Hanbell RC2-1020AV Manual Download | Manualshive

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Summary of Contents for RC2-1020AV

Page 1: ...nge 11 4 Compressor lifting and installation 12 4 1 Compressor lifting 12 4 2 Mounting the compressor 12 4 3 RC2 AV series compressor outline drawings 14 4 4 Compressors accessories 37 5 Electrical data and design 50 5 1 Motor design 50 5 2 Electrical installation with VFD 50 5 3 V F diagram 50 5 4 Compressor protection devices 51 5 5 Grounding 51 6 Operation and maintenance 52 6 1 Compressor star...

Page 2: ...trolled under severe quality procedures and good service to all customers RC2 AV series compressor is equipped with liquid injection economizer connection PTC motor temperature thermistors discharge temperature thermistors and a motor protector for additional cooling and basic protection other accessories such as oil level switch and oil pressure differential switch are also available for advanced...

Page 3: ...ns and description of design 2 1 Compressor nomenclature RC 2 x x x x A V V for applications with variable frequency driver Refrigerant Code A R134a R1234ze Compressor Displacement at 50Hz m 3 hr RC model 2 nd Version ...

Page 4: ...66 1750 3550 84 70 16 610 RC2 410AV 407 1750 4750 125 78 16 730 RC2 430AV 423 1750 4750 125 78 16 735 RC2 470AV 471 1750 4750 144 90 18 800 RC2 510AV 508 1750 3550 117 98 20 760 RC2 550AV 549 1750 4750 168 105 23 820 RC2 580AV 583 1750 3550 131 109 20 805 RC2 620AV 619 1750 4750 182 114 23 850 RC2 710AV 713 1750 3550 158 131 28 1099 RC2 790AV 791 1750 3550 175 146 28 1140 RC2 830AV 825 1750 3550 1...

Page 5: ...Cable box RC2 200AV RC2 230AV RC2 260AV RC2 300AV RC2 310AV RC2 340AV RC2 370AV RC2 410AV RC2 430AV RC2 470AV RC2 510AV RC2 580AV construction 1 2 3 4 5 6 7 8 9 14 15 16 17 18 19 20 21 22 23 24 25 26 27 12 29 30 28 10 11 13 Figure 2 Item Description Item Description Item Description Item Description 1 Compressor casing 9 Oil separator demister 17 Discharge bearing fixed ring 25 Oil heater 2 Motor ...

Page 6: ... 8 Oil separator baffle 16 Vi plug key 24 Oil guiding ring RC2 710AV RC2 790AV RC2 830AV RC2 930AV Construction Figure 4 Item Description Item Description Item Description Item Description 1 Compressor casing 11 Discharge check valve 21 Bearing lock nut 31 Suction flange 2 Motor casing 12 Thermostat terminals 22 Male rotor 32 Discharge flange 3 Oil separator 13 Bearing seat cover plate 23 Suction ...

Page 7: ...discharge ends as well as angular contact ball bearings i e axial bearings at discharge end A three phase two pole squirrel cage induction motor drives the compressor The motor rotor is located on the shaft of the male screw rotor Cooling of the motor is achieved with suction refrigerant vapor Compressor technical features Full product range RC2 V series compressor consists of 26 models with displ...

Page 8: ...gas is trapped inside the interlobe space b Compression As the male rotor and female rotor meshes the interlobe space moves towards to discharge end and its volume decreases so that gas pressure increases consequently c Discharge Gas is discharged from the interlobe space when the leading lobe crosses the discharge port whose volume ratio is designed differently for various applications Figure 6 C...

Page 9: ...ring for signals connected to VFD should be isolated from wirings of VFD power supply at a distance 3 PLC microcontroller and VFD should be well grounded respectively to prevent cross interference Procedures for initial setting are as follows 1 When completing VFD setting remove wiring of VFD power output and check if VFD s output frequency and corresponding voltage comply with output signal of PL...

Page 10: ...e will rise simultaneously In order to keep compressor running safely and continuously Hanbell recommends the following additional cooling devices 1 Oil cooler or 2 Liquid injection to chamber or 3 Liquid injection to motor Please use Hanbell selection software to get recommended additional cooling capacity 2 Hanbell recommends monitor oil pressure and keep it 4 kg cm 2 g over the suction pressure...

Page 11: ...ricant flow to bearings While reverse running it is unable to see the oil flow via sight glass The normal oil level in the compressor oil sump should be maintained above the top of the low level sight glass and in the middle level of high level sight glass when compressor is running It is strongly recommended to install the optional accessory of oil level switch to prevent compressor failure from ...

Page 12: ...nd then change oil every 20 000 hours or after 3 years continuous running while the system operates in good condition 2 Avoid clogging in oil filter with debris or swarf which may cause bearing failure An optional oil pressure differential switch is recommended The switch will trip when the oil pressure differential between the primary and secondary sides reaches the critical point and then the co...

