Hanbell RC2 Series, Technical Manual

Page 1: ...y Fort Myers FL 33905 Office 239 694 0089 Fax 239 694 0031 www mcscontrols com High efficiency Model RC2 Series Screw Compressor New generation of innovative design Screw compressor TECHNICAL MANUAL VERSION 2 0 10 18 2018 ...

Page 2: ... changing oil 18 3 3 Oil change 18 4 Compressor handling and installation 19 4 1 Compressor lifting 19 4 2 Mounting the compressor 20 4 3 RC2 compressor outline drawings 21 4 4 Compressors accessories 44 4 5 Installation and connection of compressor 58 5 Electrical data and design 61 5 1 Motor design 61 5 2 Compressor protection devices 64 5 3 Power supply 64 5 4 Grounding 65 6 Operation and maint...

Page 3: ...ipped with separated radial and axial bearings liquid injection and economizer connection PTC motor temperature thermistors and discharge temperature thermistors a motor protector and oil level switch and oil pressure differential switch connector and other accessories The complete accessories and their new designs guarantee the compressor has the best reliability longest bearing life during heavy...

Page 4: ...16 600 RC2 370A 440 366 35 50 75 100 35 100 84 70 16 610 RC2 410A 490 407 25 50 75 100 25 100 93 78 380 440 460 480 575 16 730 RC2 430A 509 423 25 50 75 100 25 100 93 78 16 735 RC2 470A 567 471 25 50 75 100 25 100 108 90 18 800 RC2 510A 611 508 35 50 75 100 35 100 117 98 20 760 RC2 550A 660 549 25 50 75 100 25 100 126 105 23 820 RC2 580A 702 583 35 50 75 100 35 100 131 109 20 805 RC2 620A 745 619 ...

Page 5: ... 35 100 121 101 16 620 RC2 370B 440 366 35 50 75 100 35 100 130 108 16 640 RC2 410B 490 407 25 50 75 100 25 100 146 121 380 440 460 480 575 16 740 RC2 470B 567 471 25 50 75 100 25 100 170 141 18 810 RC2 510B 611 508 35 50 75 100 35 100 183 152 20 780 RC2 550B 660 549 25 50 75 100 25 100 195 162 23 850 RC2 580B 702 583 35 50 75 100 35 100 210 175 20 840 RC2 620B 745 619 35 50 75 100 35 100 220 183 ...

Page 6: ... 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 rotor spacer ri...

Page 7: ...ed ring 28 Suction filter 9 Oil separator cartridge 19 Disc spring 29 Oil heater 10 Piston 20 α Balance piston 30 Refrigeration Lubricant RC2 1020 RC2 1130 RC2 1270 RC2 1530 Construction Figure 5 Item Description Item Description 1 Compressor casing 20 Balance piston 2 Motor casing 21 Bearing slot nut 3 Oil separator 22 Male rotor 4 Motor rotor assembly 23 Suction bearings 5 Motor stator assembly ...

Page 8: ... and α axial balance piston to ensure longer bearing life and higher compressor reliability Double walled rotor housing Double casing structure with high strength inner ribs has been designed to minimize noise and ensure rigidity The rotor housing is made of high strength gray cast iron FC25 that is extremely stable therefore no expansion will occur even at high pressure condition These casings ar...

Page 9: ... the compression chamber increases This means the displacement of refrigerant gas also increases as a result the refrigeration capacity also increases However when any of the step solenoid valve for 3 step 4 step capacity control system is opened the high pressure oil in the cylinder bypasses to the suction side which causes the piston and the slide valve to move toward the left side and then some...

Page 10: ...cylinder through the capillary the high pressured oil in the cylinder bypasses directly into the suction port so the piston is kept in its initial position It is strongly recommended to energize SV25 33 solenoid valve for 1 3 minutes before starting the compressor to ensure the slide valve is in min position b 50 capacity omitted for RC2 100 140 180 When SV50 solenoid valve is energized by the tem...

