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RC2-D Technical Manual

Figure 3-4 25%

、

50%

、

75%

、

100% Loading schematic diagram

◎

Note:

ON: the solenoid valve is activated; OFF: the solenoid valve is not activated

3.2.2

Continuous loading of compressor

Since it will take a long time for compressor to reach the required working conditions, the compressor

shall be started at 25% or 33% loading and kept for about 30 seconds (the startup time length

recommended by Hanbell).

Then the compressor is gradually loaded to 50% (66%) in time "t" and then

loaded to 75% in another"t" time. The time "t" is determined according to different working conditions

and application conditions.

Figure 3-5 Continuous loading time chart of compressor

Summary of Contents for RC2-D

Page 1: ...ration 30 6 2 Pre cautions for changing oil 31 6 3 The Replacement of Lubricanting oil 31 7 System Application 32 7 1 Principle Application of economizer 32 7 2 Application of pressure maintaining valve 33 7 3 Application of parallel connection system 34 7 4 Discharge temperature control oil cooler application 34 7 5 Motor temperature control Application of liquid injection 36 7 6 Key points for c...

Page 2: ...r Oil separator Application RC2 series 50m3 h Version D Null Standard M High temp S Single L Low temp P Parallel connection 1 2 Product feature High performance With stop valve of the economizer the design of the economizer connector is optimized to improve the performance of the economizer Motor temperature sensor and the throttle mechanism are adopted to reduce the influence of the motor liquid ...

Page 3: ...S P 180 7 300 330 RC2 200D S P 193 25 50 75 100 8 420 410 RC2 230D S P 230 14 540 520 RC2 260D S P 257 14 545 525 RC2 300D S P 293 16 590 570 RC2 310D S P 308 14 575 555 RC2 340D S P 339 16 600 580 RC2 370D S P 366 16 610 590 RC2 410D S P 407 15 730 700 RC2 470D S P 471 18 800 770 RC2 510D S P 508 20 760 730 RC2 550D S P 549 23 820 790 RC2 580D S P 583 20 805 775 RC2 620D S P 619 23 850 810 RC2 71...

Page 4: ...rew compressors are equipped with either 3 4 step capacity control system This capacity control systems consist of slide valve piston rod piston cylinde and piston ring The slide valve and the piston are connected by a piston rod the oil pressure in the system pushes the piston in the cylinder to move thus the slide valve moves Step capacity control as shown in Figure 3 2 The lubricating oil flows...

Page 5: ...ty of the compressor from the minimum capacity to the full load state 100 These two three normally closed NC solenoid valves are used to control the required capacity When the compressor with a 3 4 step capacity control system the compressor is loaded through 33 66 to 100 or 25 50 75 to 100 process and the compressor is unloaded through 100 66 33 or 100 75 50 to 25 process If needs to operate unde...

Page 6: ...er and pushes the piston to move to the right When it moves to 50 66 the high pressure oil flows back from the oil unloading hole to the suction port through 50 66 so the piston stops running at this position and the compressor remains at 50 66 load state 3 2 1 3 75 loading RC2 100 RC2 180 without this loading state When 75 solenoid is activated and the 50 solenoid valve is off the high oil pressu...

Page 7: ...compressor to reach the required working conditions the compressor shall be started at 25 or 33 loading and kept for about 30 seconds the startup time length recommended by Hanbell Then the compressor is gradually loaded to 50 66 in time t and then loaded to 75 in another t time The time t is determined according to different working conditions and application conditions Figure 3 5 Continuous load...

Page 8: ... Figure 3 6 Diagram of outlet water temperature and capacity control Please refer to the chapter of capacity control system for specific information If you need special capacity control system please contact Hanbell directly ...

Page 9: ...0 25 seconds and the MCM MCD gets the power to conduct the delta operation In 0 25 seconds it may cause pseudo short circuit due to improper contactor action resulting in compressor jumping When this happens it is recommended to use an adjustable Y Δ time relay or delay device to extend the conversion of MCM and MCD and the power gain time is about 0 25 to 0 5 seconds Please refer to the Y Δ Conve...

