensure good oil management.

1. Oil contamination caused by debris or swarf might clog the oil filter and cause compressor bearing failure. In order to prevent the clogging of oil filter, an optional pressure differential switch is recommended to be installed. The switch will trip when the oil pressure differential reaches the setting point. The compressor will shut down automatically to prevent the bearing away from getting damage by lacking of lubrication.

2. Acidified system due to the moisture will cause the reduction of bearing and motor’s life. Check the oil acidity periodically and change the oil if the oil acidity value is lower than PH6. Change the deteriorated dryer periodically if possible to keep the system dryness. Refer to the oil changing procedure especially after overhauling the system due to motor burned out, check the oil quality monthly or periodically and change the oil if the oil is out of standard specs. It is necessary to take care of the oil quality and system cleanliness and dryness periodically.

3. Compressor running at high discharge temperature for a long time will cause the change of oil property and short the bearing life. If the compressor’s discharge temperature keeps at high stage (approaching the critical point) then the oil will spoil gradually in a short time. Check the oil characteristic every 2 months if possible. It is necessary to change the oil if the characteristics of the oil are out of the specification. In case if the oil characteristics cannot be checked periodically, change the oil after 1 years of operation. For the first operation of the compressor, it is recommended to check oil and clean oil filter after running 200 hours. Because the piping debris or swarf could be accumulated inside the system after continuous operation, it is necessary to check the oil after 2,000 hours or after 6 months of running. Good oil management can ensure the system operating under good condition.

66

SPECIFICATION

UNITS

HBR -B10

HBR -A02

HBR -A04

HBR -B09

HBR -B02

HBR -B01

COLOR, ASTM

1.5

L1.0

  

SPECIFIC GRAVITY

0.883

0.914

0.925

0.95

1.01

1.05

VISCOSITY

40℃

mm2/s (cSt)

56.0

54.5

96.5

175

168

298

100℃

7.0

6.07

8.12

16.5

20.2

32.0

FLASH POINT

℃

220

188

198

265

290

271

POUR POINT

℃

-40

-35

-25

-30

-43

-35

T.A.N

mg KOH/g

0.01

0.00

0.01

  

COPPER STRIP

100℃/3hr

1a

  

MOISTURE

ppm

15

20

  

FLOC POINT

℃

-75

-45

-35

  

DIELETRIC STRENGTH

(2.5mm)

kV

75

50

46.6



SPECIFICATION

UNITS

HBR -B05

HBR -B08

HBR -B09

HBR -B04

COLOR, ASTM

  



SPECIFIC GRAVITY

0.945

0.94

0.95

VISCOSITY

40℃

mm2/s (cSt)

64

131

175

215.9

100℃

8.9

14.53

16.5

20.8

FLASH POINT

℃

266

254

265

271

POUR POINT

℃

-43

-36.5

-30

-25

T.A.N

mg KOH/g

  



COPPER STRIP

100℃/3hr

  



MOISTURE

ppm

  



FLOC POINT

℃

  



DIELETRIC STRENGTH

2.5mm

kV



46.6



4.3 Lubricants table

Applicable oil types (R22)

Applicable oil types (R134a, R404A, R407C, R507)

67

5. Electrical data and design

Full load Amper

Starting Current

Time

I

Y- shift time 0.25~0.5msec

5.1 Motor design

HANBELL RC2-F series screw compressors are fitted with Y-Δ motor as standard. But Δ/ΔΔ motor (Part Winding Starting – PWS) is also available for model RC2-100F ~ RC2-580F. i.e.

● RC2-100F ~ RC2-580F both Y-Δ motor and Δ/ΔΔ motor are available.

● RC2-620F ~ RC2-1530F only Y-Δ motor are available.

Y-Δ Starting Y-Δ motor connects motor coil by Y connection during starting therefore reducing voltage on coils to 1/√3 of input voltage and reconnects motor coil by △ connection after starting. By doing so, we can decrease starting current thorough voltage drop, i.e., so-called voltage-drop starting.

In Y connection, MCM、MCS are inductive while motor leads Z,X,Y are tied together as a neutral connecting as Y fashion. A few seconds later ( 3 ~ 5 sec is recommended), MCM, MCS become deductive. Around 0.25 sec later, MCM,MCD are inductive，it turns out △ run connection. Y-Δ motor connection method is shown in the following motor wiring diagram:

Please pay attention : After Y start，MCM & MCS are deductive for 0.25msec and then MCM & MCD are inductive for Δ run. Within as transient as 0.25msec, pseudo short circuit might occur due to inappropriate action of contactors, causing trip of compressors. When it occurs, we recommend usage of adjustable Y-Δ dedicated Timer or slightly lengthen span of time for MCM, MCS deduction - MCM,MCD re-induction from 0.25 msec to 0.5 msec max directly in micro controller or PLC program. Please refer to Y-Δ shift time diagram for details. Because motor is not powered during Y-Δ shift, shorter Y-Δ shift span is suggested to prevent second start due to decreased rotation speed. However, if Y-Δ shift span is too short, aforementioned pseudo short circuit might occur.

68

Full load Amper

Starting Current

Time

I

(AMP)

sec

PW2:7,8,9

B:Pt100Ω / Pt1000Ω

(Option)

PW1:1,2,3

93

A:PTC

2 8

Earth Bolt

71

A

B

Y-Δ Starting features

1. Starting current in Y connection is 1/3 of lock rotor ampere.

2. Starting torque in Y connection is 1/3 of lock rotor torque.

3. Acceleration of motor rotor becomes smaller at full-load starting,，therefore compressors require starting at

partial load.

Δ/ΔΔ (PW) starting RC2-100F ~ RC2-580F are available to be fitted with PWS motor for customer’s application as an optional accessory。 Please refer to the follow diagram for the wiring of PWS motor.

The selection of both of the motor contactors (k1 / k2) is each for approx. 60% of the max. running current. The recommended time delay of the switching relay k1 is to be set at 0.5 second and not more than 1 second.

69

PWS Starting features

A:PTC

B:Pt100Ω / Pt1000Ω

Earth Bolt

W

V

U

(Option)

Y

X

Z

A

B

Protection device

Set point

Remark

Motor wiring temperature protector (PTC sensor)

Cutout 120℃, Cut in 75℃

Standard

Discharge temperature protector (PTC sensor )

Cutout 110℃, Cut in 60℃

Standard

Phase reversal protector (INT69 HBY)

Optional

Phase failure protector (INT69 HBY)

Optional

Oil level switch

Optional

Oil filter pressure differential switch

Cutout 2.5Kg/cm2G

Optional

Oil flow switch

Optional

PT100Ω or PT1000Ω for liquid injection to motor chamber.

