Hanbell RT Series Manual Download

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6.5 Operation and maintenance

6.5.1 Compressor start-up

The table below shows the required procedures and points before commissioning the
compressor.

Items

Check Points

Remarks

Leakage test

1. Inject 13.5 bar of nitrogen.
2. No leakage within 12 hours.
3. Mark the confirmed pressure on the pressure gauge.

1. Close the service valve on the

evaporator

Vacuum test

1. Vacuum pressure should below 750mmHg.
2. Maintain the vacuum state for 12 hours and confirm

whether the degree of vacuum has changed or not.

1. High pressure gauge must be

closed (no vacuum scale).

2. Do not conduct electrical testing

under vacuum state.

Lubricant oil
refilling

1.Use vacuum method and the angle valve on the

return flange of compressor for filling lubricant oil

2. Fill the oil until oil display at H scale. Verify the oil

level and refill (if necessary) after commissioning

3.Remove the wiring of the built-in oil pump to avoid

malfunction of the oil pump due to insufficient oil
which will result in damage to the oil pump

4.The oil heater should be powered on 24 ~ 48 hours

before compressor started to ensure oil temperature
is above "evaporation temperature " + 20

℃

1. The oil level should not be higher

than the H scale on the oil display
to avoid agitating the oil when the
gear rotates.

2. Determine the lubricating oil

heating time on condition like
under high latitude or cold area.

Refrigerant refilling

1. Confirm whether the chilling water pump and the

cooling water pump are running before refrigerant
filling.

2. Firstly add the gaseous refrigerant to above

saturation temperature 0

℃.

3. Fill the gaseous refrigerant to 2bar (g) after

connecting the oil pump power.

4. Then charge the liquid refrigerant to 80% of the

standard amount.

1. Record the amount of refrigerant

filled.

Motor fluid spray
volume

1. Adjust firstly the angle valve opening of the motor

housing to 2 cycles, and then open fully the outlet
valve at the bottom of the motor housing.

1. Please adjust the opening of the

valve according to the actual
maximum load condition of the
model and control the motor
temperature at <90

℃.

2. The present specifications are

Pt100 (or Pt1000) a total of 4
groups, need to be connected to
the control system to monitor
motor temperature.

Control setting

1. Verify if the electrical specifications of the Actuator

and hot gas bypass valve are correct.

2. Actuator: Control signal of 5% ~ 100% is 4.8 ~ 20mA

(or 0.5 ~ 10V), check if the actuator indicator
steering is rotating.

3. Actuator starting point is set to be 5% (for start-up

program).

4. Hot gas bypass valve: check if movement from 0% ~

100% is normal.

1. Make sure the Actuator is

working properly.

Summary of Contents for RT Series

Page 1: ...3 Digital BCD switch setting 37 3 2 4 Duty cycle 39 3 2 5 Wiring 40 3 2 6 LED indicator lights 42 3 2 7 Manual operation 43 3 2 8 Overload protection 43 3 2 9 Troubleshooting 43 3 2 10 Actuator capacity control 43 3 3 SURGE AND STALL PHENOMENON 44 3 3 1 Fixed frequency capacity control and surge protection strategy 46 3 3 2 Energy savings with variable frequency compressor 48 3 4 HOT GAS BYPASS HG...

Page 2: ...AND SAFETY PRACTICES 81 5 4 1 Electrical Safety Precautions 81 5 4 2 The Inspection and Preparation before Electrical Wiring 81 5 4 2 1 Inspection of Unpacking 81 5 4 2 2 Cable Selection 82 5 4 3 Power Wiring Detail 82 5 4 3 1 Caution for wiring 82 5 4 3 2 Making of cable end and the connector 83 5 4 4 Limitation of power supply 85 CHAPTER 6 COMPRESSOR LIFTING AND INSTALLATION 86 6 1 COMPRESSOR LI...

Page 3: ...ss mechanical loss JIS 0 ISO Grade 4 Enclosure IP54 protection Ambience RT series compressors should be stored and operated within the following ambient temperature Storage 10 to 70 14 to 158 Operation Water cooled ET 8 20 17 to 68 CT 20 50 68 to 122 Operation Heat pump ET 8 20 17 to 68 CT 20 60 68 to 140 Note Please refer to Application limits in page 2 for allowable operating conditions and Hanb...

