J&E Hall HallScrew HSO 2000 Series Installation, Operation And Maintenance Manual Download Page 2 | Manualshive

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HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual

Page 2 of 94

Publication 2-119

Issue 1.2 : 03/10

J & E Hall International

©

2010

All rights reserved. No part of this publication may be reproduced or transmitted in any form or by
any means, electronic or mechanical, including photocopying, recording or by any information
storage or retrieval system, without permission in writing from the copyright holder.

The copyright in this publication shall be and remain the sole property of J & E Hall International.

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Summary of Contents for HallScrew HSO 2000 Series

Page 1: ...HallScrew HSO 2000 Series Open Drive Single Screw Compressors HSO 2024 HSO 2028 HSO 2031 and HSO 2035 Manufactured after 06 03 Installation Operation and Maintenance Manual...

Page 2: ...erved No part of this publication may be reproduced or transmitted in any form or by any means electronic or mechanical including photocopying recording or by any information storage or retrieval syst...

Page 3: ...operation and the hazards involved All personnel should make a thorough study of these instructions before undertaking installation commissioning maintenance or repair procedures WARNING A minimum of...

Page 4: ...t is at a voltage high enough to endanger life Before undertaking maintenance or repair procedures on electrical equipment personnel must isolate equipment from the electrical supply and test to verif...

Page 5: ...t of refrigerant to atmosphere It is essential to restrict the amount which escapes to a minimum by pumping over and isolating the charge in another part of the system Where lubricating oil may be pre...

Page 6: ...ilter element for example caution must be exercised as the oil will contain a certain amount of refrigerant which will be released when subjected to atmospheric conditions Refrigerant and lubricating...

Page 7: ...4 1 Suction 16 3 4 2 Compression 17 3 4 3 Discharge 17 4 Capacity Control and Volume Ratio 18 4 1 Slide Valve Actuation 19 4 1 1 Minimum Load Interlock 19 4 2 Capacity Control Solenoid Valve Arrangeme...

Page 8: ...5 Lubricating Oils 41 8 Prolonged Storage 42 8 1 Placing the Compressor into Store 42 8 2 Taking the Compressor out of Storage 43 9 Installing the Compressor 44 9 1 Lifting the Compressor 44 9 2 Makin...

Page 9: ...ide Valve in Operation 18 Fig 3 Capacity Control Arrangement Using Separate Pairs of Solenoid Valves 22 Fig 4 Capacity Control Arrangement Using a 4 Way Solenoid Valve 24 Fig 5 HBLVDT Arrangement and...

Page 10: ...tial Information WARNING This denotes an immediate hazard with a high likelihood of personal injury or death if instructions including recommended precautions are not followed There is also a potentia...

Page 11: ...250 or better d If the system is fitted with an economiser fit an adequately sized strainer in the economiser suction line The strainer must have a mesh aperture of 250 or better e To prevent excessiv...

Page 12: ...place Under no circumstances must the HallScrew compressor be used to evacuate or pump out the system The evacuation procedure is described in publication Part E Evacuation and Dehydration available...

Page 13: ...ork i e that part of the machine which performs the compression function consists of three rotating parts there are no eccentric or reciprocating motions These fundamental components comprise the cyli...

Page 14: ...ain rotor can be likened to the cylinders of a reciprocating compressor the star rotor teeth taking the place of conventional pistons Instead of using suction and discharge valves gas flow in and out...

Page 15: ...ough solenoid valves which respond to signals from the plant control system The solenoid valves direct oil to each end of the compressor capacity control cylinder via two connections positioned at the...

Page 16: ...As the main rotor turns the effective length of the flutes increases with a corresponding increase in the volume open to the suction chamber Diagram 1 Fig 1 clearly shows this process As flute a assum...

Page 17: ...scharge port Compression immediately ceases as the gas is delivered into the discharge manifold The star rotor tooth continues to scavenge the flute until the flute volume is reduced to zero This comp...

Page 18: ...s known as the built in volume ratio VR and is an important characteristic of all fixed port compressors In order to achieve maximum efficiency the pressure within the flute volume at the end of the c...