Page 10: ...lowest load when starting 1 Compressor start up RC2 100D 580D compressor should not start more than 6 times per hour and RC2 620D 930D compressor should not start more than 4 times per hour When starting the compressor should be at the lowest load 25 or 33 In case of low ambient temperature the oil heater must be powered on and heated 6 hours before the compressor start to maintain the oil tempera...

Page 11: ...iate contactor according to AC3 specification compressor selection program and system design status 5 Grounding requirements There is a grounding connector in the wire box please connect it to the grounding terminal of the system control panel accurately Note A The setting value of normal leakage protector should be higher than 50mA In humid environment 25mA is better B The grounding voltage shall...

Page 12: ...119 510 RC2 580D S P 300 925 RC2 260D S P 129 510 RC2 620D S P 317 1295 RC2 300D S P 148 645 RC2 710D S P 360 1410 RC2 310D S P 157 645 RC2 790D S P 382 1510 RC2 340D S P 174 730 RC2 830D S P 429 1640 RC2 370D S P 188 780 RC2 930D S P 491 2090 Table 4 1 RC2 D series compressor MCC LRA Note MCC in table 4 1 above will vary depending on voltage and frequency 4 4Wiring diagram of terminal cover plate...

Page 13: ...is started please check if the insulation is normal and if the circuit and setting are correct Please turn on the power after confirmation If you have any questions please contact the equipment supplier Specification for terminal plate nut Model Specification Torque N m RC2 100 180D S P M8 20 RC2 200 930D S P M12 35 Note when the surface temperature of compressor is lower than the air dew point te...

Page 14: ...e Qty Parallel application Single application 1 Discharge stop valve 1 2 Discharge check valve 1 3 Suction stop valve 1 4 Suction check valve 1 5 ECO stop valve 1 6 Liquid injection controller 1 7 Suction discharge bushing 1 set 8 Damping pad 4 9 Oil circuit solenoid valve 1 10 External oil filter 1 11 Oil flow switch 1 12 Oil sight glass 1 13 External oil filter differential pressure monitoring s...

Page 15: ...103 Steel 4 110 128 RC2 620 RC2 930 Suction flange 5 Copper 4 1 8 80 174 35 106 121 Steel 5 75 135 154 Note The above specification is for standard RC2 D series compressor D S type If need non standard bushing please confirm with hanbell RC2 100 930D P suction and discharge flange bushing configuration Model Flange Size Material Size Dimension A B C D E RC2 100 RC2 140 Suction flange RC2 100 RC2 2...

Page 16: ...2 RC2 550 4 3 RC2 230 3 2 1 2 RC2 580 4 3 RC2 260 3 2 1 2 RC2 620 5 4 RC2 300 3 2 1 2 RC2 710 5 4 RC2 310 3 2 1 2 RC2 790 5 4 RC2 340 4 2 1 2 RC2 830 5 4 RC2 370 4 2 1 2 RC2 930 5 4 5 2 3 Suction check valve Check valve is a kind of valve which can automatically prevent the backflow of fluid The disc of the check valve opens under the action of fluid pressure and the fluid flows from the inlet sid...

Page 17: ... Max working pressure φA B φC φD Nut 2 90 85 102 91 16 140 28 Bar 2 1 2 110 97 122 111 16 150 3 120 109 138 121 20 170 4 145 125 163 146 20 190 5 175 150 203 176 M20 200 5 2 5 Gravity check valve Gravity check valve can automatically prevent the backflow of fluid The valve disc opens under the action of fluid pressure and the fluid flows from the inlet side to the outlet side When the pressure at ...

Page 18: ...ntaining valve The pressure maintaining valve enables the compressor to quickly establish enough high and low pressure difference within a short period of time after starting up so as to ensure the smooth loading of the compressor and ensure that the compressor will not be adversely affected by oil loss Size A B C D E F Model 7 8 131 5 11 46 22 3 89 3 124 RC2 100 RC2 180D S P 7 8 131 5 11 46 22 3 ...