Page 4: ...ion pipe If the sensors are installed on condenser and evaporator pressure drop need to be considered Surge point 2 Surge point each IGV opening has a corresponding maximum pressure ratio surge point 3 Surge line the curve formed by connecting surge points of each IGV opening 4 Safety margin line the line formed by translating the surge line to a safety margin at the maximum upper limit of pressur...

Page 5: ... compressed air but with reduced effectiveness Stall zone is defined to confine application of the compressor under unsteady flow with small volume flow 6 Allowable operating range ranging from the maximum IGV opening 100 to the smallest IGV opening 10 with the maximum operation load of 105 and covering the operating range from safety margin line to the minimum pressure ratio ...

Page 6: ... charge Liter 38 Motor Type 3 Phase 2 Pole Induction Starting Y Starting Direct starting Voltage 50 60 Hz V 380 600 10k 6k 4k 3k Insulation Class F Protection PTC Pt100 Pt1000 Oil heater kW 2x0 5 Chamber heater kW 2x0 3 Maintenance butterfly valve 8 optional Dimension LxWxH m 2 30 x 1 20 x 1 02 Weight kg 3 500 Hydrostatic pressure test kg cm g 22 Table 2 1 Refrigeration Compressor specifications 1...

Page 7: ...or Type 3 Phase 2 Pole Induction Starting Y Starting Direct starting Voltage 50 60 Hz V 380 600 10k 6k 4k 3k Insulation Class F Protection PTC Pt100 Pt1000 Oil heater kW 2x0 5 Chamber heater kW 2X0 3 Maintenance butterfly valve 10 optional Dimension LxWxH m 2 62 x 1 29 x 1 27 Weight kg 4 500 Hydrostatic pressure test kg cm g 22 Table 2 2 Refrigeration Compressor specifications 1 Under CT ET 36 6 r...

Page 8: ...g Voltage 50 60 Hz V 380 600 10k 6k 4k 3k Insulation Class F Protection PTC Pt100 Pt1000 Oil heater kW 2x0 5 Chamber heater kW 2X0 3 Maintenance butterfly valve 10 optional Dimension LxWxH m 2 60 x 1 30 x 1 20 Weight kg 4 500 Hydrostatic pressure test kg cm g 22 Table 2 3 Refrigeration Compressor specifications 1 Under CT ET 36 6 refer to ASHRAE 90 1 2015 2 Setting IGV1 5 applied only in startup i...

Page 9: ...Starting Y Starting Direct starting Voltage 50 60 Hz V 380 600 10k 6k 4k 3k Insulation Class F Protection PTC Pt100 Pt1000 Oil heater kW 2x0 5 Chamber heater kW 2x0 3 Maintenance butterfly valve 8 optional 10 optional Dimension LxWxH m 2 60 x 1 30 x 1 20 Weight kg 4 500 Hydrostatic pressure test kg cm g 22 Table 2 4 Heating Compressor specifications 1 Under CT ET 36 6 refer to ASHRAE 90 1 2015 2 S...

Page 29: ...scharge 8 218 221 5 305 350 30 12 25 11 Mid press Eco 4 116 116 185 225 24 8 23 8 5 Remarks Material standard JIS 20 kg cm2 g steel unit mm thickness must be equal to the standard or larger Table 2 5 Flange dimensions Note 1 Please weld steel pipes onto flanges by butt welding and make sure debris has been cleaned otherwise the compressor might be damaged badly during running Flow velocity in the ...

Page 30: ...maining gas inside compressor can be led to the condenser without additional refrigerant recovery procedure Model Dimension inch Flow Resistance Coefficient K Density kg m3 Flow Speed m s Pressure Drop kPa RT 120 8 0 5 45 14 69 2 43 RT 130 8 0 5 45 15 98 2 87 RT 140 8 0 5 45 16 49 3 06 RT 160 10 0 51 45 12 70 1 9 RT 180 10 0 51 45 14 61 2 4 RT 200 10 0 51 45 15 72 2 8 RT 240 10 0 51 45 19 05 4 2 R...

Page 31: ...198 176 241 130 22 16 32 114 24 10 250mm 332 70 248 217 273 155 30 22 51 114 27 Remarks Size C is the minimum size when the valve is fully open unit mm Operating Temperature 29 260 Operating Pressure 1480psi Material Valve body is conformed to the standard of ASTAM351 GR CF8M stainless steel pressure rating is ASME 150 The butterfly valve is of wafer type butterfly valve and installed in between A...