Page 19: ...n balanced gas loads and low bearing loads within the compressor The position of the slot at the suction end of the slide and the position of the moving delivery port can both be chosen to give the de...

Page 20: ...at start up only A 4 way valve or separate pairs of solenoid valves can be used Continuously running or demand oil pump All oil pump applications compressor located in a Zone 1 or Zone 2 hazardous are...

Page 21: ...nnected to the unload side of the piston which controls the speed of loading while the valve connected to the load side of the piston controls the speed of unloading this is illustrated in Fig 3 Closi...

Page 22: ...De energise open De energise close Hold slide valve position De energise close Energise close De energise close 1 Flow control valves enclosed in boxes incorporate NRV as shown in Fig 11 Fig 3 Capacit...

Page 23: ...e spool to the centre off position closing all the ports and hydraulically locking the capacity control piston and slide valves at the desired load position 4 4 4 Flow Control Valves The capacity cont...

Page 24: ...energise De energise No flow 1 Flow control valves enclosed in boxes incorporate NRV as shown in Fig 11 2 The solenoids on the 4 way valve are normally closed energise to open Fig 4 Capacity Control A...

Page 25: ...ortance that it is both sized and set up correctly 4 5 1 Inverter Size The inverter must be sized to deliver the maximum current taken by the compressor motor at the maximum power conditions in most c...

Page 26: ...Transducer HBLVDT External wiring connections are illustrated in Fig 5 and Fig 6 Two LEDs are provided red for calibration and green for slide valve position indication An explosion proof version of t...

Page 27: ...ng enough for the procedure to be completed The HBLVDT should be wired as shown in Fig 5 or Fig 6 check this point a Start the compressor if it was not already running If the compressor will not start...

Page 28: ...lustrated is recommended DIN Plug Connector Safe Area 24 V dc supply 1 Ex Area Zone 1 0 V dc common 2 or Zone 2 4 to 20 mA signal 3 No connection Fig 6 HBLVDT External Wiring Connections for Explosion...

Page 29: ...interlocked to prevent starting unless the slide valves are at minimum load refer to 4 1 1 therefore either of the above conditions will result in the controller refusing to allow the compressor to st...

Page 30: ...a signal conditioning module is available part number 2848 601 for applications where this is not possible The module is suitable for DIN rail mounting refer to Fig 8 The method of 4 to 20 mA signal...

Page 31: ...Number HallScrew Compressor Series MSI LVDT HBLVDT 7876 143 7876 120 HS 2024 HS 2000 7876 144 7876 121 HS 2028 7876 145 7876 122 HS 2031 7876 146 7876 123 HS 2035 1 The J E Hall part number appears o...

Page 32: ...face element located in the cover plate attached to the shaft seal housing Each sealing face has a highly polished optically flat surface separated by a thin oil film which provides an effective seal...

Page 33: ...ion process when the pressure of the gas trapped in the flutes is considerably lower than discharge pressure this means that in the majority of instances the system pressure difference can be used to...

Page 34: ...the internal drain ceases to function In such applications and for all low stage booster and other low pressure difference applications where a continuously running oil pump is used provision must be...

Page 35: ...the separator into the compressor Additionally as the separator efficiency changes with load and operating conditions then the amount of oil carried into the system through the separator will also va...

Page 36: ...maintain an oil temperature 20 C above the ambient temperature thereby preventing refrigerant migration into the oil and the resultant loss of viscosity and potential foaming The oil heaters must be...

Page 37: ...al examples are under low ambient conditions low load operation and most low stage booster applications If the difference between absolute discharge pressure measured at the outlet from the oil separa...

Page 38: ...start up only Not used ODP2 by transducers Oil injection pressure Discharge pressure during start up only 1 Designated ODPS on applications with no oil pump or a continuously running oil pump only on...

Page 39: ...e start up oil pump runs to establish a discharge oil pump pressure differential in excess of the ODP2 value After allowing sufficient time for the pressure differential to rise ODP2 is brought into t...

