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33

3. Lubricants 

The main functions of lubrication oil in screw compressors are lubrication, internal sealing, cooling and capacity control. Positive 

oil pressure in the cylinder pushes the piston together with the slide valve that is connected by a piston rod to move forward and 

backward in the compression chamber. The design of positive pressure differential lubrication system makes RC2 series normally 

omit  an  extra  oil  pump  which  is  necessary  for  reciprocating  compressors.  However,  in  some  special  applications,  it  is  still 

necessary to install an extra oil pump to screw compressors for safety. 

Bearings  used  in  RC2  series  compressors  require  a  small  and  steady  quantity  of  oil  for  lubrication.  Oil  injection  into  the 

compression chamber creates a film of oil for sealing in the compression housing to increase efficiency and also can dissipate part 

of compression heat. In order to separate oil from refrigerant gas, an external oil separator is required to ensure the least amount of 

oil carried into the system.   

Please pay more attention to the oil temperature, which is crucial to compressor bearings’ life. Oil is with much lower viscosity at 

high  temperatures.  Too  low  viscosity  of  oil  will  result  in  poor  lubrication  and  heat  dissipation  in  the  compressor.  Viscosity  is 

recommended to keep over 10mm2/s at any temperatures for oil. Oil temperature in the oil sump should be kept above the saturated 

condensing  temperature  to  prevent  refrigerant  migration  into  lubrication  system.  Oil  has  a  higher  viscosity  in  low  ambient 

temperature circumstances. When viscosity is too high, slow flow speed of oil into the cylinder may result in too slow loading of 

the compressor. To solve this problem, use of oil heaters can warm up oil before starting. 

If  the  compressor  operates  under  critical  operating  conditions,  an  extra  oil  cooler  is  required  –  please  refer  to  Hanbell  selection 

software for the required capacity and oil flow of the extra oil cooler. High-viscosity oil is recommended to apply in high operating 

conditions because high discharge temperature will make viscosity of oil lower. Oil return from the evaporator may be insufficient 

in  refrigeration  systems,  flooded  chillers…etc.,  in  which  it’s  difficult  for  oil  to  be  carried  back  and  it  may  cause  oil  loss  in  the 

compressor. If the system encounters the oil return problem then an extra 2nd oil separator is recommended to be installed between 

the compressor discharge tube and condenser.   

Hanbell RC2-230ExP~RC2-930ExP compressors is equipped  with two oil sight glasses  as a standard, one is the  high-level sight 

glass, and the other is the low-level sight glass (RC2-100ExP~RC2-200ExP only have one 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 oil level switch to prevent the failure results from lose 

of oil. 

 

 

Содержание ExP Series

Страница 1: ...1 ...

Страница 2: ...marking 27 2 8 Cable Box 27 2 9 INT69HBY control module and PTC temperature sensor 28 2 10 Oil heater 29 2 11 Oil level switch 30 2 12 Oil drain valve 30 2 13 Solenoid valve 31 2 14 Power Supply 31 3 Lubricants 33 3 1 Lubricants table 34 3 2 Pre cautions of changing oil 35 3 3 Oil change 35 4 Compressor handling and installation 36 4 1 Compressor lifting 36 4 2 Mounting the compressor 36 4 3 Compr...

Страница 3: ...plosive gas and are manufactured or sold in the EU Directive range includes safety equipment control equipment adjustment device and equipment and protection system that are expected to contain potential explosive gas This directive is suitable on product manufacturing conditions and belongs to product s technical field responsibility The aim is to let products using in a probable explosive enviro...

Страница 4: ...efinition Zone0 Gas Explosive environment which exist continuously usually and with a long period of time and which is formed by a mixture of air with flammable material such as gas vapor or droplets Zone1 Gas Explosive environment which sometimes exist under a normal operation and which is formed by a mixture of air with flammable material such as gas vapor or droplets Zone2 Gas Explosive environ...

Страница 5: ...e II A Acetic acid Ammonia Benzene Propanone Ethane Ethyl acetate Carbon monoxide Methanol Propane Methylbenzene Ethanol 1 4 Butane Butanol Gasoline Diesel Kerosene Fuel oil Hexane Acetaldehyde II B Coal gas Ethylene Diethyl ether II C Hydrogen Acetylene Carbon disulfide ...