Page 32: ...two flanges on evaporator and condenser need to be released during the connection of the compressor so as to reduce the effect of welding pipe deformation Caution Sometimes in order to prevent leakage at the connections of compressor the overtightening of flange bolts can happen This could cause the suspension of the compressor in the air leading to excessive vibration and damage of the compressor...

Page 33: ...Flare Liquid injection outlet 1 1 8 Copper 52 75 35 28 8 42 12 RT 160 280 RT 161 RT 221 Liquid injection inlet 7 8 Copper 52 60 35 22 6 42 12 Liquid injection outlet 1 5 8 Copper 52 75 35 41 6 52 12 Remarks unit mm Table 2 6 Dimensions of bushings Note To effectively control motor temperature some service valve can be installed in the piping before the bushing for motor liquid injection to provide...

Page 34: ...tion NO Description 1 Suction 8 Oil drain valve 2 Discharge 9 Sight glass oil level 3 Sight glass motor 10 Oil return flange 4 Sight glass refrigerant level 11 Gas return pipe 5 Power bolt 12 Inlet flange for motor cooling 6 Oil return connection 13 Outlet flange for motor cooling 7 Oil pump 14 Actuator 10 3 2 4 6 5 13 7 9 11 8 12 1 14 ...

Page 35: ...e to the compressor suction inlet After the inlet nozzle gas flow velocity increases due to the narrow passage By changing angles of IGV1 refrigerant gas enters with a pre rotation angle into impellers Both gas flow speed and pressure will increase with rotation of impellers Double guide vane performance Impeller of each stage in front of IGV can only control energy change of that particular stage...

Page 36: ... Ltd All rights reserved Figure 3 2 System with an economizer Figure 3 2 1 Figure 3 2 1 Refrigerant cycle diagram with economizer contributes to higher efficiency and this is due to an approximately 7 capacity gain occurs between point 5 point 6 ...

Page 37: ...in the basic flow of refrigerant to the compressor The refrigerant flow is at minimum nlet flow guide vane is completely closed The freezing capacity at this point is also at the minimum but often in the surge zone which cannot be used Normal 10 uses T series IGV1 5 The lower pressure ratio stands for the lower minimum unloading capacity Therefore it is NOT applied to all operation conditions that...

Page 38: ...heater 10W HQ 015 5W HQ 010 ceramic housed Table 3 2 1 Actuator data Type Model Maximum output torque Operation time second Rated current A Duty type kg m 50 60Hz 50 60Hz Actuator 1 for IGV1 HQ 015 15 21 25 0 72 0 84 70 Actuator 2 for IGV2 HQ 010 10 17 20 0 47 0 46 70 Note1 Please contact technicians from Hanbell if explosion proof is required Note2 Started from 2017 standard version of actuator i...

Page 39: ...Actuator 3 2 3 Digital BCD switch setting Selection of input signal User can select input signal type by adjusting DIP switches as follows Note Actuator IGV1 terminal 15 ve terminal 16 ve Actuator IGV2 terminal 10 ve terminal 11 ve Caution Do not adjust DIP switch when power is supplied to the actuator ...

Page 40: ... recover signal setting Note Factory default setting is at the off position Delay working time Delay setting is to avoid excess continuous operation of the actuator which would result in the overheating of the actuator motor Delay time ranges from 0 7 5 seconds and is adjusted to 15 stages with 0 5 seconds at each stage Factory default setting scale 4 is 2 seconds Seconds 0 0 0 5 1 0 1 5 2 0 2 5 3...

Page 41: ... settings for operating time and rest time of the actuator are based on the standards of IEC International Electrotechnical Commission IEC34 1 as follows Start frequency operating time operating time rest time 100 Rest time operating time 1 start frequency start frequency Example Actuator duty cycle start frequency on the compressor of 50 Hz is 70 the operating time is 21 seconds Rest time 21 1 70...

Page 42: ...for full open and full close positions Close 3 to 8mA DC Open 16 to 21mA DC For example If the user would like to assign 5mA to the fully closed position supply a 5mA signal and then allow the actuator to move to the corresponding position Move switch 4 CH1 to the on position and press the Zero button one time The actuator acknowledges that position as fully closed and transmits 4mA Push the Span ...