Page 40: ...element should be capable of filtering to 10 microns or better 10 A typical filter specification would be 25 75 10 3 5 1 This specification indicates that the filter element will pass 1 particle in 75...

Page 41: ...er to publication 2 122 Compressor Cooling 7 5 Lubricating Oils The choice of lubricant depends on the refrigerant the type of system and the operating conditions As choosing the correct lubricant is...

Page 42: ...gland seal faces these surfaces should be lightly greased before the compressor is placed in store If the compressor drive half coupling is already fitted this must be removed from the mainshaft Purge...

Page 43: ...tial start in order to minimise the possibility of damage NOTE specially negotiated guarantee terms to cover stored compressors will not be honoured unless these procedures are followed a Carefully pu...

Page 44: ...from rust dirt or burrs Lift the compressor and make the same check on the underside of the compressor s four mounting feet As the compressor is being positioned insert the holding down bolts through...

Page 45: ...Rotate the mainshaft by hand to ensure that the motion work turns smoothly and evenly If the compressor proves very stiff to turn turns unevenly or rotation is accompanied by any unusual noise contac...

Page 46: ...k incoming main supply cables and fuses are correctly sized refer to the wiring diagrams supplied d Check that the compressor package unit is correctly earthed Depending on circumstances this may requ...

Page 47: ...rst time If there is any doubt whether the motor has been affected by moisture the value of the motor insulation resistance must be checked The motor should not be run if the insulation resistance exc...

Page 48: ...re of approximately 45 C is about right If the heaters are thermostatically controlled the thermostat should be set to maintain the desired oil temperature NOTE the oil heaters must NOT be energised w...

Page 49: ...differential to become established ODPS is brought into circuit Oil is now being supplied to the compressor under the action of the system pressure differential monitored by ODPS If the system pressur...

Page 50: ...the cooling water outlet to give an oil temperature of 40 C If automatic flow regulation is not fitted a manual valve must be throttled to achieve the correct temperature If the compressor is fitted w...

Page 51: ...ed lines Make sure that stop valves are opened as required before restarting NOTE in the case of prolonged shutdown periods the procedures described under 13 5 9 Prolonged Shutdown should be followed...

Page 52: ...100 compressor operating hours After the commissioning period clean the suction strainer annually or at intervals of 5 000 operating hours whichever is the sooner 11 3 Oil Filter Renew the oil filter...

Page 53: ...hecking for Leaks Check the plant daily during the first week or two of operation for leakage of refrigerant or oil thereafter check for leaks weekly 11 8 Compressor Drive Motor Coupling After the fir...

Page 54: ...enerally applicable where suction and discharge stop valves are provided Close the discharge gauge valve and disconnect the gauge line Connect a suitably sized refrigerant recovery unit to the gauge v...

Page 55: ...d disconnect the refrigerant recovery unit and allow air to enter the compressor via the gauge valve 12 5 Opening up the Compressor Before opening up drain off any oil left behind in the compressor WA...

Page 56: ...te and dehydrate the compressor and all other parts of the system open to atmosphere Adopt the procedures described in publication Part E Evacuation and Dehydration available from J E Hall Internation...

Page 57: ...y refrigerant if used Pressure test certification The component is capable of withstanding the pressures likely to be encountered within the system For plants located within the European Economic Area...

Page 58: ...arises the HallScrew compressor should not need opening up until the first inspection after six years or 25 000 operating hours run have elapsed whichever is the sooner Maintenance during the guarant...

Page 59: ...all other refrigerants Check the sight glass moisture indicator If there is evidence of an increase in the moisture content of the system corrective action must be taken immediately by changing the re...

Page 60: ...may be necessary to fit a new element before this interval hours run time expires if the oil filter pressure drop exceeds the clean filter pressure drop plus 1 4 bar d Clean strainers throughout the s...

Page 61: ...loves goggles and a respirator must be worn refer to Safety Equipment in the publication for the refrigerant in Section 5 If new coalescing elements are to be fitted after removing the old elements th...