Page 13: ...ains or steel cables Figure 9 Lifting the compressor with safety ropes 4 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 electrical power supply for easy connection...

Page 14: ...discharge piping to minimize vibration and noise 3 Remove oxidized impurities swarf or debris brought by welding in the piping tubes If they fall into the compressor the oil filter might be clogged resulting in malfunctioning of lubrication system bearings and capacity control system 4 The material of suction and discharge flanges is forged steel and it can be welded directly with piping After wel...

Page 15: ...4 3 RC2 AV series compressor outline drawings ...

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Page 38: ...level switch 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 Mi...

Page 39: ... D E F G H I 2 102 6 53 69 91 65 90 85 5 2 1 2 122 6 69 89 111 85 110 97 5 3 138 6 80 99 121 95 120 108 5 4 163 6 96 124 146 120 145 123 5 Figure 12 Suction check valve outline drawing Horizontal type Dia Dimension unit mm A B C D E F G H I J K L M N P 1 1 2 109 109 5 55 59 76 105 6 34 60 75 M16x2 105 18 105 2 122 122 5 65 69 91 110 6 46 70 90 M16x2 120 18 120 2 1 2 134 134 5 85 89 111 125 6 55 90...

Page 40: ... 97 6 3 138 4 95 99 121 80 100 120 108 6 4 163 4 120 124 146 96 125 145 123 6 6 238 5 190 195 216 146 190 215 160 6 No 1 2 3 4 5 6 7 8 Item Body C clipper Spring Valve platet Gasket Nut Guide seat Shaft Model Standard Discharge Flange Bushing Standard Suction Flange Bushing Steel pipe Copper pipe Steel pipe Copper pipe RC2 100 1 1 2 1 5 8 2 2 1 8 RC2 140 1 1 2 1 5 8 2 2 1 8 RC2 180 1 1 2 1 5 8 2 1...

Page 41: ... 2 90 Suction Copper 3 1 8 76 145 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 510 RC2 550 RC2 580 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 76 145 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 620 Discharge Copper 2 1 8 66 120 45 5...

Page 42: ... 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 30 126 194 194 248 230 230 214 338 474 161 Specification of stop valve Maximum working pressure Hydrostatic pressure test Refrigerant ...

Page 43: ...le frequency drive application Technical data of INT69HBY Supply voltage AC 50 60 Hz 115 120V 15 10 3VA AC 50 60 Hz 230 240V 15 10 3VA Ambient temperature 30 70 Relay output max AC 240V max 2 5A C300 min 24V AC DC 20 mA Figure 19 INT69HBY Blink codes display e Oil heater One UL approved 150W oil heater has been installed in every compressor as a standard accessory Before restart of compressor afte...

Page 44: ... DC Max voltage 300V DC AC Max current 0 5A DC AC Figure 21 Oil level switch Notes 1 There is a triangle mark on the float indicating the sensor direction Before you install an oil level switch on a compressor or an external oil separator please take the triangle mark as reference before installing any oil level switch on the compressor or external oil separator 2 Please check the triangle mark an...

Page 45: ...ntrol power lines refer to the drawing below cable box RC2 200 620AV cable box RC2 1020 1530AV cable box Figure 25 IP54 cable box Liquid injection system solenoid valve expansion valve additional cooling to motor coil RC2 AV compressors applications whose condensing temperature is high or evaporating high compression ratio applications liquid injection to compression chamber is high compression he...

Page 46: ...ture and parallel systems system with long piping Hanbell specially designs a complete series of external oil separators OS series with characteristics of high separation efficiency and low pressure drop The following table shows details of OS series Technical data Ⅰ Model Type Oil Volume Liter Range of application based on Displacement m3 hr Recommended Shell Diameter High level Low level OS40 Ve...

Page 47: ... caused by resonance Ⅳ Drawing Vertical OS40 65 Horizontal OS80 150 Figure 28 OS series external oil separator m External oil filter External oil filter is an optional accessory It is suggested to install an external oil filter in oil return line before the suction port of compressor for safe running of compressors Figure 29 External oil filter n Oil flow switch Oil flow switch operates in oil ret...

Page 48: ...sor oil return port 47 Qmax Recom l min switch value l min selectable range for fixed switch mm 20 0 4 12 40 0 6 25 60 1 5 40 Figure 30 Oil flow switch Average pressure loss 0 4 bar at Qmax Hysteresis depending on switch value minimum 0 4 l min Switch value is indicated for horizontally decreasing flow Figure 31 Installation of oil flow switch When economizer is used it is recommended to install a...