Page 19: ...ically One second after the motor starts the motor phase monitoring function will be activated and remain to be activated for 5 seconds Motor phase being abnormal or motor being under phase will cause the protection module to be disconnected and locked In order to avoid the tripping caused by reversal after the compressor shutdown the phase monitoring function will only maintain for 20 seconds aft...

Page 20: ...r 3 times within 30s Phase monitor Phase sequence Phase loss Inactivation Activated 1 second after the motor starts and will remain monitoring for 5 seconds Activated 1 second after the motor starts and will remain monitoring till the machine stops About 20 seconds after the motor stops Delay reset relay Power Mechanical lifetime AC 240V 2 5A C300 at least AC DC 24V 20mA One million times on and o...

Page 21: ...trical installation standards The power distribution is not allowed to exceed the maximum supply voltage of the module 5 2 9 NTC Temperature Sensor NTC is one kind of embedded temperature sensor which is installed inside the motor coil It is connected with the micro control system to display the temperature of the motor and set the alarm point and disconnection point to protect the compressor NTC ...

Page 22: ... 1 33 6 21 53 21 15 20 78 47 4 68 4 59 4 51 88 1 38 1 34 1 30 7 20 64 20 30 19 95 48 4 52 4 44 4 36 89 1 34 1 30 1 26 8 19 81 19 48 19 15 49 4 38 4 30 4 22 90 1 31 1 27 1 23 9 19 01 18 70 18 39 50 4 24 4 16 4 08 91 1 27 1 23 1 19 10 18 25 17 96 17 67 51 4 10 4 03 3 95 92 1 24 1 20 1 16 11 17 51 17 24 16 97 52 3 97 3 90 3 82 93 1 21 1 17 1 13 12 16 81 16 56 16 30 53 3 85 3 77 3 70 94 1 17 1 14 1 10...

Page 23: ...ompressor starts up again after a long time shutdown so as to ensure that the internal temperature of the compressor is higher than the system temperature and ambient temperature and avoid the poor lubrication effect caused by liquid compression or low viscosity of lubricating oil caused by the liquid refrigerant in the compressor oil tank 5 2 11 Oil level switch The oil level switch is equipped w...

Page 24: ...mpurities adsorbed on the surface of the oil filter screen from causing danger to the oil supply system Figure External oil filter pressure differnece switch HP LP 150kpa Connection digram for External oil filter pressure differnece switch 5 2 14 Muffler Check valve for Ecocnmize When using the economizer it is recommended to install an economizer muffler before the medium Technical data Contact c...

Page 25: ...eration The oil filter is of washable type with the precision of 300 meshes See the following figure for the dimensions The thread welding ports of the inlet and outlet are connected with 3 8 5 8 and 1 copper pipes Figure External Oil filter 5 2 16 Oil flow switch The oil flow switch should be installed in the system with external oil separator to prevent oil loss of the compressor The specificati...

Page 26: ...l the damping pad at the position shown in the figure below The installation torque requirement is 20 30n M No A mm B mm C mm D mm E mm Model 1 50 55 20 20 20 RC2 100 RC2 370 2 70 100 20 25 25 RC2 410 RC2 620 3 80 100 20 25 25 RC2 710 RC2 930 5 2 18 IP54 Terminal box The terminal box reaches IP54 protection level Please refer to the figure below to understand the external dimension and internal di...

Page 27: ...RC2 D Technical Manual 2 RC2 200 470 D S P terminal box 3 RC2 510 930 D S P terminal box ...

Page 28: ... is high and the pressure drop in the oil circuit is too large to load normally which leads to the heavy load start Therefore an oil heater is needed to heat the lubricating oil to improve the oil temperature in a short time If the compressor is operating under limit condition it is necessary to install an external oil cooler please use hanbel program to determine the cooling capacity and oil flow...

Page 29: ...il especially after the motor is burned down the acid residue remains in the system The acidity of the system lubricating oil can be checked by changing the oil and the lubricating oil can be changed again after 72 hours of operation until the acidity of the lubricating oil reaches the standard value 4 When filling the lubricating oil it is necessary to ensure that the total amount of lubricating ...