Solenoid valve open 85℃ , Solenoid valve close 75℃

Optional

1. The starting current is around 40% ~ 70% of full-winding Locked Rotor Current. It depends on the design and

motor size.

2. Low starting torque. Direct On Line start

Besides Y-Δ and PWS start, if there were any inquiry of Direct on line start、Soft start、Inverter start or Series reactance reduced voltage start, please contact Hanbell for further.

5.2 Compressor protection devices

The table below shows the list of protection devices which are essential to protect the compressor and operate safely. Follow the protection devices listed in the below table to ensure the compressor running under normal condition.

The motor thermister and discharge thermister are the temperature sensors with quick response while the temperature approach to their set point; the thermisters must be connected in series to a controller (INT69HBY) in terminal box as a guardian to protect the compressor. Alarm lamp for this protector is required to be embedded on the control panel as indicator. Any intention to short the controller for startup the compressor is prohibited

especially in Hanbell. It is beyond Hanbell’s responsibility to keep the warrantee of compressor if there is any

above action found.

5.3 Power supply

70

(maximum voltage deviation from average voltage)

(average voltage)

1. Limitation of supply power

a. Voltage limitation

Long term running : rated voltage ±5% Instant running : rated voltage ±10%

b. Frequency : Rated frequency ±2%

Note that in the region where the electricity power is unstable, install an additional Hi-Low voltage protector with ± 5% under and over tolerance outside the normal voltage to ensure the safe running of the compressor.

2. Unbalanced voltages :

Unbalanced voltages usually occur because of variations in the load. When the load on one or more of the phases is different than the other(s), unbalanced voltages will appear. This can be due to different impedances, or type and value of loading on each phase. Unbalanced voltages can cause serious problems, particularly to motor.

NEMA defines voltage unbalance as follows :

Percent voltage unbalance = 100 x

NEMA states that polyphase motors shall operate successfully under running conditions at rated load when voltage unbalance at the motor terminals does not exceed 1%. Further, operation of a motor with above a 5% unbalance condition is not recommended, and will probably result in damage to the motor. Unbalanced voltages at motor terminals cause phase current unbalance ranging from 6 to 10 times the percent voltage unbalance for a fully loaded motor. This causes motor over current resulting in excessive heat that shortens motor life, and hence, eventual motor burnout. If the voltage unbalance is great enough, the reduced torque capability might not be adequate for the application and the motor will not attain reated speed. Some of the more common causes of unbalance voltages are :

 Unbalanced incoming utility supply  Unequal transformer tap settings  Large single phase distribution transformer on the system.  Open phase on the primary of a 3 phase transformer on the distribution system  Faults or grounds in the power transformer  Open delta connected transformer banks  A blow fuse on 3 phase bank of power factor improvement capacitors  Unequal impedance in conductors of power supply wiring  Unbalanced distribution of single phase loads such as lighting  Heavy reactive single phase loads such as welders

An 3 phase unbalanced voltages protector is upon request as optional accessory. Please contact with Hanbell

71

2 8

(Option)

A:PTC

B:Pt100Ω / Pt1000Ω

PW2:7,8,9

PW1:1,2,3

3 9

Earth Bolt

1 7

B

A

Grounding Terminal

for more detail.

5.4 Selection of magnetic contactor

Please refer to AC3 specification, compressor selection program and design conditions of system to choose suitable contactor.

5.5 Grounding

There’s a grounding terminal inside cable box. Please accurately connect it to grounding of control panel for the system.

Suggestion: a. The regular setting of electric leak protection should be greater than 50mA; for a humid location, 25mA is

better. b. Grounding voltage of casing should be no greater than 50V; for a humid location, the limit is 25V. c. Grounding resistance should be no greater than 500 Ohm. d. Air cut board (ACB) is regularly equipped with electric leak protection. Please refer to related settings for its

normal action. e. If electric leak protection is active, please check if insulation of equipments is normal and if its wiring and

setting are correct. Please make sure nothing is wrong before turning on the power. If there are any questions,

please contact the supplier of equipments.

72

Model

RC2 - F

&

Accessory

100

140

180

200

230

260

300

310

320

340

370

410

430

470

510

550

580

620

710

790

830

930

1020

1130

1270

1530

Steps or Step-less capacity control system

● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● Compatible Steps& step-less capacity control system

△ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △

△

Discharge check valve

● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● Suction & discharge connection bushings

● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ●

●

Suction & discharge stop valves

△ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △

△

PTC temp. sensor

● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ●

●

INT69HBY controller

● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ●

●

IP54 cable box

● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ●

●

Oil drain valve

△ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △

△

Liquid injection system (solenoid valve + expansion valve)

△ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △

△

Liquid injection system (solenoid valve + stop valve)

△ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △

△

Horizontal check valve

△ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △

△

External oil separator

△ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △

△

External oil filter

△ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △

△

Oil flow switch

△ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △

△

Economizer

△ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △

△

Economizer connection stop valve

△ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △

△

Oil cooler

△ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △

△

Oil pump

△ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △

△

Oil filter pressure differential switch connector

△ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △

△

Safety valve

△ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △

△

Explosion proof accessories

△ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △

△

Mounting pad

△ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △

△

Lubricant oil

△ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △

△

Micro controller

△ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △

△

Sound jacket

△ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △

△

Temperature sensors

△ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △

△

Pt100 or Pt1000 – for motor coil temp. monitoring

6. Compressors accessories

6.1 Compressors standard and optional accessories

●：Standard, △ ：Optional, Χ：No need

Note : The accessory chart is just for customers’ reference only. Actual specification and accessories enclosed

might vary with different quotation & agreement. If any optional accessory is required and out of the above mentioned standard accessory, please contact with Hanbell for detail specification and price of accessory.