Page 11: ...min before start and for 60 90 sec before stop 4 Start the compressor at min and SV50 can be energized right after start 2 8 Continuous stepless capacity control system In continuous stepless capacity control system solenoid valve SV2 for loading and solenoid valve SV1 for unloading are equipped to inlet and outlet of piston cylinder respectively These two solenoid valves are controlled by chiller...

Page 12: ...ding SV1 N C OFF LOADING SV2 N C ON Oil bypasses SV1 N C OFF LOADING SV2 N O OFF Oil bypasses b Unloading Standard When NC SV1 is energized but NC SV2 is not energized oil inside piston cylinder will bypass to suction port through NC SV1 Option When both NO SV2 and NC SV1 are energized oil inside piston cylinder will bypass to suction port through NC SV1 SV1 SV2 UNLOADING N C ON Oil bypasses N C O...

Page 13: ...lse time 1 1 5 seconds t2 t4 Pause time 15 20 seconds 2 9 Dual capacity control system optional Figure 16 Dual capacity control No Component No Component No Component 1 Suction filter 7 Discharge bearings 13 Capillary 2 Gas in low pressure 8 Oil separator baffle 14 Solenoid valve 3 Motor 9 Gas out high pressure with oil 15 Solenoid valve 4 Oil filter cartridge 10 Lubricant 16 Solenoid valve 5 Suct...

Page 14: ...io Pd system pressure absolute pressure Pd discharge pressure absolute pressure Ps suction pressure absolute pressure Vs suction volume Vd discharge volume K refrigerant specific heat ratio 2 11 Application limits Application limits of the compressor vary significantly with the type of refrigerant used The operating limits shown below are based on saturated suction and discharge operating conditio...

Page 15: ...ture additional cooling 25 50 75 With Min pressure valve Motor A Motor B 86 30 4 0 68 14 50 68 32 86 104 122 140 158 F 20 30 40 50 60 70 20 10 10 20 0 C Evaporating Temperature Condensing Temperature additional cooling 25 50 75 With Min pressure valve Motor A 86 30 b Application limits of of RC2 1020 RC2 1530 are described on the respective refrigerant charts ...

Page 16: ...election software for application of additional cooling system Hanbell recommends monitoring oil pressure differential and keep it 4 over the suction pressure for adequate seal lubrication and capacity control by pressure differential switch passively or by additional oil pump or minimum pressure valve actively Especially under operation conditions with low condensing temperature and high evaporat...

Page 17: ... 1850 589 823 2470 509 663 1990 487 693 2080 466 617 1850 389 555 1665 RC2 1020A A1 360 583 1750 342 613 1840 330 537 1610 434 763 2290 374 583 1750 358 613 1840 343 537 1610 287 493 1480 RC2 1020A A2 536 753 2260 510 793 2380 491 690 2070 645 945 2835 557 753 2260 533 793 2380 510 690 2070 426 635 1905 RC2 1130A A1 395 583 1750 375 613 1840 362 537 1610 475 763 2290 410 583 1750 393 613 1840 376 ...

Page 18: ...935 2805 582 782 2345 486 717 2150 RC2 1020B B2 684 1085 3255 650 1142 3425 626 920 2760 823 1290 3870 710 1085 3255 680 1142 3425 651 920 2760 544 868 2605 RC2 1130B B1 671 888 2665 637 935 2805 614 782 2345 806 1168 3505 697 888 2665 666 935 2805 638 782 2345 533 717 2150 RC2 1130B B2 766 1085 3255 728 1142 3425 702 920 2760 922 1290 3870 796 1085 3255 762 1142 3425 730 920 2760 609 868 2605 RC2...

Page 19: ...gh 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 betwe...

Page 20: ...change the oil in motor 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 lub...

Page 21: ...Make sure that chains cables or other lifting equipments are properly positioned to protect the compressor and its accessories from damaging Keep the compressor in horizontal position when lifting and prevent it from crashing or falling on the ground hitting the wall or any other accident that may damage it or its accessories Figure 19 Lift the compressor with safety ropes Figure 18 Lift the compr...