Page 62: ...valves are opened as required before restarting WARNING The compressor must NEVER be started with the discharge stop valve closed or partially closed b It is important to run the plant for at least on...

Page 63: ...er cores not usually applicable to plants charged with ammonia R717 applicable to all other refrigerants Check pressure and temperature safety controls operate correctly Check the condition of the cou...

Page 64: ...ssue 1 2 03 10 13 7 Oil Acid Content Record Plants charged with refrigerant other than ammonia R717 Each time the oil s acid content is checked record the value in Table 7 ACID CONTENT SIGNATURE PRINT...

Page 65: ...Page 65 of 94 Appendix 1 Compressor Data HSO 2000 Series Compressor Model Nomenclature HSO 2000 Series Physical Data HSO 2000 Series Starting Torque Characteristics HSO 2000 Series Limits of Operatio...

Page 66: ...Nominal 0 Without motor Motor Voltage 0 No voltage without motor Refrigerant A R134a F R404a B R22 G R717 C R407c H R23 D R410a X Other E R507a Voltage Auxiliary 0 No voltage Capacity Indicator 0 No c...

Page 67: ...COMPRESSOR NORMAL SPEED RANGE SWEPT VOLUME m3 hr MAX ALLOWABLE SHAFT POWER kW WEIGHT kg 50 HZ 60 HZ 50 HZ 60 HZ HSO 2024 1450 to 3600 rpm 853 1024 250 300 449 HSO 2028 1273 1528 350 420 564 HSO 2031...

Page 68: ...FULL LOAD TORQUE Does not include accelerating torque SYSTEM PRESSURE RATIO 2000 Series Starting Torque Characteristics 20 30 40 50 60 70 0 20 40 60 80 100 Speed Full Load Torque Does not include acce...

Page 69: ...Compressors With Liquid Injection Oil Cooling Standard 7 Controlled discharge temperature Discharge high temperature cut out Injected oil high temperature cut out 8 75 C 100 C maximum 80 C 1 Assemble...

Page 70: ...sducers and controller software programme Refer to Table 4 1 Oil temperature High Cut out or thermistor 80 C Temperature in oil line to compressor Oil flow Low Oil flow switch Contacts close at 0 15 l...

Page 71: ...0 PCD 125 mm 5 NB BS 4504 Table 40 3 8 x M24 on 220 PCD 150 mm 6 NB BS 4504 Table 40 3 8 x M24 on 250 PCD Suction pressure gauge 1 3 8 BSP x 6 mm OD male stud coupling Discharge pressure gauge 1 3 8 B...

Page 72: ...Gauge Discharge End Cover Oil Drain Gland Oil Feed Economiser Connection Top Capacity Control Load Capacity Control Unload Discharge Pressure Gauge Economiser Connection Bottom Discharge Top Option D...

Page 73: ...normally closed Dual relief valve to atmosphere Thermostatic expansion valve Sight glass on vessel Liquid drainer Sight glass in line Heater Strainer Opto sensor in drain line Oil filter Oil pump 4 Wa...

Page 74: ...ion Oil Filter Oil Cooler Water Air or Refrigerant Cooled Instead of Liquid Injection refer to 7 4 Compressor Cooling Circuit Completion When Using Liquid Injection Cooling PSH Discharge PI PI Oil ODP...

Page 75: ...r if Double Duplex Oil Filters Required Oil Separator Reservoir Coalescing Elements for Oil Separation Down to 5 ppm Weir LSL Oil Cooler Water Air or Refrigerant Cooled Instead of Liquid Injection ref...

Page 76: ...Separation Down to 5 ppm Weir LSL PI OD P2 HP LP Oil Oil Filter PI Oil Drain Line FS Oil Pressure After Filter TE HT Oil Second Filter if Double Duplex Oil Filters Required Oil Cooler Water Air or Ref...

Page 77: ...Gauge C 30 20 10 0 10 20 30 40 50 60 70 60 50 40 30 20 10 0 10 20 Suction Gauge C Continuously running oil pump required below this line Booster This diagram is approximate for guidance only Refer to...