73

6.2 Description of accessories

Model

Standard Discharge Flange Bushing

Standard Suction Flange Bushing

Steel pipe

Copper pipe

Steel pipe

Copper pipe

RC2-100F/140F

1 1/2

1 5/8”

2

2 1/8”

RC2-180F

1 1/2

1 5/8”

2 

2 1/8”

RC2-200F

2

2 1/8”

2 1/2

2 5/8”

RC2-230F/260F RC2-300F/310F

RC2-320F

2 1/2

2 5/8”

3

3 1/8”

RC2-340F/370F

2 1/2

2 5/8”

4

4 1/8”

RC2-410F/430F RC2-470F/510F RC2-550F/580F

3

3 1/8”

4

4 1/8”

620F/RC2-710F 790F/RC2-830F

930F

4

4 1/8”

5

5 1/8”

RC2-1020F/1130F

4

4 1/8”

6

N/A

RC2-1270F/1530F

5

5 1/8”

8

N/A

a. Suction and discharge connection bushings

74

Model

Discharge / Suction port

Materials and Sizes of pipes

Dimension of flanges bushing

A B C

D

E

RC2-100F RC2-140F

Discharge

Copper

1 5/8"

50

90

30

41.6

55

2 1/8"

54.3

65

2 5/8"

67

74

Steel

1 1/2"

49.3

60

2"

61.3

74

Suction Copper

1 5/8"

50

90

30

41.6

55

2 1/8"

54.3

65

2 5/8"

67

74

Steel

1 1/2"

49.3

60

2"

61.3

74

RC2-180F RC2-200F

Discharge

Copper

1 5/8"

50

90

30

41.6

55

2 1/8"

54.3

65

2 5/8"

67

74

Steel

1 1/2"

49.3

60

2"

61.3

74

Suction Copper

2 1/8"

60

110

35

54.3

65

2 5/8"

67

77

3 1/8"

79.8

90

Steel

2 1/2"

77.2

90

RC2-230F RC2-260F RC2-300F RC2-310F RC2-320F

Discharge

Copper

2 1/8"

60

110

35

54.3

65

2 5/8"

67

77

3 1/8"

79.8

90

Steel

2 1/2"

77.2

90

Suction Copper

2 1/8'

66

120

45

54.3

65

2 5/8"

67

77

3 1/8"

79.8

90

Steel

2 1/2"

77.2

92

3"

90.2

103

RC2-340F RC2-370F

Discharge

Copper

2 1/8"

60

110

35

54.3

65

2 5/8"

67

77

3 1/8"

79.8

90

Steel

2 1/2"

77.2

90

Suction Copper

3 1/8"

76

145

50

79.8

87

3 5/8"

92.4

103

4 1/8"

105.1

116

Steel

3"

90.2

105

3 1/2"

102.8

117

4"

115.6

128

RC2-410F RC2-430F RC2-470F RC2-510F RC2-550F RC2-580F

Discharge

Copper

2 1/8"

66

120

45

54.3

65

2 5/8"

67

77

3 1/8"

79.8

90

Steel

2 1/2"

77.2

92

3"

90.2

103

Suction Copper

3 1/8"

7

6

145

50

79.8

90

3 5/8"

92.4

103

4 1/8"

105.1

116

Steel

3"

90.2

105

3 1/2"

102.8

117

4"

115.6

128

RC2-620F RC2-710F RC2-790F RC2-830F RC2-930F

Discharge

Copper

3 1/8"

7

6

145

50

79.8

90

3 5/8"

92.4

103

4 1/8”

105.1

116

Steel

3

90.2

105

3 1/2"

102.8

117

4"

115.6

128

Suction Copper

4 1/8"

80

174

35

105.1

121.2

5 1/8"

75

130.5

146.5

Steel

5"

75

141.3

154

RC2-1020F RC2-1130F

Discharge

Copper

4 1/8”

80

174

35

105.1

121.2

5 1/8”

75

130.5

146.5

Steel

5”

80

141.3

154

Suction

Steel

6”

75

215

40

166.7

196

RC2-1270F RC2-1530F

Discharge

Steel

6”

75

215

40

166.7

196

Suction

Steel

8”

75

260

40

218

241

Specification and dimension of optional flange bushing

75

b. Suction and discharge stop valves

Model

Stop Valve Size

Model

Stop Valve Size

Discharge

Suction

Discharge

Suction

RC2-100F/140F

2

RC2-410F/430F RC2-470F/510F RC2-550F/580F

3

4

FC2-180F/200F

2

2 1/2

RC2-620F/710F RC2-790F/830F

RC2-930F

3

4

RC2-230F/260F RC2-300F/310F

RC2-320F

2 1/2

3

RC2-1020F RC2-1130F

4

6

RC2-340F/370F

2 1/2

4

RC2-1270F RC2-1530F

6

8

Dia.

Dimensions unit: mm

A B C D E F G H I J K L M N P

1 1/2

60

75

36

59

76 6 5

106

75

256

115

18

105

M16x2

105

2”

70

90

60

69

91 6 5

122

86

280

128

18

120

M16x2

120

2 1/2

90

110

67

89

111 6 5

137

95

307

153

18

140

M16x2

140

3

100

120

80

99

121 6 5

154

117

398

177

22

160

M20x2.5

160

4

125

145

105

124

146 6 5

171

130

445

201

22

185

M20x2.5

185

5

30

126

194

248

230

214

338

474

161

--

For maintenance and service of compressor, it is recommended to install the suction and discharge stop valves. Please refer to following detail of Hanbell stop valves

Dimensions for 1 1/2”~4” stop valves Dimensions for 5” stop valve

Note: Please contact Hanbell for specification of 6” and 8” stop valves.

76

Maximum working pressure

Hydrostatic pressure test

Refrigerant

Temperature range

28 kg / cm² G

42 kg / cm² G

HFC, HCFC

40˚C~150˚C

Suction check valve Discharge check valve

* Specification of stop valve

c. Suction and discharge check valve

Hanbell designs a complete series of suction and discharge check valves for customer’s application. Suction

check valves are widely used in the refrigeration system (SST< -10℃) or system which has big pressure differential between suction and discharge side. With the help of suction check valve, it can help to reduce the reversal run time after compressors stop to protect bearings. For a parallel system, a discharge check valve on the oil separator outlet is necessary. With an additional suction check valve installed on each compressor, it can help to separate the suction pressure from discharge pressure if a common oil separator is used in the system. Besides, suction check valve can prevent the unwanted refrigerant enters the suction port of non working compressor because of head of height (potential energy).

The inner structure of suction check valve is opposite to the inner structure of discharge check valve which you can see from the figures below. Users can contact Hanbell representative to get more information on the suction and discharge check valves.

d. Oil temperature sensor

Oil temperature sensor is used to detect the oil temperature and control the oil heater. When oil temperature

reaches the setting value, oil heater will be off to save the energy. The oil heater and temperature sensor operate with each other regardless whether the compressor is operating or not. Hanbell recommends keeping oil temperature above 30 ℃ for a safe and easy start-up.

e. Oil level switch Hanbell recommends installing an oil level switch on the external oil separator to ensure oil supply to the compressor. To prevent from oil level switch trip caused by oil foaming or surging in the sump, a time delay around 15 ~ 30 seconds is recommended before shut down the compressor.