Page 43: ...xceed more than 30m 2 Power connecting point 220V AC 1PH 50 60Hz 5 13 Caution An independent power supply is required for actuator power supply Power source should not be used in conjunction with other electrical equipment particularly not use in connection with two phase power from compressor motor main power source and isolation transformer and electric filter have to be installed to avoid volta...

Page 44: ... 1PH 50 60Hz 4 5 Note Actuator 2 is used in heat pump models and T series dual IGV not for standard compressor models 3 2 6 LED indicator lights LED Indication Blue light Power on Flickering Blue light Auto calibrating Green light Fully closed Flickering Green light Closing Red light Fully open Flickering Red light Opening Yellow light Manual mode Flickering Yellow light Error indicator for one of...

Page 45: ... power supply of actuator Check that the voltage matches the rating on the actuator nameplate Check internal wiring against actuator wiring diagram Check the limit switch cams Actuator is receiving power but does not operate Check the power supply of actuator Check actuator torque to see if it is greater than the valve torque Check the limit switch cams Check that the torque switches have not trip...

Page 46: ...3 Surge and Stall phenomenon Definition Surge When the flow rate continues to decrease after stalling further breakdown of steady through flow will occur which ultimately leads to complete expansion of separation zone in the flow path This results in significant drop in discharge pressure and when the discharge pressure is lower than the backpressure reversal of flow will take place Such phenomena...

Page 47: ...dy loading due to the reversal of flow during surging With an approximately 5 seconds cycle of surge frequency the compressor can be considered as surging when three consecutive peak current differential is 10 higher than the average current within 15 seconds except during loading control of the compressor Please refer to section 3 3 1 for surge protection strategy mechanism Note RT series compres...

Page 48: ...sm of a fixed frequency compressor is generally divided into two modes unloading mode and loading mode Unloading mode If surge occurs during unloading mode of cooling water then open the hot gas bypass valve for 1 2 minutes to reduce the operating pressure ratio raising the lower pressure The system can return to normal operating mode after the hot gas bypass valve is closed Loading mode If surge ...

Page 49: ...2 98 2 66 e 2 27349E 00 4 16545E 02 3 06201E 04 1 38454E 06 1 66588E 08 1 61850E 04 6 98360E 07 5 66460E 10 RT 111 RT 161 RT 221 y 2 27349 4 16545E 02x 3 06201E 04x2 1 38454E 06x3 1 66588E 08x4 constant a b c d RT 160T RT 280T y 2 3101 1 6313E 02x 1 6185E 04x2 6 9836E 07x3 5 6646E 10x4 constant a b c d e 2 31010E 00 1 63130E 02 e 2 55474E 00 1 18314E 02 1 22987E 04 3 07100E 07 1 53292E 09 1 72966E...

Page 50: ...ut power is as follows P H m η P compressor input power H energy head m mass flow rate of refrigerant η motor efficiency According to the Laws of Similarity in fluid mechanics IGV1 100 90 80 70 60 50 40 30 20 10 IGV2 100 100 100 100 95 2 87 8 77 6 64 5 48 5 29 6 IGV1 100 90 80 70 60 50 40 30 20 10 IGV2 100 98 9 96 3 92 7 88 4 83 1 76 3 66 8 53 2 33 5 IGV1 100 90 80 70 60 50 40 30 20 10 IGV2 100 10...

Page 51: ...based on the chilled water outlet temperature and the compressor head pressure ratio so that the unit always operates under the best condition The basic parameter of VSD control is the temperature difference between the actual value of the chilled water outlet temperature and the set value 1 When the unit is operating at full load the IGVs are fully opened and the motor rotational speed control lo...

Page 52: ... cy dx2 ey2 fxy gx3 hy3 ixy2 jx2 y x IGV opening 10 100 y pressure ratio Pr Z Frequency Hz RT 120E a b c d e 3 99639E 01 5 25339E 02 7 47371E 01 1 28399E 03 2 21462E 01 f g h i j 2 20465E 02 8 07113E 06 2 51895E 00 1 42502E 03 1 35207E 04 RT 130E RT 140E a b c d e 2 10165E 01 1 11192E 01 4 57809E 01 7 54248E 04 1 00315E 01 f g h i j 5 47750E 02 6 23802E 06 1 06767E 00 1 95358E 02 9 99493E 04 RT 16...