Страница 6: ...6 1 4 ATEX code description II 2 G c IIB T4 II 2 G Ex d IIB T4 Gb ...

Страница 7: ... 2 Specifications and description of design 2 1 Compressor Nomenclature R C 2 x x x x ExP Explosion proof products Displacement at 50Hz RC model 2nd version 2 2 Compressor outline RC2 100ExP 140 ExP A B ...

Страница 8: ...8 RC2 180 ExP A B RC2 200 ExP A ...

Страница 9: ...9 RC2 200 ExP B RC2 230 ExP A B UNIT SI mm Imperial in ...

Страница 10: ...10 RC2 260 ExP A B SI mm Imperial in UNIT RC2 300 ExP 320 ExP A ...

Страница 11: ...11 RC2 300 ExP 320 ExP B RC2 310 ExP A B ...

Страница 12: ...12 RC2 340 ExP 370 ExP A RC2 340 ExP 370 ExP B ...

Страница 13: ...13 RC2 410 ExP A B RC2 470 ExP A ...

Страница 14: ...14 RC2 470 ExP B RC2 510 ExP A B ...

Страница 15: ...15 RC2 550 ExP A RC2 550 ExP B ...

Страница 16: ...16 RC2 580 ExP A B RC2 620 ExP A B ...

Страница 17: ...17 RC2 710 ExP A RC2 710 ExP B ...

Страница 18: ...18 RC2 790 ExP A RC2 790 ExP B SI mm Imperial in UNIT ...

Страница 19: ...19 RC2 830 ExP A RC2 830 ExP B ...

Страница 20: ...20 RC2 930 ExP A R2C 930 ExP B ...

Страница 21: ... Suction flange 3 Oil separator 11 Piston spring 19 Bearing lock nut 27 Discharge flange 4 Motor rotor assembly 12 Piston rod 20 Male rotor 28 Cable box 5 Motor stator assembly 13 Bearing seat s cover plate 21 Suction bearings 29 Power bolt 6 Motor rotor washer 14 Modulation slide valve 22 Oil filler cartridge 30 Motor cable cover plate 7 Motor rotor spacer ring 15 Slide valve key 23 Suction filte...

Страница 22: ...g lock nut 29 Discharge flange 3 Oil separator 12 Piston rod 21 Male rotor 30 Cable box 4 Motor rotor assembly 13 Bearing seat s cover plate 22 Suction bearings 31 Power bolt 5 Motor stator assembly 14 Modulation solenoid valve 23 Suction bearings inner outer spacer ring 32 Thermostat terminals 6 Motor rotor washer 15 Modulation slide valve 24 Oil guiding ring 33 Motor cable cover plate 7 Motor ro...

Страница 23: ...tridge 18 Discharge fixed ring 27 Refrigeration Lubricant RC2 710ExP RC2 790ExP RC2 830ExP RC2 930ExP Construction Item Description Item Description Item Description Item Description 1 Compressor casing 11 Piston spring 21 Bearing lock nut 31 Suction flange 2 Motor casing 12 Piston rod 22 Male rotor 32 Discharge flange 3 Oil separator 13 Bearing seat cover plate 23 Suction bearings 33 Cable box 4 ...

Страница 24: ...Y PWS DOL 208 220 230 380 440 460 480 575 380 400 415 Class F PTC Protection 7 250 42 275 B 38 31 280 RC2 140ExP A 165 137 33 66 100 33 100 32 26 7 280 B 50 41 285 RC2 180ExP A 216 180 33 66 100 33 100 42 35 7 300 B 66 55 335 RC2 200ExP A 233 193 25 50 75 100 25 100 45 37 8 420 B 70 58 425 RC2 230ExP A 277 230 35 50 75 100 35 100 53 44 14 540 B 81 67 555 RC2 260ExP A 309 257 25 50 75 100 25 100 59...