77

Max. contact capacity= 50VA DC/AC

*Flow Rate: max 50 (l/m)

*Weight:1.4KG/Set

*Working Pressure: 40 bar

(the weight is not including element)

*Material: Aluminum alloy

*Operating Temp.: from -25℃to 110℃

*Seal: VITON

Compressor Model

Material Code

Inlet Size

Outlet Size

RC2-100/140/180/200 230/260/300/310/320/340 /410/430/470/510

3130-3240AA

5/8”

RC2-550/580/620/710/790 /830/930/1020/1130/1270/ 1530

3131-3240AA

3/4”

3130-3240AA

3131-3240AA

Initial contact resistance=150mΩ(Max.) Switching voltage = 600V DC Max. voltage = 300V DC/AC Max. current = 0.5A DC/AC

Oil level switch on an external oil separator

f. External oil filter External oil filter is optional accessory of external oil separator. It is suggested to install external oil filter in oil return line before suction port of compressor for safe running of compressor.

External oil filter

78

G

Type

PN

bar

Qmax. Recom.

l/min

switch value l/min

selectable range for

fixed switch

L

mm

H

mm

SW mm

X

mm

Weight

kg

bronze

G 3/8

FF-010GR010

200

15

0.4-10

68

79

29

12

0.6

G 1/2

FF-015GR012

200

20

0.4-12

68

79

29

13

0.6

G 3/4

FF-020GR025

25

40

0.6-25

73

79

32

11

0.7

G 1

FF-025GR040

25

60

1.5-40

87

90

41

14

1

(1)Tolerance: ±0.3l/min (2)Media temperature: max 110 ℃ (3)Average pressure loss: 0.4 bar at Qmax (4)Hysteresis:depending on switch value minimum 0.4 l/min Note: Switch value is indicated for horizontally decreasing flow

g. Oil flow switch Oil flow switch is widely used on external oil circuit. With the installation of oil flow switch, user can ensure sufficient flow rate of lubricating oil. Specifications are shown below. Specification:

Outline drawing h. INT69 control module and PTC temperature sensor In order to protect compressor, each RC2 series compressor has been installed three PTC temperature sensors inside motor coil and another one at the discharge side of compressor. These sensors are connected to an INT69 control module to monitor the motor coil temperature and discharge temperature as well. If the temperature in one of the positions monitored exceeds the nominal response temperature of the respective PTC thermistor, the sensor resistance increases and the INT69 control module output relay trips. The module resets when the temperature drops below the response temperature by approx. 5K. The output replay provides a potential-free change-over contact and is energized as long as the nominal response temperature is not exceeded.

Technical data of INT69

● Supply voltage 220V ~ 240V ±10%, 3VA , 40 ~60 Hz 115V -15% ~ +10%, 3VA , 50/60 Hz

● Ambient temperature

-30 ~ +70 ℃

● Relay output Switch voltage AC 250V Continuous current max. 6A

79

i. INT69Y motor protector

V/2

W/3

U/1

X/8

Y/9

Z/7

A

B

B Set:PT100Ω/PT100Ω(Optional)

A Set:PTC

In addition to the temperature monitoring function of INT69, Hanbell also supplies INT69Y motor protector with the monitoring functions of phase loss, phase sequence, motor temperature, discharge temperature as an optional accessory.

INT69Y connection diagram PT100Ω/PT1000Ωconnection diagram

Note：Electric plate with PT100Ω/PT1000Ω connection (B) shown in above diagram is optional accessory. Only when customer chooses PT100Ω/PT1000Ω function, Hanbell will supply this type of electric plate. Phase loss, phase sequence: Phase sequence and phase loss monitoring functions are active during a 5s window 1s after compressor start ( power on L1-L2-L3). If one of these parameter is incorrect, the relay locks out ( contacts M1-M2 are open). The lockout can be cancelled by mains reset of approx. 5s (disconnect L-N)

Note: To make sure phase loss and phase sequence protection function well, please connect L1, L2 and L3 to motor side as figure shown above.

Motor temperature: Motor temperature is constantly measured by a thermistor (PTC) loop connected on S1-S2. If any thermistor exceeds its response temperature, its resistance increases above trip level and the output relay trips ( contacts M1-M2 are open ). After cooling down below the response temperature, a 5min time delay is activated. After the delay has elapsed, the relay pulls in again (The contact M1-M2 is closed). The time delay can be cancelled by mains reset of approx. 5s (Disconnect L-N)

Note: When choosing aforementioned INT69 or INT69Y motor protection, Hanbell strongly recommends adding

“Shutdown Lock-out” function and restarting by manual reset after abnormal trip and troubleshooting to prevent too frequent cycle of “abnormal trip → auto reset → restart.”

Technical data of INT69Y

● Supply voltage ● Relay output 115V ~ 240V -15% ~ +10% 3VA , 50/60 Hz Switch voltage AC 240V, max. 2.5A, C300

80

V/2

W/3

U/1

X/8

Y/9

Z/7

A

B

V/2

W/3

U/1

X/8

Y/9

Z/7

A

B

B Set:Pt100Ω/Pt1000Ω(Optional)

A Set:PTC

● Ambient temperature ● Phase sensor

-30 ~ +60 ℃ 3 AC, 50/60Hz, 200 ~ 575 V ± 10%

j. INT69HBY motor protector Hanbell develops an optional accessory, INT69HBY motor protector, of which major functions are the same with those of INT69Y: monitoring of phase loss, phase sequence, motor temperature, discharge temperature but with manually reset function.

INT69HBY & PTC temperature sensors connection diagram

Other major functional descriptions are as follow:

1. When supply voltage is applied, the output relay pulls in after an initialization period of approx. 3 seconds, provided all thermistors lie below their rated response temperature.

2. 1 to 9 PTC thermistors with varied rated response temperatures can be connected in series to the input terminals.

3. If any thermistor resistance increases above trip level the relay drops out. This failure results in a lockout. (5 minutes delay for 1st PTC failure, 60 minutes delay for 2nd failure, lockout for 3rd failure.)

4. If a rapid temperature increase is detected (locked rotor condition), the output relay drops out. This failure results in a lockout.

5. The phase monitoring function is active 1 second after motor start during a 10 second window. Incorrect phase sequence results in lockout trip. Phase loss results in lockout trip.

6. Lockout and time delay can be cancelled by mains reset of approx. 5 seconds.

7. To avoid nuisance tripping due to reverse running after shutdown (pressure equalization), the phase monitoring function is only re-enabled approx. 20 seconds after motor stop.

8. A twin LED (red / green) provides operational information.

9. The relay is fed out as a N/O dry contact, which is closed under good conditions.

10. Sensor and supply circuits are galvanic isolated.

11.The motor protector is not suitable for use with frequency converters.