Page 53: ...e formula and multiply the calculated value by 1 2 VSD allowable operating range as shown in Figure 3 7 the allowable operating range of a VSD compressor is formed by the maximum operable capacity 105 VSD surge formula and pressure ratio IGV opening and surge line Surge line Insert Z 50Hz fixed frequency IGV opening 10 100 into VSD surge formula the values of y pressure ratio obtained forms the su...

Page 54: ...ately 7 2 58RT of cooling capacity change rate 2 Assuming that the set value of cooling water output temperature is 7 C neutral zone temperature difference is 0 2 C output cycle time is 30 seconds rapid loading and unloading frequency is 1 Hz Normal loading and unloading temperature difference is 0 5 C and frequency increase and decrease is 0 5Hz Change of CHWT and inverter output are listed in th...

Page 55: ...to keep flow speed under 10 m sec In piping the proportional valve should be installed as close as possible to the evaporator and also at another side of suction entry motor side to lower the noises at suction side Setting the piping on suction pipe can also prevent liquid strike Besides a muffler should be installed at the evaporator Hot gas bypasses to the evaporator should be prevented from liq...

Page 56: ...ol the pressure in the economizer to maintain a certain pressure difference between intermediate pressure and low pressure when operating in low pressure ratio Thus the intermediate inlet is less likely to suffer from the phenomenon of liquid absorption as shown in Figure 3 8 b so double IGV model users do not need additional intermediate pressure valve Note 1 For dual IGV models intermediate inle...

Page 57: ... where Pc 9 63 bar Pe evaporator pressure IGV 100 Pc condenser pressure Pm 6 05 bar Pm intermediate pressure 1 RT 111 When IGV 0 Pm 1 025 IGV IGV100 0 5 Pe Pc 0 5 Pe Pc 1 9 When IGV 0 Pm 1 025 0 82 Pe Pc 0 5 E g Pe 3 62 bar where Pc 11 9 bar Pe evaporator pressure IGV 50 Pc condenser pressure Pm 7 08 bar Pm intermediate pressure 2 RT 161 221 When IGV 0 Pm 1 025 IGV IGV100 0 035 Pe Pc 0 5 Pe Pc 0 5...

Page 58: ... on the top and lubricates bearings in front of the motor the gears and the front back bearings which are around the high speed shaft and returns to the oil tank finally Caution RT series centrifugal compressor uses positive displacement gear pumps which release pulsating wave at the discharge of the oil pump Therefore a buffer tube and a steel wire hose length 40cm should be added at the outlet o...

Page 59: ...V 50Hz 3ψ 220V 60Hz 3ψ 380V 60Hz Max operating current A 3 6 2 1 3 5 2 LRA A 19 1 11 06 17 6 10 2 Table 4 1 Specifications of the oil pump Note Voltage Specifications 3ψ 220V 50Hz 60Hz are shared oil pump With different power supply frequencies the motor output and oil flow rate will also be different This is similar for 3ψ 380V 50Hz 60Hz However the internal windings of oil pump motor for 220V an...

Page 60: ...l oil cooler As built in oil pump is used in all models and the oil flow rate is fixed at 20 25L min the oil cooler should be the same for all models excessive oil discharged will be bypassed back into the oil tank through an internal valve Taking highest oil tank temperature as the temperature of oil entering the oil cooler while the temperature of cooled oil needs to be around 30 40 C and it is ...

Page 61: ...ose paper as filter material is economical and works fine Cellulose as the filter may block particles while allowing oil to pass through There is synthetic fiber for high end filters that has smaller passages to block smaller particles but still make fluid pass it through There is also a kind of material that is a blend of these two materials HANBELL provides oil filter with spec below Working pre...

Page 62: ...ral an ejector is applied to recirculation of leaked oil Power of ejection comes from high pressure in the condenser or middle pressure in the economizer Gas with oil will be separated firstly by internal oil separator in the oil tank and gas will re circulate stably without fluctuation of oil level For better evaporation of liquid refrigerant in the oil tank oil heaters in the bottom of the oil t...

Page 63: ... controlled independently and needs to be turned on during temporary shut down or 24 hours before restart Oil temperature control stated above is still required during operation Warning Do not start the machine when the oil temperature is lower than ET 20 Warning Excessively high oil temperature indicates insufficient oil for compressor circulation or heat imbalance Continuous running will cause d...

