Hanbell RC2-100AF Manual Download Page 100

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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

Summary of Contents for RC2-100AF

Page 1: ...ants 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 st...

Page 2: ...er 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 hi...

Page 3: ...ed 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...

Page 4: ...F 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 R...

Page 5: ...BF 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 ...

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Page 28: ...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 ...

Page 29: ...od 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 Moto...

Page 30: ...tion 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 beari...

Page 31: ...tion 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...

Page 32: ...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 Solenoid Valve 1 2 3 4 Normal Open Normal Close NC NC NC Standard Optional STANDARD STANDARD STANDARD Control Logic S Start ON OFF OFF M1 66 or 50 OFF ON OFF M2 75 OFF OFF ON F Full Load 100 OFF ...

Page 33: ...mperature 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 Solenoid Valve 1 1 2 3 4...

Page 34: ...riods 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 ...

Page 35: ...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 liqu...

Page 36: ...ating 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 compre...

Page 37: ...oftware 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 mec...

Page 38: ...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...

Page 39: ...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 3...

Page 40: ...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...

Page 41: ...5 177 481 740 424 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 ...

Page 42: ...r 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 ...

Page 43: ...pper 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...

Page 44: ... 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 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 Note Please refer to the selection softwar...

Page 45: ...ssion 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 ...

Page 46: ...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 ...

Page 47: ...i 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...

Page 48: ... 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...

Page 49: ... 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 ...

Page 50: ...lubricant circuit 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 ...

Page 51: ...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 ...

Page 52: ... 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 ...

Page 53: ...uid 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 cool...

Page 54: ...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 ...

Page 55: ...lubricant circuit 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 ...

Page 56: ...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 ...

Page 57: ... 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 ...

Page 58: ...uid 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 cool...

Page 59: ...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 ...

Page 60: ... lubricant circuit 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 ...

Page 61: ...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 ...

Page 62: ... 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 ...

Page 63: ...uid 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 cool...

Page 64: ...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 ...

Page 65: ... also reduce the oil viscosity which might become the root cause of bearing failure in the future The oil viscosity is recommended at 10 s mm 2 at any temperature If the compressor operates under the critical working 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 he...

Page 66: ...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 ...

Page 67: ...INT 40 35 25 30 43 35 T A N mg KOH g 0 01 0 00 0 01 COPPER STRIP 100 3hr 1a 1a 1a MOISTURE ppm 15 20 20 FLOC POINT 75 45 35 DIELETRIC STRENGTH 2 5mm kV 75 50 50 46 6 Applicable oil types R134a R404A R407C R507 SPECIFICATION UNITS HBR B05 HBR B08 HBR B09 HBR B04 COLOR ASTM SPECIFIC GRAVITY 0 945 0 94 0 95 0 95 VISCOSITY 40 mm 2 s cSt 64 131 175 215 9 100 8 9 14 53 16 5 20 8 FLASH POINT 266 254 265 ...

Page 68: ...CM 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 Full load Amper Starting Current Time I AMP Y shift time 0 25 0 5msec 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 cir...

Page 69: ... 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 Full load Amper Starting Current Time I AMP sec PW2 7 8 9 B Pt100Ω Pt1000Ω Option PW1 1 2 3 9 3 A PTC 2 8 Earth Bolt 7 1 A B The selection of both of the motor contactors k1 k2 is each for approx 60 of the max running current The rec...

Page 70: ...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 cm 2 G Optional Oil flow switch Optional PT100Ω or PT1000Ω for liquid injection to motor chamber Solenoid valve open 85 Solenoid valve close 75 Optional...

Page 71: ...mmended 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...

Page 72: ... 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 pl...

Page 73: ...n 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 co...

Page 74: ... 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 ...

Page 75: ...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 ...

Page 76: ...F 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 Dimensions for 1 1 2 4 stop valves Dimensions for 5 stop valve 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...

Page 77: ...rigerant 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...

Page 78: ...rnal oil filter in oil return line before suction port of compressor for safe running of compressor 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 5 8 RC2...

Page 79: ...ompressor 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 r...

Page 80: ...ss 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 temp...

Page 81: ...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 durin...

Page 82: ...perature 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 b...

Page 83: ...ed 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 ...

Page 84: ...l S G 1 PCS 7 Oil level switch 1 PCS 8 Oil heater 150W 150W 150W 150W 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 2 1 2 1 1 1 1 2 1 1 2 3 Dimensions 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 300 350 350 300 300 400 400 E 18 22 22 23 ...

Page 85: ...84 Horizontal External Oil Separator OS80 Horizontal External Oil Separator OS100 OS125 OS150 ...

Page 86: ... 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 l...

Page 87: ...00F 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 ...

Page 88: ...ted 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 senso...

Page 89: ...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 risi...

Page 90: ...ly 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 ...

Page 91: ...ompressor 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 2 cm kg this means the oil filter is clogged by debris ...

Page 92: ...e 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 shou...

Page 93: ... 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 valv...

Page 94: ...sary 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 rotor...

Page 95: ...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 intern...

Page 96: ...5 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 ...

Page 97: ...pressure differential between main oil inlet port and suction side 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 ...

Page 98: ... 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 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 Fr...

Page 99: ...ulation 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 be...

Page 100: ...n 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 ...

Page 101: ...nstalling oil separator where the oil level is below the compressor outlet with inclining discharge gas line 1 cm per m This design can ensure no oil flows back to the compressor during standstill Discharge gas line design when oil level in oil separator below the compressor level Sometimes although the oil level in oil separator is below the compressor level the inlet port of oil separator might ...