Page 22: ...uce the vibration on the piping tubes it is recommended to use copper tube to be the suction and discharge piping tubes Copper tubes are better to minimize the vibration in the piping while the compressor is in operation In case steel tubes are used in piping system the suitable welding works are very important to avoid any stress in the piping This inner stress can cause harmonic vibration and no...

Page 23: ...Technical Manual VERSION 2 0 10 18 2018 23 Figure 23 Limits of oblique angle for the installation of the compressor 4 3 RC2 compressor outline drawings 1 RC2 A outline drawings UNIT SI mm Imperial in ...

Page 24: ...Technical Manual VERSION 2 0 10 18 2018 24 UNIT SI mm Imperial in UNIT SI mm Imperial in ...

Page 25: ...Technical Manual VERSION 2 0 10 18 2018 25 SI mm Imperial in UNIT UNIT SI mm Imperial in ...

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Page 34: ...Technical Manual VERSION 2 0 10 18 2018 34 UNIT SI mm Imperial in ...

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Page 44: ...Technical Manual VERSION 2 0 10 18 2018 44 SI mm Imperial in UNIT ...

Page 45: ...Technical Manual VERSION 2 0 10 18 2018 45 Note For RC2 1020B RC2 1130B RC2 1270B and RC2 1530B outline drawing please refer to those of RC2 1020A RC2 1130A RC2 1270A and RC2 1530A ...

Page 46: ...INT69HBY controller IP54 cable box 150W oil heater Oil level switch Oil drain valve Oil temperature sensor 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 muffler Oil cooler Oil pump Oil filter pressure differential switch conne...

Page 47: ... 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 Figure 24 Suction check valve outline drawing Horizontal type Dia Dim...

Page 48: ...e table below If non standard bushing is needed please double check with Hanbell sales representatives when placing order for compressors No 1 2 3 4 5 6 7 8 Item Body C clipper Spring Valve plate Gasket Nut Guide seat Shaft Standard Discharge Flange Bushing Standard Suction Flange Bushing Steel pipe Copper pipe Steel pipe Copper pipe RC2 100 1 1 2 1 5 8 2 2 1 8 RC2 140 1 1 2 1 5 8 2 2 1 8 RC2 180 ...

Page 49: ...8 90 Steel 2 1 2 77 2 90 Suction Copper 3 1 8 76 145 50 79 8 90 3 5 8 92 4 103 4 1 8 105 1 116 Steel 3 90 2 105 3 1 2 102 8 117 4 115 6 128 RC2 510 RC2 550 RC2 580 Discharge Copper 2 1 8 66 120 45 54 3 65 2 5 8 67 77 3 1 8 79 8 90 Steel 2 1 2 77 2 92 3 90 2 103 Suction Copper 3 1 8 76 145 50 79 8 90 3 5 8 92 4 103 4 1 8 105 1 116 Steel 3 90 2 105 3 1 2 102 8 117 4 115 6 128 RC2 620 Discharge Coppe...

Page 50: ... M20x2 5 160 4 125 145 105 124 146 6 5 171 130 445 201 22 185 M20x2 5 185 Dia Dimensions unit mm A B C D E F G H I J K L 5 30 30 126 194 194 248 230 230 214 338 474 161 Specification of stop valve Maximum working pressure Hydrostatic pressure test Refrigerant Temperature range 28 kg cm G 42 kg cm G HFC HCFC R717 40 C 150 C f INT69HBY control module and PTC temperature sensor In order to protect co...

Page 51: ... red green provides additional information about the motor protector and compressor status 9 The relay is fed out as a N O dry contact which is closed under good conditions 10 Sensor and supply circuits are galvanic isolated 11 The motor protector is not suitable for application of frequency converters Technical data Supply voltage Relay output AC 50 60 Hz 115 120V 15 10 3VA max AC 240V max 2 5A C...