Page 64: ...achinery Co Ltd All rights reserved Figure4 4 Oil separator Refrigerant heater specifications Two UL approved 300W oil heaters have been installed in the compressor casing compressor after shutdown for a long time please turn on refrigerant hours to make temperature inside the compressor higher than syste temperature and ambient temperature Therefore it can prevent condensation of compression cham...

Page 65: ...e P3 is 0 6 kg cm higher than the suction pressure Ps system should provide an alarm signal to users When the oil tank pressure is 0 8 kg cm higher than the suction pressure system should be stopped for protection and troubleshooting P3 Ps 0 6kgf cm 2 2 2 2 alarm P3 Ps 0 8kgf cm2 2 2 2 shut down Figure 4 6 Labyrinth ring RT series compressors are equipped with rigid bearings and fine oil separator...

Page 66: ...ion temperature is 14 degrees then the concentration of refrigerant inside the lubricant will be higher resulting in lower oil viscosity Therefore please use HBR B05 oil instead 4 6 2 Precautions in changing of oil 1 Use HANBELL approved oil and does not mix different brands of oil together Choices of oil should match characteristics of refrigerant Some types of synthetic oil are incompatible with...

Page 67: ...oices of oil Figure 4 6Oil sight glass Oil level Note Users can refer to Figure 4 4 for charging of oil After opening the oil separator flange oil can be charged at the port item16 or oil could be charged by vacuuming the angle valve item13 Warning When the compressor is running please check white floating ball inside as oil level indicator and it s recommended to maintain oil level between High a...

Page 68: ...o prevent bearings from damage due to oil loss Note1 Pressure gauges should be installed separately at P1 the outlet of the oil pump and P2 the outlet of the oil filter An oil pressure differential switch should be installed on piping in between for prevention of oil loss Please refer to the Figure 4 1 Schematic diagram of oil piping Note2 It is recommended replacing the external oil filter core a...

Page 69: ...trol In order to keep the motor temperature between30 90 it is estimated that heat exchange is equal to around 6 10 of motor power input for motor cooling Figure 5 1Motor cooling system Figure 5 2 Two aux inlets for cooling Note1 Two auxiliary injection inlets on the motor casing are the main source of motor coil cooling please make sure both of them are connected Note2 Change of the two auxiliary...

Page 70: ...e the insulation of main power terminals In addition when the motor casing pressure is lower than bearing housing pressure the lubricant will flow into the motor casing and then enter the evaporator Therefore it is a must to install MPV Minimum Pressure Valve in the main motor injection outlet pipes and make sure to keep the standard below 1kgf cm2 Motor Pressure Pmotor Evaporating pressure Ps 1 5...

Page 71: ...sulation test voltage U is AC 1 5kV Figure 5 4Pt100 sensor Specifications Pt1000 sensor 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 Figure 5 5 Pt1000 sensor 1 Please specify Pt100 or Pt1000 sensors when placing orders to Hanbell In addition all models can be equipped wit...

Page 72: ...he protector will recover in five minutes for the second trip the protector will recover in sixty minutes Force lock will take place if three trips occur and reset after 24 hours Technical data of INT69HBY INT69HBY motor protector monitors phase loss phase sequence motor temperatures and discharge temperatures with manual reset Supply voltage AC 50 60 Hz 115 120V 15 10 3VA AC 50 60 Hz 230 240V 15 ...

Page 73: ...nce works after the motor starts 1 second power on L1 L2 L3 and lasts 10 seconds t0 1sec to t0 11sec 2 If one of these parameters is incorrect the relay locks out M1 M2 is open 3 The lockout can be cancelled by main reset of approx 5 seconds disconnect L N Note In order to make sure phase loss and phase sequence protection function well please connect L1 L2 and L3 to the motor side as Figure5 6 sh...

Page 74: ...mostat 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 of the three phase motor voltage becomes active 1 secon...

Page 75: ...tart MCM MCS are deductive for 0 25sec and then MCM MCD are inductive forΔ run Within transient 0 25sec a pseudo short circuit might occur due to inappropriate action of contactors then causing compressor trip When it occurs we recommend you use adjustable Y Δ timer to lengthen the time span for MCM MCS deduction MCM MCD re induct from 0 25sec to 0 5sec directly in the micro controller or the PLC ...

Page 76: ...art 1 High voltage motor could operate with high voltage step down transformer Any technical advice please contact Hanbell 5 3 3 Motor design Direct on line start soft start inverter start RT series compressors with high voltage motors can start by direct start as below shown Figure 5 9 Wiring for high voltage RT series compressors with low voltage motors can start by Y Δ start soft start and inve...