Page 78: ...0 0 10 20 30 40 50 60 70 60 50 40 30 20 10 0 10 20 Suction Gauge C Continuously running oil pump required below this line Booster This diagram is approximate for guidance only Refer to HallScrew selec...

Page 79: ...0 30 40 50 60 70 80 90 50 40 30 20 10 0 10 20 30 Suction Gauge C Continuously running oil pump required below this line Booster This diagram is approximate for guidance only Refer to HallScrew selecti...

Page 80: ...10 0 10 20 30 40 50 60 70 60 50 40 30 20 10 0 10 20 Suction Gauge C Continuously running oil pump required below this line Booster This diagram is approximate for guidance only Refer to HallScrew sel...

Page 81: ...10 20 30 40 50 60 70 60 50 40 30 20 10 0 10 20 Suction Gauge C Continuously running oil pump required below this line Booster This diagram is approximate for guidance only Refer to HallScrew selectio...

Page 82: ...e Kit serial number ends 500 N02210038 95822 445 1 1 Capacity Control Slides 8 N A Capacity Control Slide Kit 2 2 VR serial number ends 500 N02860038 95822 403 1 8 N A Capacity Control Slide Kit 2 6 V...

Page 83: ...N02210039 95822 545 1 1 Capacity Control Slides 8 N A Capacity Control Slide Kit 2 2 VR serial number ends 500 N02860042 95822 503 1 8 N A Capacity Control Slide Kit 2 6 VR serial number ends 500 N02...

Page 84: ...city Control Slide Kit 2 2 VR serial number ends 500 N02860046 95822 603 1 8 N A Capacity Control Slide Kit 2 6 VR serial number ends 500 N02860047 95822 604 1 8 N A Capacity Control Slide Kit 3 5 VR...

Page 85: ...l number ends 500 N02860051 95822 704 1 8 N A Capacity Control Slide Kit 3 5 VR serial number ends 500 N02860052 95822 705 1 8 N A Capacity Control Slide Kit 4 9 VR serial number ends 500 N02860053 95...

Page 86: ...designing a log sheet for the plant either on paper or as an electronic form held in a computer database there are certain pressures temperatures and flow rates which are common to nearly every plant...

Page 87: ...OIL COOLER COOLING MEDIUM Inlet Temperature C Outlet Temperature C Rate of Flow m3 h CONDENSER COOLING MEDIUM Inlet Temperature C Outlet Temperature C Rate of Flow m3 h 3 Ambient Dry Bulb Temperature...

Page 88: ...application because it has a pre programmed function which does not allow the required Factor to be set up also mA cannot be used as a unit because this is the same as the input units It is therefore...

Page 89: ...nput Output OK Relay Analogue Out OK Characteristic OK 0 to 20 mA Flashing 4 to 20 mA NE4 Flashing 6 235 mA OK 4 to 20 mA NE4 Set saved 9 0 mA Temporary value ESC Characteristic Start Value OK Numeric...

Page 90: ...teristic Start Value End Value OK Numeric Teach In OK 15 76 mA Flashing 15 1 mA OK 15 76 mA End value saved 20 mA Maximum load set ESC Teach In ESC End Value ESC Analogue Out ESC Output Maximum load E...

Page 91: ...g 10 49 Set value 100 15 765 6 235 OK 10 49 Multiplying factor set ESC Factor ESC Input Min load ESC 0 000 slide valve setting 4 mA Max load 100 0 slide valve setting 20 mA 1 Operation can be done wit...

Page 92: ...Trip value set ESC Trip Hysteresis OK 20 98 For example Flashing 2 000 Set value for example Flashing OK 2 000 Hysteresis value set ESC Hysteresis ESC Relay ESC Output Min load ESC 0 000 4 mA 1 Operat...

Page 93: ...HSO 2024 to HSO 2035 Installation Operation and Maintenance Manual Issue 1 2 03 10 Publication 2 119 Page 93 of 94 This page intentionally blank...

Page 94: ...in any form or by any means electronic or mechanical including photocopying recording or by any information storage or retrieval system without permission in writing from the copyright holder The cop...

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