Page 30: ... compression ratio the power consumption of the compressor increases very little which can not only achieves a better energy efficiency ratio but also improves the refrigeration capacity efficiency and reliability of the system Please get efficiency of the economizer through hanbell selection program 7 1 1Sub cooled Economizer System The subcooled economizer system uses a heat exchanger subcooler ...

Page 31: ...n and serious damage to the compressor so the pressure maintaining valve is recommended to be installed In addition to the installation of pressure maintaining valve it is also recommended to install high and low pressure difference switches If necessary please contact hanbell for specific information Application of pressure maintaining valve Single compressor Application of pressure maintaining v...

Page 32: ...ed with the liquid injection the application of oil cooler can reduce the discharge temperature and help the system achieve higher efficiency Oil cooler can be divided into three categories refrigerant cooling air cooling and water cooling The capacity of oil cooler can be calculated by manual or Hanbell program When calculating manually the worst operating conditions should be considered the lowe...

Page 33: ...r cooling The water cooling system is to use a shell tube type heat exchanger and a cold source from an external cooling tower or evaporative cooler or use a water pump to make the cooling medium water circulate and release heat to the environment in the cooling tower or evaporative cooler The water cooling system diagram is shown in the figure below ...

Page 34: ...35 7 5 1 Application An auxiliary cooling system should be provided in the region with high condensation temperature or low evaporation temperature on the operation range diagram to prevent compressor overheating and ensure the normal operation The simple auxiliary cooling way is to directly lead a pipe from the system liquid pipe into the preset liquid injection connector of the compressor to coo...

Page 35: ... down is harmful to the compressor and compression chamber 3 When pump down the minimum suction pressure should be kept above 0 5bar 4 When pump down the discharge temperature should be kept less than 100C 5 Pay attention to the high and low pressure of the compressor and the noise during operation If there is any abnormal situation stop the pump down immediately 7 6 2 Long term partial load opera...

Page 36: ...way from the heat source to avoid heat radiation The compressor shall be installed as close to the power supply as possible for wiring and the air and drying in good environment shall be maintained Ensure the foundation strength is enough to avoid additional noise and vibration during compressor operation and enough space shall be reserved for compressor maintenance in the future In addition the c...

Page 37: ...mpressor is installed If the inclination angle is bigger than the limit value the oil level will be too low which causes the compressor to stop However in some special applications the inclination may exceed the limit For example when it is used on the ship it is recommended to have an external oil separator and associated auxiliary components Please contact Hanbell for further installation instru...

Page 38: ...ted to the terminal box and it should have good insulation The power line should be far away from the heat source and metal parts with edges and corners to avoid the damage of the insulation skin The power supply should be well installed and shall have good insulation Terminal box and bolt shall be provided 5 Confirmation of installation 6 Refer to Chapter of Protection Device Piping system 1 Outp...

Page 39: ...fference between suction superheat and evaporation temperature should be within 15K 4 The whole system especially the pipeline and capillary must pass the vibration test If there is abnormal vibration or noise during operation please contact Hanbell 5 If the compressor operates for long time the following items should be inspected daily The operation data such as 3 phase voltage compressor line cu...

Page 40: ...ng liquid refrigerant injection device is not installed or failure 3 Coil protection switch failure 4 Electrical system failure 5 Poor motor coil or temperature too high 6 Excessive suction superheat and poor heat dissipation 2 Compress fail to load 1 Ambient temperature too low viscosity of lubricating oil too high 2 Capillary blocked 3 Discharge port of the capacity control stuck and cannot be c...

Page 41: ... transfer effect poor 3 Compression ratio too large and no auxiliary cooling 4 Bearing damage rotor friction 5 Oil loss or oil level too low 8 2 3 Troubleshooting INT69HBY Diagnose troubleshooting Fault Phenomenon Troubleshooting 1 Abnormal power supply of module Red flash 3 Orange flash 1 The power supply of the module is too low The normal operating voltage of NT69HBY Diagnos is 115v 240v 15 10 ...