Technical data of INT69HBY

●Supply voltage ●Relay output

81

AC 50/60 Hz 115/120V-15 …+10% 3VA max. AC 240V, max. 2.5A, C300

indicates PTC sensor exceeds its response temperature

V/2

W/3

U/1

X/8

Y/9

Z/7

A

B

B Set:Pt100Ω/Pt1000Ω(Option)

A Set:PTC

AC 50/60 Hz 230/240V-15…+10% 3VA min. ＞ 24V AC/DC, >20 mA

●Ambient temperature ●Phase monitor

-30 … +70 ℃ 3 AC, 50/60Hz, 200 ~ 575 V ± 10%

k. Temperature sensors Pt100Ω or Pt1000Ω

PT100 or PT1000 is a kind of “built-in” type temperature sensor installed in the motor coil. Please connect it to microcontroller of system and use for motor temperature display, setpoint of alarm & trip (lockout), and precisely controlling liquid injection solenoid valve in order to properly protect Hanbell compressor.

LA-1090,1280 & 1520 compressor adopts independent liquid injection cooling system to motor. Other models utilize suction return gas to cool motor coil. To effectively detect temperature of motor coil and adequately adjust volume of liquid injection by measured temperature, Hanbell specially mounts PT100 or PT1000 sensor on motor coil as an standard accessory for LA-1090,1280 & 1520 and optional accessory for others.

82

Model

Type

Oil Volume (Liter)

Range of application based on

Displacement (m3/hr)

(Recommended)

Shell

Diameter

High level

Low level

OS40

Vertical

17

9

205

14”

OS50

Vertical

22

12

206~270

16”

OS65

Vertical

31

18

271~440

18”

OS80

Horizontal

33

20

441~705

20”

OS100

Horizontal

40

27

706~1120

20”

OS125

Horizontal

50

30

1121~1310

24”

OS150

Horizontal

60

36

1311~1835

24”

 Recommended max. meas. Current for heat

coefficient <0.1K - DC 1 ~ 3 mA

 Heating coefficient - 10mΩ/K  Sensor resistance at 0℃ - 100Ω±0.12Ω

 Change of resistance 0 ~ 100℃ - 0.385Ω/K  Insulation test voltage U is – AC 1.5kV

 Recommended max. meas. Current for heat

coefficient < 0.1K – DC0.2 ~ 2mA

 Sensor resistance at 0℃ - 1000Ω±1.20Ω  Change of resistance 0 ~ 100℃ - 3.85Ω /K  Insulation test voltage U is – AC 1.5kV

Specification : PT100 sensor

PT1000 sensor

l. External oil separator Hanbell specially designs a complete series of external oil separators – OS series with characteristics of high

filtration efficiency and low pressure drop. The following table shows details of OS series: Note : It is recommended to install a buffer before the external oil separator to avoid noise and vibration which

caused by resonance.

1. Technical data：

83

2. Accessories：

No.

Description

OS40

OS50

OS65

OS80

OS100

OS125

OS150 1 Refrigerant inlet

1 1/2”

2”

2 1/2”

3”

4”

5”

6” 2 Refrigerant outlet

1 1/2”

2”

2 1/2”

3”

4”

5”

6”

3

Oil outlet

5/8” Flare

1” PF

1 1/4”

PF

1 1/4”

PF

4

Oil charge valve

1/4” Flare

5

High oil S.G.

1 PCS

6

Low oil S.G.

1 PCS

7

Oil level switch

1 PCS

8

Oil heater

150W

300W

300W 9 Oil drain valve

1/4” Flare

10

Oil temp. protection

(option)

1/8” NPTF

11

Safety valve (option)

1/2”

1”

1 1/2”

No.

OS40

OS50

OS65

OS80

OS100

OS125

OS150

A

930

1050

1110

1227

1637

1829

2229

B

505

585

595

650

1000

1080

1480

C

240

275

300

568

354

409

409 D 300

350

300

400

400 E 18

22

23

23 F 320

360

688

698

830

3. Dimensions：

Vertical External Oil Separator-OS40, OS50, OS65

84

Horizontal External Oil Separator-OS80

Horizontal External Oil Separator-OS100, OS125, OS150

85

m. Oil heater

A

E

B

C

D

Oil heater is used to maintain the oil temperature in the oil separator during shutdown cycles. It can help to get a safe start-up especially when the ambient temperature is low. Oil heater should be energized only when the compressor unit is not in operation and should not be energized when there is no oil in the reservoir. The selection of oil heater depends on total quantity of oil.

Before restart of compressor after shutdown for a long time, please turn on oil heater at least 8 hours to make the temperature inside compressor higher than system temperature and ambient temperature and then it can prevent condensation of refrigerant inside oil sump of compressor which may result in liquid compression in next start and poor lubrication due to too low viscosity. In addition, Hanbell also offers 300W oil heater to keep adequate lubricant temperature for large external oil separator and applications in areas with low ambient temperature.

Specification : 150W, 300W, 110V or 220V, IP 54, UL approval

150W , 300W oil heater

n. Mounting pad To avoid extra vibration and noise resulted from direct contact between compressor footings and the base on which compressor is mounted, it is recommended to add mounting pads in between as the drawing below shown.

86

Model

A B C D E

Thickness

RC2-100F RC2-140F RC2-180F RC2-200F RC2-230F RC2-260F RC2-300F RC2-310F

25

70

60

25

18

15 mm

RC2-340F RC2-370F RC2-410F RC2-430F RC2-470F RC2-510F RC2-550F RC2-580F RC2-620F RC2-710F RC2-790F RC2-830F RC2-930F

35

110

85

30

22

15 mm

RC2-1020F RC2-1130F RC2-1270F RC2-1530F

42.5

105

85

41

22

15 mm

87

7. Operation and trouble shooting

Items

Things to be checked

States or standard values

1. Accessories

1. Oil level

2. Oil heater

3. System valves status

4. Solenoid valves

5. Capillary

1. Higher than the middle line of oil level sight glass

2. Should be kept energizing after compressor shut down.

3. Opened

4. Fixed

5. No serious distortion or damaged

2. Electrical system

1. Voltage of main power

2. Voltage of control circuit

3. Insulation resistance value of the motor between phase to phase and phase to ground.

4.

terminal connection.

5. Grounded

6. Capacity of electrical accessories

7. Settings of switches, sensors and controllers.

Electricity voltage should be kept within 5 to the rated voltage, instant maximum voltage drop while starting should be less than 10% to the rated voltage.

If there is other demand, contact HANBELL.

3. Insulation resistance value should be above 5M.

4. Power terminals are firmly fixed on terminal block and well insulated. Keep wire cables away from heat source and sharpened metal. Power terminals are fixed firmly and well insulated. Terminal screw and block are both required.