Page 77: ...ng High voltage wiring entry should not take the entry of low voltage cable wiring When taking the low voltage cable entry the magnetic induction produced among phases will cause heat to the wiring box Both entrances are applicable for low voltage wiring High voltage Motor cable entry Low voltage Motor cable entry ...

Page 78: ... 339 5 710 575 717 933 4 375 415 998 1 298 6 035 440 934 1 214 5 805 460 895 1 163 6 160 480 860 1 118 4 930 310 Modle 360 A A 312 B B 410 B A 310 410 B 520 A A 620 620 624 RT 240 E RT 221 372 520 570 RT 120 E T RT 130 E T RT 140 E T RT 111 A 360 RT 160 E T 50Hz 60Hz Motor Power kW Voltage V Rated current A MCC A LRA A Motor Power kW Voltage V Rated current A MCC A LRA A 380 829 1 078 5 485 380 82...

Page 79: ... 381 6 6kV 34 41 231 11kV 20 24 140 6kV 50 60 322 3 3kV 91 109 636 10kV 30 36 217 4 16kV 71 86 485 6 6kV 45 54 303 11kV 27 32 199 6kV 41 49 254 3 3kV 75 90 526 10kV 25 30 177 4 16kV 59 71 446 6 6kV 37 45 256 11kV 22 27 160 6kV 50 60 322 3 3kV 91 109 636 10kV 30 36 217 4 16kV 71 86 485 6 6kV 45 54 303 11kV 27 32 199 6kV 50 60 322 3 3kV 91 109 636 10kV 30 36 217 4 16kV 71 86 485 6 6kV 45 54 303 11kV...

Page 80: ... there is possibility that the compressor is electrified under malfunction condition For security purpose HANBELL strongly recommends to ensure the grounding during installation Suggestion a Dedicated M12 grounding screw instructed in terminal box should be reliably connected with grounding wire Motor Power kW Voltage V Rated current A MCC A LRA A Motor Power kW Voltage V Rated current A MCC A LRA...

Page 81: ...he dust water and oil on terminals by cleaning liquid 3 Apply 3MSCOTCHFIL gray electrical insulation materials on the joint parts to make it smooth 4 Apply 3MSCOTCHKOTE paints on the ceramic parts of power bolts up to 1 2 position Apply 3MSCOTCHKOTE on the power bolts where gray electrical insulation materials had been applied and the on cable for 10 long from power bolts Then apply SCOTCHFIL gray...

Page 82: ...ng protective fence surrounding the compressors and the units with 1 5m safe distance to prevent direct contact of electrified device Suggestion 1 Regular setting of leakage protection should higher than 50mA in humid region 25mA will be more proper 2 Terminal connecting voltage should not larger than 50V in humid region 25V 3 Grounding resistance should not larger than 500Ohm 4 Air cut board ACB ...

Page 83: ...nce work inspection or parts replacement it is a must to cut off the main power supply to the terminal discharge in order to avoid the risk of electric shock 5 4 2 The Inspection and Preparation before Electrical Wiring 5 4 2 1 Inspection of Unpacking 1 All compressors have been passed the strict test by Hanbell Users are unauthorized to disassemble to inspection if necessary please contact Hanbel...

Page 84: ... the nameplate Use copper conductors to connect to power supply b High voltage cable must fulfill national regular and standard c User and contractor are not allowed to change the shape and dimension of cable box d The material of armature terminal is brass therefore armature terminal cannot stand the weight of high voltage cable Installer must apply external cable shelve or tension ease device to...

Page 85: ...terials should be not only aligned with demands but also compatible with cable insulation Hardness expansion coefficient tensile strength and breaking extension of these two materials must be similar Rubber insulation cable must apply high viscosity and elasticity materials as additional insulation When connecting core and amour clamp must apply standard connecting tube and wiring the inner diamet...

Page 86: ... the power higher than 6kV the positive procedure to improve screened part of cable for central integration is the must and ensures the distance between terminals insulation and grounding insulation Wire terminal lugs a Use and size proper crimp type wire terminal lugs in the jobsite b The main power bolt specification is M16 Electricity distribution should be performed by professional electrician...