Страница 25: ...7 255 RC2 200ExP A 103 310 98 325 94 295 226 690 214 595 204 620 124 375 107 310 102 325 98 295 82 255 RC2 230ExP A 124 480 117 500 113 465 270 1080 256 905 244 945 148 600 128 480 122 500 117 465 98 375 RC2 260ExP A 138 480 131 500 126 465 302 1080 286 905 273 945 165 600 143 480 137 500 131 465 109 375 RC2 300ExP A 155 600 147 625 142 540 340 1385 322 1125 308 1175 186 735 161 600 154 625 147 54...

Страница 26: ...60 403 1630 244 1030 211 780 201 815 193 790 161 670 RC2 340ExP B 220 1035 209 1080 201 940 483 2160 457 1985 437 2075 264 1220 228 1035 218 1080 209 940 175 815 RC2 370ExP B 241 1035 229 1080 221 940 529 2160 500 1985 478 2075 289 1220 250 1035 239 1080 229 940 191 815 RC2 410ExP B 268 875 254 915 245 850 323 1115 279 875 267 915 256 850 214 750 RC2 470ExP B 310 1220 294 1285 284 1160 372 1445 32...

Страница 27: ...ction degree Cable box schematic diagram and the size of opening in cable box for motor power line and control power line refer to the drawing below Figure 2 1 cable glands and plugs tightening torque refer to Table2 1 1 2 NPT M2 0 3 NPT M7 5 1 2 NPT M2 0 3 NPT M75 WARNING Do not open when energized RC2 1 0 0 18 0 Exp RC2 2 0 0 9 3 0Exp Figure 2 1 cable box schematic diagram Component specificatio...

Страница 28: ...eater than 0 1 Ohm d Air cut board ACB is regularly equipped with electric leak protection Please refer to related settings for its normal action e If electric leak protection is active please check if insulation of equipments is normal and if its wiring and setting are correct 2 9 INT69HBY control module and PTC temperature sensor In order to protect compressor each RC2 series compressor has been...

Страница 29: ...e display diagram Note 1 The cutout point of the PTC is 110 2 Motor thermistors and discharge thermistor are temperature sensors with quick response while the temperature approach to their set point Thermistors must be connected in series to a controller INT69HBY in terminal box as a guardian to protect compressor Alarm lamp for this protector is required to be embedded on control panel as indicat...

Страница 30: ...re shut down the compressor Max contact capacity 50W SPST Surge current 0 5A Max voltage 200V DC 240V AC Max current 1A Note 1 On the float ball there is a triangle mark which tells you its sensor direction Therefore before you install an oil level switch on a compressor or an external oil separator please use the triangle mark as your reference before install any oil level switch on the compresso...

Страница 31: ...Rated frequency 2 Instant running rated voltage 10 Note 1 In the region where the electricity power is unstable install an additional hi low voltage protector with 5 tolerance of normal voltage to ensure safe operating of the compressor 2 Other than power supply cable cables must be located at the safety zone 2 Unbalanced voltages Unbalanced voltages usually occur because of variations in the load...

Страница 32: ...and hence eventual motor burnout If the voltage unbalance is great enough the reduced torque capability might not be adequate for the application and the motor will not attain rated speed Some of the more common causes of unbalance voltages are Unbalanced incoming utility supply Open delta connected transformer banks Large single phase distribution transformer in the system Open phase on the prima...

Страница 33: ...ept above the saturated condensing temperature to prevent refrigerant migration into lubrication system Oil has a higher viscosity in low ambient temperature circumstances When viscosity is too high slow flow speed of oil into the cylinder may result in too slow loading of the compressor To solve this problem use of oil heaters can warm up oil before starting If the compressor operates under criti...

Страница 34: ... 01 0 00 0 01 COPPER STRIP 100 3hr 1a 1a 1a MOISTURE ppm 15 20 20 FLOC POINT 75 45 35 DIELETRIC STRENGTH 2 5mm KV 75 50 50 46 6 Applicable oil types R134a R404A R407C SPECIFICATION UNITS HBR B05 HBR B08 HBR B09 HBR B04 COLOR ASTM SPECIFIC GRAVITY 0 945 0 94 0 95 0 95 VISCOSITY 40 mm2 s cSt 64 131 175 215 9 100 8 9 14 53 16 5 20 8 FLASH POINT 266 254 265 271 POUR POINT 43 36 5 30 25 T A N mg KOH g ...