Page 42: ...r to ensure the safe operation of the use of the following external cooling devices is necessary a Oil cooler b Motor liquid injection cooling c Please select the appropriate external cooling device according to hanbell program It is necessary to install pressure difference switch or pressure maintaining valve to ensure that the oil pressure is 4bar higher than the suction pressure to ensure that ...

Page 43: ...hown in the blue full line area and the operation range of RC2 D M is shown in the black full line area In order to avoid high temperature of compressor motor caused by high suction superheat or high pressure it is recommended to install motor liquid injection system ...

Page 44: ...RC2 D Technical Manual 46 10 Appearance Drawing 10 1 RC2 100 930D S Drawing RC2 100 140D S Drawing ...

Page 45: ...RC2 D Technical Manual 47 RC2 180D S Drawing ...

Page 46: ...RC2 D Technical Manual 48 RC2 200 620D S Horizontal suction port Drawing ...

Page 47: ...755 221 67 755 661 320 433 103 276 270 230 132 652 408 70 100 22 43 271 567 RC2 510D S 1675 107 798 231 76 789 696 288 484 103 276 270 230 132 638 450 70 100 22 46 271 567 RC2 550D S 1724 107 798 236 76 800 720 320 477 103 280 270 230 132 642 450 70 100 22 35 399 392 RC2 580D S 1707 107 798 231 76 789 696 320 484 103 276 270 230 132 638 450 70 100 22 46 275 570 RC2 620D S 1904 107 798 236 76 800 7...

Page 48: ...RC2 D Technical Manual 50 RC2 620 930D S Vertical suction port Drawing ...

Page 49: ...RC2 D Technical Manual 51 10 2 RC2 100 930D P Drawing RC2 100 140D P Drawing ...

Page 50: ...RC2 D Technical Manual 52 RC2 180D P Drawing ...

Page 51: ...RC2 D Technical Manual 53 RC2 200 620D P Drawing ...

Page 52: ...22 277 517 320 433 103 275 220 270 230 132 652 408 70 100 22 43 271 567 RC2 510D P 1515 490 365 122 277 517 288 484 103 275 220 270 230 132 638 450 70 100 22 46 271 567 RC2 550D P 1534 490 365 126 272 512 320 477 103 280 220 270 230 132 642 450 70 100 22 35 399 392 RC2 580D P 1534 490 365 122 277 517 320 484 103 275 220 270 230 132 638 450 70 100 22 46 275 570 RC2 620D P 1819 490 379 140 331 615 3...

Page 53: ...RC2 D Technical Manual 55 RC2 620 930D P Drawing ...

Page 54: ... Flare 9 7 1 2 Flare 12 8 RC2 340D S 2 1 2 Flange Φ68 Φ77 2 4 Flange Φ93 Φ110 1 1 8 Flare 28 8 5 8 Flare 16 3 8 Flare 9 7 1 2 Flare 12 8 RC2 370D S 2 1 2 Flange 4 Flange 1 1 8 Flare 28 8 5 8 Flare 16 3 8 Flare 9 7 1 2 Flare 12 8 RC2 410D S 2 1 2 Flange 4 Flange 1 1 8 Flare 28 8 5 8 Flare 16 3 8 Flare 9 7 1 2 Flare 12 8 RC2 470D S 2 1 2 Flange 4 Flange 1 1 8 Flare 28 8 5 8 Flare 16 3 8 Flare 9 7 1 ...

Page 55: ...e 16 3 8 Flare 9 7 1 2 Flare 12 8 RC2 340D P 2 1 2 Flange 4 Flange Φ93 Φ110 1 1 8 Flare 28 8 5 8 Flare 16 3 8 Flare 9 7 1 2 Flare 12 8 RC2 370D P 2 1 2 Flange 4 Flange 1 1 8 Flare 28 8 5 8 Flare 16 3 8 Flare 9 7 1 2 Flare 12 8 RC2 410D P 3 Flange Φ80 5 Φ90 2 4 Flange 1 1 8 Flare 28 8 5 8 Flare 16 3 8 Flare 9 7 1 2 Flare 12 8 RC2 470D P 3 Flange 4 Flange 1 1 8 Flare 28 8 5 8 Flare 16 3 8 Flare 9 7 ...

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