Page 52: ...Please check this triangle mark and modify the oil level switch if needed 3 If you have any other question don t hesitate to contact with Hanbell representatives for help 4 The illustration below show you the outside appearance of our oil level switch Figure 33 Oil level switch on a compressor Figure 34 Oil level switch on an external oil separator i Oil drain valve Oil drain valve is installed in...

Page 53: ...mended Opening ratio of stop valve could not vary with system loading and change of temperature Therefore frequent check of discharge temperature can prevent damage of compressor due to over cooling or insufficient cooling Figure 40 Liquid injection solenoid valve stop valve m Horizontal check valve installation Horizontal check valve is standard accessory of RC2 F Series compressor Considering li...

Page 54: ...gerant inlet 1 1 2 2 2 1 2 3 4 5 6 2 Refrigerant outlet 1 1 2 2 2 1 2 3 4 5 6 3 Oil outlet 5 8 Flare 5 8 Flare 5 8 Flare 1 PF 1 PF 1 1 4 PF 1 1 4 PF 4 Oil charge valve 1 4 Flare 5 High oil S G 1 PCS 6 Low oil S G 1 PCS 7 Oil level switch 1 PCS 8 Oil heater 150W 150W 150W 150W 150W 300W 300W 9 Oil drain valve 1 4 Flare 10 Oil temp protection option 1 8 NPTF 11 Safety valve option 1 2 1 2 1 2 1 1 1 ...

Page 55: ...ressor for safe running of compressor Specification Flow Rate max 50 l m Weight 1 4KG Set Working Pressure 40 bar the weight is not including element Material Aluminum alloy Operating Temp from 25 to 110 Seal VITON Compressor Model Material Code Inlet Size Outlet Size RC2 100 140 180 200 230 260 300 310 320 340 410 430 470 510 3130 3240AA 5 8 5 8 RC2 550 580 620 710 790 830 930 1020 1130 1270 1530...

Page 56: ...recommended to install a muffler and check valve before middle pressure returned gas port in compression chamber to effectively mitigate pulsation noise in middle pressure as shown in the drawing below Figure 47 Installation of ECO muffler r Mounting pad To avoid extra vibration and noise resulted from direct contact between compressor footings and the base on which compressor is mounted it is rec...

Page 57: ...control on off of liquid injection valve accordingly to provide suitable liquid injection as shown in the diagram below s Condensor s Evaporator Dryer Chiller in Chiller out W U Earth Bolt V B Pt100 Pt1000 Optional A PTC Z Y X B A Controller Electric Plate Liquid Injection S V Figure 49 Liquid injection connection diagram 1 Note Hanbell suggests to control temperature of motor coil at 60 not highe...

Page 58: ...t 0 100 0 12 Change of resistance 0 100 0 385 K Insulation test voltage U is AC 1 5kV Specification Pt1000 sensor Recommended max meas Current for heat coefficient 0 1K DC0 2 2mA Sensor resistance at 0 1000 1 20 Change of resistance 0 100 3 85 K Insulation test voltage U is AC 1 5kV Note Please specify Pt100 or Pt1000 sensor when placing orders to Hanbell Figure 52 Pt1000 sensor ...

Page 59: ...re valve the pressure differential can be built shortly after the start up so the capacity control and oil supply to those moving parts won t be a problem Therefore the compressor protection can be achieved In addition to protection function it can also act as check valve to reduce the reverse running time after compressor s stopping Flange on minimum pressure valves are provided for the ease of i...

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Page 61: ... 25 30 35 3 Solenoid valve 50 4 Solenoid valve 75 Capacity control system module A Step less capacity control 1 step less 2 25 30 35 B 4 step capacity control 2 25 30 35 3 50 4 75 C Step less step capacity control 1 2 3 4 Suction Filter Suction filter Flange Cable box Power bolt PTC terminal PTC controller connector Refrigerant service valve Angle valve Oil heater Stop valve Suction port Discharge...