Page 87: ...oltage maximum 100 voltage unbalanced of Percentage NEMA states that poly phase motors shall operate successfully under running conditions at rated load when unbalanced voltage at the motor terminals does not exceed 1 Furthermore operation of a motor under above 5 unbalanced condition is not recommended It probably results in motor damage Unbalanced voltages at motor terminals cause unbalanced pha...

Page 88: ...ground hitting on the wall or any situation that may damage it and its accessories 6 2 Compressor mounting The position of the compressor in the refrigeration system should be accessible and makes sure that the chiller base or site is far enough from any heat source to prevent heat radiation The compressor should also be installed as closer as possible to the power supply for easier connection It ...

Page 89: ...lation of Economizer Note1 It is suggested position of compressor should be higher than evaporator and the compressor foot base should be higher than economizer liquid level as figure 6 3 to prevent pressure loss of liquid return Note2 Compressor fixed bolts are required for 2 side of compressor The middle one is not necessary ...

Page 90: ...ion protector INT69HBY Standard phase failure protection protector INT69HBY Standard Oil filter pressure difference switch Trip pressure 1 5kg cm2 Optional Motor temp sensor Pt10 Pt1000 motor liquid injection usage Temp control 30 90 Standard Manual reverse setting recommended As compressor protection device Compressor motor coil protection and compressor discharge temperature must connect with IN...

Page 91: ...drain valve Motor PTC Motor temperature sensor Pt100 or Pt1000 Oil tank temperature sensor Pt100 or Pt1000 Discharge temperature sensor Pt100 or Pt1000 Lubricant External oil filter Oil cooler 5RT Oil pressure differential switch Mounting pad Actuator heater Ejector Discharge valve Table 6 1 Spare parts Standard Optional Note The accessory chart is for purpose only Actual specification and accesso...

Page 92: ... be higher than the H scale on the oil display to avoid agitating the oil when the gear rotates 2 Determine the lubricating oil heating time on condition like under high latitude or cold area Refrigerant refilling 1 Confirm whether the chilling water pump and the cooling water pump are running before refrigerant filling 2 Firstly add the gaseous refrigerant to above saturation temperature 0 3 Fill...

Page 93: ...ate and should be at Tc 5 10 g Measurement and recording on vibration and noise h Unloading test Testing the load change is to test the relationship between hot gas bypass valve opening and safety margin line or the inverter surge line 1 The maximum liquid level of the liquid refrigerant in the economizer should not be exceeding 1 2 of the economizer muffler to avoid liquid compression or to insta...

Page 94: ...r 4 Check all stop valves in the system which should be opened 5 The operating condition of the compressor after commissioning at the job site should be adjusted discharge temperature will be at least 5 abovesaturated condensing temperature and suction vapor superheat should be within 1 comparing to saturated evaporating temperature 6 Contact HANBELL or the local distributor if any abnormal vibrat...

Page 95: ... point 8 the shutdown command is issued and the heater bypass valve hits to fully open position 6 Time Zone 9 10 The Actuator IGV1 is still unloaded according to the safety margin equation the medium pressure valve begins to close to fully close position Note2 When the pressure ratio is high IGV1 may not close to 10 position Note3 After the heater bypass valve is fully open it will start to count ...

Page 96: ...incorrect Check power supply Motor failure Replace the motor Incorrect power supply connection Check and reconnect it Y Δtimer failure Check or replace it Rotor jam Check and repair it Protection device trip Check devices Abnormal vibration and noise of the compressor Damaged bearings Replace bearings Insufficient lubricant Check oil level of the compressor if enough or add some oil if necessary W...

Page 97: ...uid or gas make sure start circuit of the compressor is open and oil heater must be powered When reclaiming refrigerant till 1 2psi it s recommended to drain out refrigerant and charge nitrogen to establish positive pressure and during repair keep purging some amount of nitrogen if the job of greater opening is done dismantle gas return pipe of motor cover it s recommended to reclaim refrigerant a...

Page 98: ...96 Vol 2 6 2020 Hanbell Precise Machinery Co Ltd All rights reserved 6 7Compressor vibration measuring point 1 Simple vibration measurement Motor rear parts MV MH MA MV MH MA MH MV MA ...

Page 100: ...d All rights reserved 2 Spectrum measurement Please contact service technicians for spectrum measurement settings Besides simple vibration meter point 6 additional measurement of the gear part distal COV COH COA is necessary COH COV COH COV COA COA ...

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Hanbell RT Series, Manual

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