5. (Ruled by the local Electricity Regulations.)

6. designer.)

7. designer.)

3. Piping system

1. Outer piping system

2. Leakage test

3. Bolts to fix the compressor.

1. Fixed firmly.

2. No leakage.

3. Fix the compressor tightly.

4. Safety devices

1. Motor coil sensor (thermister)

2. Discharge sensor (thermister)

3. Controller

1. Connected in series with discharge sensor to controller.

2. Connected in series with motor sensor to controller.

3. Closed circuit with N.C. & N.O.

7.1 Compressor start-up

PRE-START CHECKING Table below shows the required procedures and checkpoints before starting-up the compressor during commissioning or initial operation of the unit.

Note:

1. Don’t start compressor under vacuum.

2. Check the rotating direction of screw compressor by checking its suction and discharge pressure. The correct rotating direction is: suction pressure drops immediately and the discharge pressure increases at the same time.

3. It is necessary to pay more attention to the auxiliary facilities while the chiller is commissioning at the job-site and the periodic maintenance after the initial start-up.

4. Danger or severe damage to compressor is possible if the compressor is flooded with oil during standstill.

5. Check that all the settings on each pressure switch are correct.

6. Oil foaming can be generated during starting phase, but it should reduce when the compressor is under stable

88

operating conditions. Otherwise this can indicate excessive liquid in the suction gas.

7. Avoid touching the compressor surface during compressor operation.

8. Don’t remove any parts of compressor before release the compressor inner pressure.

9. The discharge temperature of compressor is recommended to be controlled at 80 ℃ for R22 and HFC application. Normally the discharge temperature doesn’t increase quickly after starting. If it increases quickly during commissioning, user should review the oil supply situation and additional cooling status.

10. The supply oil temperature should be kept below 60 ℃ for R22 and HFC application.

11. The oil level in oil separator might slightly drop after the start-up. A lower level happened by gas or air spot which is existed in oil circuit. If the level continuously goes down, an oil separator problem should be assumed. User should check the working condition and find out the problem during the commissioning.

12. During the commissioning, user should listen if any abnormal noise comes from compressor’s bearing seat or compression casing. Normally a middle tone of rhythmical sound can be obtained. Irregular, high tone and metallic noise show some abnormal conditions that the compressor is passing through. User should stop the compressor immediately and find out the root cause of abnormal noise.

13. Vibration shall be checked carefully by using a vibration analyzer on compressor casing, the surface of the base frame and piping. Compressor itself doesn’t generate excessive vibration if mechanical condition and shaft alignment are normal. Therefore, resonance should be often the cause of vibrations.

14. Normally the pressure drop at oil filter should be around 0 to 0.5 bar. If the pressure drop is continues rising and reaches 1 bar. The oil filter cartridge should be cleaned or replaced to ensure a sufficient oil supply.

15. Normally the pressure drop at suction strainer is around 0 to 0.2 bar. If the pressure drop is continues rising and reaches 0.5 bar. The suction strainer should be cleaned or replaced immediately.

16. Check sight glass on liquid line to see the supply condition of refrigerant.

17. Check suction gas superheat not only at 100% capacity, but also 75%, 50% and 25% capacity to ensure sufficient superheat for system operation.

18. Avoid slugging compressor with liquid refrigerant. Make certain that adequate superheat or properly size suction accumulator is applied to avoid dumping liquid refrigerant into compressor. Keeping liquid injection valves properly adjusted and in good condition to avoid flooding compressor with liquid.

19. The whole plant, especially the pipelines and capillary tubes must be checked for abnormal vibrations. Contact HANBELL or local distributor if any abnormal vibrations or noise found while the compressor is running.

20. The running condition of compressor after commissioning at the job-site should be adjusted as; the discharge temperature will be at least 20K above the saturated condensing temperature and the suction vapor superheat should be within 10K to the saturated evaporating temperature.

21. Regularly check-up the plant according to national regulations and the following items should also be

checked:

- Operating data of the machine

- Check the lubrication/level of oil

- All compressor monitoring parts

- Check electrical cable connections and tightness

89

7.2 System adjustment

This session is mainly focused on system adjusting besides compressor. The information here is based on general type or common situation. Any special design or different case should be reviewed separately with Hanbell representative

Liquid/Oil injection to chamber Liquid/Oil injection to chamber is widely used for the controlling of discharge temperature. In the case of using Liquid/Oil injection to chamber for the discharge temperature control, the Liquid/Oil line should be controlled by a liquid line solenoid (Normally Closed type). The liquid line solenoid is suggested to be energized when the discharge temperature reaches 80 ℃ (HFC and HFC application). On the Liquid/Oil line, there should be a regulation valve after the solenoid to adjust the injection flow rate. Before the start-up of compressor, user should completely close the regulation valve. When the system is running and the discharge temperature exceeds the set-point, the N.C. solenoid will be energized and user can open the regulation valve gradually to see the variation of discharge temperature. Try to adjust the regulation valve to the position that the discharge temperature starts to decrease to the setting point then keep the valve at this position for a while. When the discharge temperature down to 75 ℃ (HFC and HFC application), the liquid line solenoid can be off to stop the injection. Normally the discharge temperature will start to increase after the stop of Liquid/Oil injection. Therefore, user should observe the working situation for some time to ensure the proper work of Liquid/Oil injection. Note: The adjustment of Liquid/Oil injection regulation valve should be executed at all operating conditions, including partial load.

ECO function ECO is often used in the refrigeration system to get higher cooling capacity. Compared with using 2 compressors at a 2-stage compression system, using ECO can save the initial investment and simplify the system design. The information below should be noted when user applies ECO in the system.

1. There should be a muffler connected to the ECO port directly to absorb the pulsation caused by high speed refrigerant/gas flow. Sight glass is recommended to be used on the ECO pipe to know whether liquid exists or not. If liquid refrigerant enters the compression chamber, this will cause damage to screw rotors and bearings. Accumulator can be used in this line to avoid liquid compression.

2. In a regular start procedure with ECO application, ECO line solenoid (Normal Close Type) should be energized after the slide valve reaches its minimum ECO working position and should be energized all the time during the compressor working period. Running compressor without sufficient cooling might cause severe damage to compressor.

3. Before stop the compressor, the controlling program should unload the slide valve to its initial position (minimum capacity). ECO line solenoid should be off when the slide valve position is below minimum ECO working position.