Page 62: ... Liquid injection solenoid valve Liquid injection expansion valve Compression chamber Soleniod valve description 1 Solenoid valve only step less 2 Solenoid valve 25 3 Solenoid valve 50 4 Solenoid valve 75 Capacity control system module A Step less capacity control 1 step less 2 25 B 4 step capacity control 2 25 3 50 4 75 C Dual capacity control 1 2 3 4 Oil cooler in Let 2 4 3 1 Oil cooler out Let ...

Page 63: ...e inductive it turns out run connection Full load Amper Starting Current Time AMP Y shift time 0 25 0 5sec Figure 54 Y Starting diagram Attention After Y start MCM MCS are deductive for 0 25 sec and then MCM MCD are inductive for run Within as transient as 0 25 sec pseudo short circuit might occur due to inappropriate action of contactors causing trip of compressors When it occurs we recommend usa...

Page 64: ...ue Direct on line features The starting equipment consists of only a main contactor and thermal or electronic overload relay During a direct on line start the starting torque is very high and is higher than necessary for most applications The disadvantage with this method is that it gives the highest possible starting current Please refer to the follow diagram for the wiring of DOL starting B Pt10...

Page 65: ...ased each power supply conduit connects to each conductor in correct sequence to ensure equal phase representation as number 1 2 3 in order 5 Use flexible conduit to enhance serviceability and minimize transmission of vibration 6 Size the circuit breaker or fuse according to NEC or local guidelines 7 As install the power supply conduit make sure that its position does not interfere with any compre...

Page 66: ...ntioned found Note when any protection device trips please do troubleshooting and reset manually Do not let the compressor reset automatically after abnormal trip 5 3 Power supply 1 Limitation of power supply a Voltage limitation b Frequency Long term running rated voltage 5 Rated frequency 2 Instant running rated voltage 10 Note In the region where the electricity power is unstable install an add...

Page 67: ...r b Grounding voltage of casing should be no greater than 50V for a humid location the limit is 25V c Grounding resistance should be no greater than 500 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 set...

Page 68: ...ve table please also consider the following a It is necessary to pay more attention to the auxiliary facilities while the chiller is commissioning at the job site and the periodic maintenance after the initial start up b For a new chiller with compressor put in stock for a long time it is recommended to add 1 to 1 5 liter of oil in the motor casing to provide better screw rotor lubrication during ...

Page 69: ...otor thermister sensor trip See sudden trip of motor sensor above Incorrect supply power connection Check and re connect Y timer failure Check or replace Discharge or suction stop valve closed Open the stop valve Improper connection between node terminals of Y wiring Check and re connect the wiring Rotor locked Check and repair Earth fault Check and repair Protection device trip Check Abnormal vib...

Page 70: ...o control the suction superheat by means of refrigerant flow rate When the initial startup the loading of the chiller is heavy due to the high temperature of chilled water so the liquid injection devices capacity should be selected or calculated enough to reduce the overheat of the compressor Calculating the cooling capacity of liquid injection devices Liquid injection devices can be calculated wi...

Page 71: ...ay not be turned on although motor load is severe and motor coil temperature is high This may lead to motor failure Therefore in applications mentioned above Pt100 or Pt1000 for liquid injection to motor is recommended instead Figure 61 Liquid injection high temperature type Figure 62 Liquid injection high temperature type connected to motor to compression chamber b Oil cooler applications Compare...

Page 72: ...r Note 1 Please decide appropriate oil cooler capacity by referring to HANBELL selection software 2 The max pressure drop allowed in external oil cooler is 1 5 kg cm2 3 When applying an oil cooler with a compressor please add appropriate refrigeration oil in accordance with the size of oil cooler as well as the length of piping 4 For RC2 100 140 180 their oil circuit design is different from other...

Page 73: ...of efficiency System with Economizer sub cooler With this form of operation a heat exchanger refrigerant sub cooler is used to sub cooled liquid refrigerant The sub cooling is achieved by injecting a part of the refrigerant from the condenser through an expansion device in counter flow into the sub cooler which then evaporates due to the absorption of heat The superheated vapor is pulled into the ...