Страница 35: ...or burned out case because acid debris may still remain inside the system Please follow the procedures mentioned above to change oil in the system Check acidity of oil after 72 hours of operation and then change it again until acidity of oil becomes normal 5 Please contact Hanbell local distributors agents for selection of oil 3 3 Oil change 1 Change oil periodically Check lubrication oil every 10...

Страница 36: ...n of the compressor in the refrigeration system should be 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 the electrical power supply for easier connection and must keep good ventilation and low humidity condition in the site Make sure that the frame or supporter is s...

Страница 37: ...ds the use of a copper tube in discharge port to best minimize abnormal vibration and noise 3 Remove the oxidized impurities swarf or debris caused by welding in the piping tubes If these materials fall into the compressor the oil filter might be clogged and result in the malfunction of lubrication system bearings and capacity control system 4 The material of suction and discharge flange bushing i...

Страница 38: ...ve 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 Cable Glands Mounting pad Lubricant oil Micro controller Sound jacket Oil heater so...

Страница 39: ...ompressor Teflon taper guider inside can simultaneously seal up the precisely machined base of check valve by gravity force to effectively prevent return of high pressured gas to compressor The gravity driven check valve is equipped vertically Due to limitation of space or piping requirements alternative horizontal check valve is also available Dia Dimension unit mm A B C D E F G H 2 102 6 53 91 6...

Страница 40: ...own in the table below If non standard bushing is needed please double check with Hanbell sales representatives when placing order for compressors Model Standard Discharge Flange Bushing Standard Suction Flange Bushing Steel pipe Copper pipe Steel pipe Copper pipe RC2 100ExP 1 1 2 1 5 8 2 2 1 8 RC2 140 ExP 1 1 2 1 5 8 2 2 1 8 RC2 180 ExP 1 1 2 1 5 8 2 1 2 2 5 8 RC2 200 ExP 1 1 2 1 5 8 2 1 2 2 5 8 ...

Страница 41: ... 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 620EXP 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 4 1 8 80 174 35 105 1 121 2 5 1 8 75 130 5 146 5 Steel 5 75 141 3 154 RC2 710EXP RC2 790EXP ...

Страница 42: ...s and wire cables terminals connection 5 Grounded 6 Capacity of electrical accessories 7 7 Settings of switches sensors and controllers 1 Electricity voltage should be kept within 5 to the rated voltage instant maximum voltage drop while starting should be less than 10 to the rated voltage 2 Standard voltage is 220V Maximum voltage is 230V If there is other demand contact HANBELL 3 Insulation resi...

Страница 43: ...in the suction gas h The running condition of compressor after commissioning at the job site should be adjusted as the discharge temperature will be at least 20K above the saturated condensing temperature and the suction vapor superheat should be within 10K to the saturated evaporating temperature i The whole plant especially the pipelines and capillary tubes must be checked for abnormal vibration...

Страница 44: ...ide valve piston unable to go back to its lowest original position Check if the unloading SV is energized once the compressor shut down Unload the compressor before shot down Voltage incorrect Check the power supply Voltage drop too big when starting the compressor or magnetic contactor failure or phase failure Check the power supply and the contactor Motor broken down Change the motor Motor therm...

Страница 45: ...t to Hanbell if any failure of compressor happened Hanbell will reply and suggest the solution to resolve the failure CHECK LIST FOR TROUBLESHOOTING OF HANBELL SCREW COMPRESSOR Compressor model Compressor S N System design condition SCT SST Evaporator type Refrigerant type Liquid injection Motor Chamber Voltage R S S T R T Over load setting A Y Δ setting Sec Δ Δ setting Sec Starting current A Δ cu...

Страница 46: ...le entry shall be installed with an ATEX certified cable gland 7 The end user needs to install the oil level switch an intrinsic safety loop Ex ib or ia the oil level switch is installed in the oil sump 8 The end user shall not open the terminal box till the compressor has been shut down 9 The oil heater must be fully installed in the chamber It shall not be exposed th the explosive atmosphere the...

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