90

2

/cmkg

2

/cmkg

Discharge bypass line Discharge bypass line is widely used to reduce the pressure differential between low and high pressure side. In this kind of application, the discharge check valve is normally installed on the oil separator outlet which can isolate the high pressure side (condenser) from the oil separator side. Because a suction check valve is usually installed on the compressor’s suction port, the pressure in oil separator and compressor will be equalized in the end. Using a discharge by pass line which connects the oil separator and the suction pipe line can reduce the pressure in the oil separator to ensure a light-duty-start of the compressor.

Oil cooler Oil cooler is often used to control the oil temperature at desire setting. The proper oil temperature can ensure the oil viscosity and lubricity and can provide necessary help for chamber cooling and discharge temperature control. Because the oil temperature in the beginning of system running is not high (normally around 20 to 30 ℃), oil cooling will not be necessary during this period. By pass the oil at oil cooler can help to increase the oil temperature faster to the desired temperature and having system stabilized. When the oil temperature reaches the setting, oil cooler can start to work to control the oil temperature for the system.

Oil cooler should be installed as close as possible to the compressor and preferably below the level of compressor / oil separator to avoid gas pads or any drainage of oil into the oil separator during standstill.

Oil filter Oil filter is usually installed on the oil line. User should consider installing a pressure differential protector which helps to monitor the pressure drop between both sides of oil filter. When oil pressure drop reaches 1 to

1.2

supply to compressor. Insufficient oil supply leads to severe damage to internal moving parts and malfunction of capacity control.

Oil pump When pressure differential between main oil inlet port and suction side is less than 4 oil pump for the oil circuit becomes important. The oil pump should start and stop simultaneously with the compressor to ensure sufficient oil supply.

Oil return valve (for fine/secondary oil separator)

, this means the oil filter is clogged by debris or dirt and user should clean it to ensure sufficient oil

, it means using an

In the case of using fine/secondary oil separator, an oil return line from the bottom of fine/secondary oil separator to compressor’s suction side is very important. The control of oil return valve can be simply by a solenoid valve with a regulation valve or using a floating ball as a trigger and be opened only after the compressor starts. User should adjust the flow volume during the initial start up to ensure a steady oil return to the system.

Pressure regulation valve Pressure regulation valve is suggested to be installed on the exit of the external oil separator when oil pump is not applied in the system. With its help, the oil pressure can be built up quickly to ensure sufficient oil supply to

91

compressor. User should use suction pressure as reference and make sure the valve opened when the discharge

2

/cmkg

pressure is 4 temperature condition.

7.3 Compressor stop

Compressor stop should be executed under regular procedure. The controlling program should unload the compressor gradually to its minimum capacity and stop the compressor after it reaches the minimum load. Oil line solenoid and oil pump (if apply) should be closed at the same time when the compressor stops. ECO line should be closed when the slide valve position is below 50%. Oil/Liquid injection line should be closed 3 to 5 seconds before the compressor stop. For the first start-up, check and clean the suction strainer and oil filter after the commissioning is very important to ensure the future operation.

In case of emergency stop, the oil/liquid injection line, oil line, and ECO line should be closed immediately. If discharge bypass line is designed in the system, it should be opened to balance the pressure differential between high and low pressure side then close itself for the next running. With the help of suction check valve and discharge bypass line, the reverse running time can be limited to a few seconds. If the reverse running doesn’t stop in about 10 seconds, the leakage at suction check valve and the malfunction of discharge bypass line can be assumed, User should check them during the stop of compressor. Before starting the compressor next time, user

higher than the suction pressure. This is essential especially in the low condensing

should correct the problem first then energize all solenoid valves to help the slide valve back to its initial position.

For a short period of non-operation, the oil heater power should be kept on to keep the oil temperature at proper temperature for the next start up.

For a long period of non-operation or overhauls, the power source for main and oil pump should be cut off. The oil heater power should be switched off, too. The control panel should be kept power on to resist moisture. All the stop valves related to the system should be closed. Cooling water supply should be stopped and the cooling water in the condenser and oil cooler must de drained completely.

Note: Start and stop of compressor should not be repeated more than 4 times per hour.

92

PROBLEMS

PROBABILITY CAUSES

REMEDY / CORRECTIVE ACTION

Sudden trip of motor thermister / sensor

Low suction pressure cause low refrigerant flow rate

Install liquid injection to motor coil

Refrigerant shortage

Charge refrigerant

Suction filter clogged

Clean filter

High suction temperature

Install liquid injection to motor coil

High suction superheat

Adjust the superheat less than 10°K

Unstable electricity system or failure

Check electricity power supply

Motor overload

Bad motor coil causing temperature rising rapidly

Compressor unable to load

Low ambient temperature or high oil viscosity.

Turn on the oil heater before compressor start.

Capillary clogged.

Clean or replace capillary

Modulation solenoid valve clogged or solenoid valve coil burnt.

Clean / purge solenoid valve core or replace the solenoid valve coil

Internal built-in oil line clogged.

Check and clean the compressor oil circuit

Piston stuck-up.

Change piston or piston ring

Oil filter cartridge clogged.

Clean oil filter (replace if needed)

Too small the high-low pressure differential.

Minimum pressure differential is 4 bar. Consider to install an oil pump.

Compressor unable to unload.

Modulation solenoid valve clogged or burnt.

Clean or replace the solenoid valve

Piston rings worn off or broken, or cylinder damaged resulting leakage.

Change piston (if cylinder damaged severely, change the cylinder)

Lubrication oil insufficient

Check the oil level of the compressor if enough, add some oil if necessary

Leakages at internal discharge cover plate end side.

Check or replace the gasket and tighten the bolts.

Solenoid valve voltage misused.

Check the control voltage

Piston stuck-up.

Change the piston set, and check the cylinder and slide valve.

Capacity control logic unsuitable.

Check

Poor insulation of motor

1. Bad compressor motor coil.

Check the coil or change the motor stator

2. Motor power terminal or bolt wet or frosty.

3. Motor power terminal or bolt bad or dusty.

4. Bad insulation of magnetic contactors.

5. Acidified internal refrigeration system.

6. Motor coil running long time continuously under high temperature.

7. Compressor restart counts too many times.

7.4 Troubleshooting

The table below shows some problem that might encounter in the jobsite during commissioning or upon operation of compressor. This table will only serve as a guide for the Engineer to understand the situation once the problem occurred in the site.

93

PROBLEMS

PROBABILITY CAUSES

REMEDY / CORRECTIVE ACTION

Compressor starting failure or Y-Δ starter shifting failure

Slide valve piston unable to go back to its lowest % original position.

Check if the unloading SV is energized once the compressor shut down. Unload the compressor before shot down.

Voltage incorrect.

Check the power supply

Voltage drop too big when starting the compressor or magnetic contactor failure or phase failure.

Check the power supply and the contactor.