Page 49: ... Pt1000 sensor on motor coil as optional accessories This temperature sensor along with controller of the system monitor motor coil temperature and then control on off of liquid injection valve accordingly to provide suitable liquid injection as shown in the diagram below s Condensor s Evaporator Dryer Chiller in Chiller out W U Earth Bolt V B Pt100 Pt1000Ω Optional A PTC Z Y X B A Controller Elec...

Page 50: ... K Insulation test voltage U is AC 1 5kV Compressors motor can be equipped with either Pt100 or Pt1000 sensor to precisely control liquid injection and maintain motor coil while running Please specify Pt100 or Pt1000 sensor when placing orders to Hanbell Their connection refers to Figure 37 V 2 W 3 U 1 X 8 Y 9 Z 7 A B B Set Pt100Ω Pt1000Ω Optional A Set PTC connect to discharge PTC sensor connect ...

Page 51: ...ongly recommended especially when the wiring length between VFD and motor exceeds 5m otherwise it might cause serious damage to the inverter or the motor Please discuss with your VFD providers whether this AC reactor should be installed Connection of power supply of the compressor from the inverter Pt100 1000 and PTC sensors is as shown in 37 Figure 38 RC2 AV compressor VFD installation diagram 5 ...

Page 52: ...ck response while the temperature approaches to their set point thermistors must be connected in series to a controller INT69HBY in cable box as a guardian to protect compressor Alarm lamp for this protector is required to be embedded on control panel as indicator Any intention to short controllers for starting of compressors is prohibited It is beyond Hanbell warranty of compressors if any action...

Page 53: ...1 Those functions as speed control malfunction feedback VFD reset should be workable 2 Should follow the nameplate of compressor 3 Acceleration 50 60 sec from 0Hz to 50Hz deceleration vice versa 6 Compressor motor 1 Motor temperature from Pt100 1000 2 Liquid level from motor sight glass 1 Temperature meter should be correct 2 Lower than the upper level of sight glass In addition to the pre start c...

Page 54: ...ms that might happen at jobsites This table could be a guide for engineers when problems are found PROBLEMS POSSIBLE CAUSES REMEDY CORRECTIVE ACTION Sudden trip of motor thermistor sensor Low refrigerant mass flow rate Apply liquid injection to motor Refrigerant shortage Charge refrigerant Suction filter clogged Clean change filter High suction temperature Install liquid injection to motor coil Hi...

Page 55: ...ser Check and clean the condenser Refrigerant overcharge Reduce the refrigerant charge Air moisture in refrigerant system Recover 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 necessary parts Improper Vi value...

Page 56: ...ller is heavy due to high temperature chilled water so the liquid injection devices capacity should be selected or calculated enough to reduce the overheat of the compressor Calculating the cooling capacity of liquid injection devices Liquid injection devices can be calculated with the HANBELL selection software or manually For manual calculation consider the most extreme conditions to be expected...

Page 57: ...nd motor coil temperature is high This may lead to motor failure Therefore in applications mentioned above Pt100 or Pt1000 for liquid injection to motor is recommended instead Figure 43 Liquid injection high temperature type connected to motor Figure 44 Liquid injection high temperature type to compression chamber b Oil cooler applications Compared to liquid injection applications external oil coo...

Page 58: ...cooler to reject heat from the cooling medium The basic water cooled oil cooling system is shown in Figure 47 Figure 47 Oil cooling by water Note 1 Please decide appropriate oil cooler capacity by referring to HANBELL selection software 2 Maximum pressure drop allowed in external oil cooler is 1 5 kg cm 2 When it exceeds 1 5kg cm 2 clean or change oil filter 3 When applying any oil cooler to compr...

Page 59: ...additional middle connection is at a similar level to the intermediate pressure with a two stage system As a result of these features a screw compressor of this design can be combined with an additional sub cooling circuit or an inter cooler for two stage expansion These measures result in a clearly increased refrigeration capacity due to additional liquid sub cooling especially with high pressure...

Page 60: ...59 Figure 50 Installation of ECO muffler Figure 51 System with economizer sub cooler Figure 52 System with economizer flash type sub cooler ...

Page 61: ...ion 1 Filter 6 Flow switch 11 Dryer 2 Compressor 7 Oil filter 12 Secondary cooler 3 Check valve 8 Oil cooler 13 Muffler 4 Sight glass 9 Expansion valve 5 Solenoid valve 10 Oil separator 7 4 Oil pump applications An additional oil pump is recommended to install to the system when the differential pressure between oil pressure and suction pressure is less than 4bar for example water cooled flooder c...

Page 62: ...suction pressure when pumping down should is 0 5kg cm2 c Time for pumping down should be shorter than 15 seconds d When doing pump down notice the high discharge temperature It should not go over 110 e Notice oil level of the compressor and the sound of running as well If there is any abnormal value or situation emergently stop pumping down 2 Low pressure receiver When a compressor operates in the...

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