Page 102: ... below the sight glass of the oil separator and also below the injection point of the compressor In the case of air cooled oil cooler above the oil separator and compressor the oil in the oil cooler will drain into the oil separator during standstill Thus the oil separator will be overfilled and leads to higher oil carryover during next start Therefore using a check valve with small spring force a...

Page 103: ...102 Discharge gas line and oil line design when oil level in oil separator above the compressor level Oil cooling by air cooled version ...

Page 104: ...or easier maintenance it is recommended to use a regulation valve ball valve in the oil pipe line to each oil inlet port c Temperature control Temperature control is always critical for a long trouble free system running There is a general rule that keeps the discharge temperature at 80 at all operating conditions and at all capacity range High oil temperature degrades oil properties fast Also slu...

Page 105: ...ped between the liquid line and compressor for cooling down the compression chamber and motor to ensure the continuous and safe running of the compressor The suction superheat should be controlled between 5K 10K for the application of air cooled and heat pump chillers by means of expansion valve devices These devices can be adjusted by the stem of the expansion valve to control the suction superhe...

Page 106: ... valve should be connected to the high pressure side to counter the internal pressure Please refer to the figure for design reference Liquid injection oil cooling Oil cooler application Compared to liquid injection applications oil cooler application reduces the discharge temperature and at the same time gives better efficiency Oil cooler application can be classified into 3 types cooling by refri...

Page 107: ...oil bypass line at oil cooler will be needed to ensure a quick warm up d Liquid compression Liquid compression can be classified as oil compression and liquid refrigerant compression For oil compression it is extremely dangerous to the compressor because oil can t be compressed If oil compression occurs bearings need to suffer very big load which might cause severe damage to rollers and balls in b...

Page 108: ...king compressor can have its own working temperature by system design and arrangement Maximize the usage of external oil separator The start up current can be lower at parallel system compare with the system with one bigger compressor Extensive options of capacity control which helps compressors work safely The concept diagrams of twin compressor parallel system are shown below They have slightly ...

Page 109: ...108 Parallel compounding with common oil separator and air cooled oil cooler Parallel compounding for different cold space temperatures ...

Page 110: ...the compression chamber The power consumption of the compressor increases slightly compare to the additional work that takes place at a better level of efficiency especially at high pressure ratio application HANBELL screw compressor can be fitted with an additional middle connection for economizer operation With this form of operation refrigeration capacity and also system efficiency can be impro...

Page 111: ...applied Figure 6 24 shows the system with Economizer sub cooler ECO application by heat exchanger b Economizer by flash tank The liquid sub cooling is achieved by reducing the boiling point pressure in an intermediate pressure vessel flash tank This physical effect leads to the cooling of the liquid down to the boiling point due to evaporation of part of the liquid To stabilize the pressure of the...

Page 112: ...r ECO application by flash tank Note When apply the economizer to compressor it is strongly recommended to install a economizer stop valve before the economizer gas return port to operate as a buffer or muffler or install a muffer after stop valve as the charts shown above could efficiently prevent the vibration of piping caused by compression pulse ...

Page 113: ... notice of the high discharge temperature should not exceed 110 f Take notice of high low pressure reading the oil level of the compressor and the noise of running as well If there is any abnormal value or situation then emergently stop the pump down Long term partial load operation If compressors have to run at partial load below 50 continuously though maybe within operation limits under such ope...

Page 114: ...113 8 4 Example of installation Installation of RC2 100 RC2 140 RC2 180 F type compressor Installation of RC2 200 580 RC2 620 F type compressor ...

Page 115: ...y control system module A Step less capacity control 1 step less 2 25 30 35 B 4 step capacity control 2 25 30 35 3 50 4 75 C Step less step capacity control 1 2 3 4 Suction filter Flange Cable box Power bolt PTC terminal PTC controller connector Refrigerant service valve Angle valve Oil heater Stop valve Suction port Liquid injection solenoid valve Liquid injection expansion valve ECO stop valve m...

Page 116: ...valve Compression chamber Soleniod valve description 1 Solenoid valve only step less 2 Solenoid valve 25 3 Solenoid valve 50 4 Solenoid valve 75 Capacity control system module A Step less capacity control 1 step less 2 25 B 4 step capacity control 2 25 3 50 4 75 C Dual capacity control 1 2 3 4 Oil cooler in Let 2 4 3 1 Oil cooler out Let Refrigerant charging valve Angle valve Suction port Discharg...

Page 117: ... 66 9 66 9 67 2 67 4 67 5 67 8 68 5 70 0 70 3 70 6 70 9 63 61 1 62 62 9 63 1 63 1 63 4 63 5 63 7 63 9 64 6 66 0 66 3 66 6 66 9 80 67 67 9 68 9 69 2 69 2 69 4 69 6 69 8 70 1 70 8 72 3 72 7 73 0 73 3 100 63 6 64 4 65 4 65 7 65 7 65 9 66 1 66 3 66 5 67 2 68 7 69 0 69 3 69 6 125 63 1 64 64 9 65 2 65 2 65 4 65 6 65 8 66 66 7 68 1 68 5 68 7 69 1 160 62 5 63 3 64 3 64 5 64 5 64 8 65 65 1 65 4 66 67 5 67 ...

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Hanbell RC2-100AF, Manual

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