Motor broken down

Change the motor

Motor thermister sensor trip.

See “sudden trip of motor sensor” above

Incorrect supply power connection.

Check and re-connect

Y-Δ timer failure.

Check or replace.

Discharge or suction stop valve closed.

Open the stop valve

Improper connection between node terminals of Y-Δ wiring.

Check and re-connect the wiring

Rotor locked

Check and repair

Earth fault

Check and repair

Protection device trip

Check

Abnormal vibration and noise of compressor

Damaged bearings.

Change bearing.

Phenomenon of liquid compression.

Adjust proper suction superheat

Friction between rotors or between rotor and compression chamber.

Change screw rotors or/and compression chamber.

Insufficient lubrication oil.

Check the oil level of the compressor if enough, add some oil if necessary.

Loosen internal parts.

Dismantle the compressor and change the damaged parts.

Electromagnetic sound of the solenoid valve.

Check

System harmonic vibration caused by improper piping system.

Check the system piping and if possible improve it using copper pipe.

External debris fallen into the compressor.

Dismantle the compressor and check the extent of the damage.

Friction between slide valve and rotors.

Dismantle the compressor and change the damaged parts.

Motor rotor rotates imbalance.

Check and repair.

Compressor does not run

Motor line open

Check

Tripped overload

Check the electrical connection

Screw rotors seized

Replace screw rotors, bearings etc….

Motor broken

Change motor.

High discharge temperature

Insufficient refrigerant.

Check for leaks. Charge additional refrigerant and adjust suction superheat less than 10°K

Condenser problem of bad heat exchange.

Check and clean condenser

Refrigerant overcharge.

Reduce the refrigerant charge

Air / moisture in the refrigerant system

Recover and purify refrigerant and vacuum system

Improper expansion valve.

Check and adjust proper suction super heat

Insufficient lubrication oil.

Check the oil level and add oil.

Damaged bearings.

Stop the compressor and change the bearings and other damaged parts.

Improper Vi value.

Change the slide valve.

No system additional cooling (Liquid injection or oil cooler)

Install additional system cooling (liquid injection or oil cooling or both base on working condition limitation)

94

PROBLEMS

PROBABILITY CAUSES

REMEDY / CORRECTIVE ACTION

Compressor losses oil

Lack of refrigerant

Check for leaks. Charge additional refrigerant.

Improper system piping

Check and correct the piping or install an external oil separator

Refrigerant fills back

Maintain suitable suction superheat at compressor

Low suction pressure

Lack of refrigerant

Check for leaks. Charge additional refrigerant.

Evaporator dirty or iced

Defrost or clean coil

Clogged liquid line filter drier

Replace the cartridge

Clogged suction line or compressor suction strainer

Clean or change suction strainer

Expansion valve malfunctioning

Check and reset for proper superheat

Condensing temperature too low

Check means for regulating condensing temperature

Note: The replacement of compressor internal parts should be perform only by a qualified / certified service

technician with full knowledge of HANBELL screw compressor or it should be a Service Engineer from HANBELL.

95

7.5 Compressor checking list

Please fill out the compressor checking list and send it to Hanbell, if any failure of compressor happened. Hanbell will reply and suggest the solution to resolve the failure.

96

gcmkg2/

2

/cmkg

8. System applications

8.1 General application

Compressor is the heart of the chiller/refrigeration system. To ensure a long trouble free operation, the following design factors need to be considered during the design stage for the system designer.

a. Oil circulation Compare with traditional reciprocating compressor using oil pump for oil circulation, Hanbell screw compressor uses pressure differential as the pushing force for oil circulation. To ensure the capacity control function and good oil supply to compressor, minimum 4 is necessary. System designer should consider installing the necessary pressure sensors to get the pressure values at main oil inlet port and suction side and use them as reference to monitor the oil supply condition.

For compressor working with R22 and HFC refrigerant, a general oil circulation diagram can be referred to the picture below. The pressure drop at oil cooler and oil filter should be recorded as reference. Once the pressure drop increases more than 1 good heat exchange at oil cooler and sufficient oil supply to compressor.

, regular maintenance on oil cooler and oil filter should be executed to ensure

pressure differential between main oil inlet port and suction side

Oil circulation design for R22 and HFC refrigerant

97

2

/cmkg

If the oil pressure differential can’t reach 4 should be assigned to build up the necessary oil pressure for oil circulation. User can follow the figure below for design reference. In the oil pump section, an oil filter can be found before the oil pump. It is installed to protect the oil pump away from debris and piping dirt. A pressure regulator can be seen parallel to the oil pump line. It is used to control the maximum oil pressure. The function of check valve is letting oil pass through it when the oil pressure is enough. Under such condition the oil pump won’t need to work and oil can be supplied from the oil separator to the compressor directly. The other function is to prevent back-flow of oil when oil pump works

between main oil inlet port and suction side, an oil pump

Oil pump application

When the evaporator is far away from the compressor, system designer should consider designing proper suction line to help the oil flow back from the evaporator. From the outlet of the evaporator, the suction line should always drop vertically downward or run horizontally at a downward slope (1 cm per m) to a point where it then drops vertically downward. When the line comes to a risen part, a trapping technique similar to that for the discharge line is used. Please refer to the figure below for details.

Suction line design for risen part

98

For system with flooded evaporator at HFC and R22 application, a separate oil rectifier from the evaporator or the low-pressure receiver is required. Basically the oil/refrigerant mixture should be drawn off at several points in the oil-rich phase of the liquid level. Using means of heat exchange to evaporate the refrigerant fraction (e.g. in a counter flow with the warm refrigerant liquid) then feed back the oil via the suction gas line. Checking the oil level in the external oil separator is required to ensure sufficient miscibility (oil/ refrigerant) under the corresponding operating conditions in the evaporator or oil separator. When the oil circulation problem cannot be solved, a secondary oil separator is required to minimize the oil carryover to the system.

b. Piping arrangement In the case of single compressor, the suction line design before compressor should have a sufficiently large volume and should not be angled towards the compressor. Please refer to figure below for details.

In the case of parallel compounding, the suction line runs below the level of compressor is recommended to provide the maximum possible safety. In system where liquid slugging cannot be avoided (e.g. system with long standstill under a pressure difference, hot gas defrost), the suction header shall able to take over the function of a liquid separator. Please refer to figures below for design reference.

Suction line design before compressor (single compressor)

Suction line design before compressors (parallel compounding)

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Suction line design before compressors (parallel compounding)

Suction line design from suction header to compressors (parallel compounding)

When suction header has to be positioned above compressor level, the following design reference has to be considered for safety operation.

Design reference when suction header runs above the compressors

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