Page 74: ...n each oil return line to ensure the returned oil in each compressor with normal oil level The basic design of the system is shown in Figure 69 twin compressor parallel system connections The accessories installed are the basic and if there are more applications or protection required contact HANBELL or local distributor agent for more information or further confirmation Figure 71 Parallel system ...

Page 75: ...e compressor compression chamber for pumping down repeatedly b The minimum suction pressure when doing the pump down should be over 15 psig for R 134a and 25 psig for R22 c Take notice of compressor running noise If there is any abnormal noise happened then emergently stop the pump down 2 Long term partial load operation If compressors have to run at partial load below 50 continuously though maybe...

Page 76: ...VI RG RT button of six series of Hanbell compressors 3 After selecting RC2 A will present several function buttons 3 1 choose the unit SI or Imperial default unit is SI 3 2 PERFORMANCE button shows the performance sheet of the compressor The above window is the operating mode of a compressor just key in the following condition and then click the Calculate button Refrigerant type With economizer ye...

Page 77: ...ill show the compressor model and the performance T Data The technical data is the same with function key of technical data 3 4 Print Copying the calculated performance data 3 4 button is for the detailed technical information that the customer needs to know about the compressor 3 5 EXTRA Refrigerant Contrast sheet Pressure Temperature and unit conversion Entering the window it will present the fo...

Page 78: ... 69 0 69 3 70 4 72 0 72 3 73 1 74 1 75 1 75 4 2500 69 0 69 3 70 4 72 0 72 3 73 1 74 1 75 1 75 4 3150 66 2 66 4 67 5 69 0 69 3 70 1 71 0 72 1 72 4 4000 64 7 65 0 66 0 67 5 67 8 68 6 69 5 70 5 70 8 5000 59 1 59 4 60 3 61 7 61 9 62 6 63 4 64 4 64 6 6300 55 9 56 1 57 0 58 3 58 5 59 2 60 0 60 9 61 1 8000 50 2 50 4 51 2 52 4 52 6 53 2 53 9 54 7 54 9 10000 49 6 49 8 50 6 51 7 52 0 52 5 53 2 54 0 54 2 125...

Page 79: ...ty Maintenance The technicians should be familiar with the Hanbell compressor before attempting any maintenance on the unit Periodical check and regular maintenance are very important for the long and trouble free compressor life and for maintaining the warranty The content here is to help the operator and service people to know how the regu lar maintenance can be done and when the suitable time i...

Page 80: ...ssumed to take over all the necessary routine checks Daily check for operation conditions is also very important to have a stable operating system Please refer to the recommended maintenance schedule found on the following pages This schedule is only for the technician s reference and should be considered as the minimum guideline to maintain the system s nor mal operation Technicians still can do ...

Page 81: ... moisture It is also important to keep compressors and systems closed except when work is actually being done on the equipment and to filter out undesirable contaminants This can be achieved with proper installation and service techniques as well as the use of correct filters and driers Once moisture is in the oil it is extremely difficult to remove even under a high vacuum it can take many hours ...

Page 82: ..._______________________ Site Information Installation Site Name _________________________________________________________________________ 8QLW QIRUPDWLRQ 86 6 3 5 7 6 7 25 2035 6625 Model Number Serial Number Type Oil Used Unit Check Points Maintenance Schedule 24 hrs 200 hrs 1000 hrs 2500 hrs 5000 hrs 10000 hrs 15000 hrs 20000 hrs 25000 hrs 30000 hrs Motor Insulation Oil Filter Cartridge Suction ...

Page 83: ...Technical Manual VERSION 2 0 10 18 2018 83 NOTES ...

Page 84: ...Providing HVAC R Control Solutions Worldwide 5580 Enterprise Pkwy Fort Myers FL 33905 Office 239 694 0089 Fax 239 694 0031 www mcscontrols com HANBELL PRECISE MACHINERY CO LTD ...