Table of Contents
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1. General ........................................................................................................................................ 1
2. Specifications and designs ....................................................................................................... 1
2.1 Compressor nomenclature ............................................................................................... 1
2.2 Compressor specifications .............................................................................................. 2
2.3 Compressor construction ................................................................................................. 2
2.4 Design features.................................................................................................................. 4
2.5 Compression process ....................................................................................................... 4
2.6 VFD application ................................................................................................................. 5
2.7 Capacity control system ................................................................................................... 5
2.8 Volume ratio (Vi) ................................................................................................................ 6
2.9 Application limits ............................................................................................................... 7
3. Lubricants ................................................................................................................................... 8
3.1 Lubricants table ................................................................................................................. 9
3.2 Suggestions of changing oil............................................................................................. 9
3.3 Oil change .......................................................................................................................... 9
4. Compressor lifting and installation ......................................................................................... 10
4.1 Compressor lifting ........................................................................................................... 10
4.2 Compressor mounting .................................................................................................... 10
4.3 Compressor outline ......................................................................................................... 12
4.4 Accessories ..................................................................................................................... 18
5. Electrical data and design ....................................................................................................... 30
5.1 Motor design .................................................................................................................... 30
5.2 Electrical installation with VFD ...................................................................................... 30
5.3 V-F diagram ...................................................................................................................... 30
5.4 Protection devices ........................................................................................................... 31
5.5 Grounding ........................................................................................................................ 31
6. Operation and maintenance .................................................................................................... 32
6.1 Start-up ............................................................................................................................. 32
6.2 Troubleshooting .............................................................................................................. 33
7. Applications .............................................................................................................................. 35
7.1 Additional cooling ........................................................................................................... 35
7.2 Parallel system applications .......................................................................................... 38
7.3 Oil pump application ....................................................................................................... 38
7.4 Inverter cooling................................................................................................................ 39
7.5 Important notes of applications ..................................................................................... 39
8. Selection program .................................................................................................................... 40
9. Warranty .................................................................................................................................... 41
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Table of Contents
Related Manuals for Hanbell RC2-AVI Series
Summary of Contents for Hanbell RC2-AVI Series
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Page 1: Table Of Contents
1. General ............................1 2. Specifications and designs ....................... 1 2.1 Compressor nomenclature ....................1 2.2 Compressor specifications ....................2 2.3 Compressor construction ....................2 2.4 Design features........................4 2.5 Compression process ....................... 4 2.6 VFD application ......................... 5 2.7 Capacity control system ....................5 2.8 Volume ratio (Vi) ........................ -
Page 2: General
Quality management system in HANBELL complies with the ISO 9001 requirements. The ISO 9001 certification assures customers that HANBELL products are manufactured within a uniform and consistent quality system from the time an order is placed until shipment. -
Page 3: Compressor Specifications
(122 ) Nominal Horse Power: All the above Nominal Hp’s are not equal to the maximum compressor Hp. Please refer to Hanbell selection software’s output for rated current according to various operating conditions while selecting contactor, cable, fuse and wire, etc…... - Page 4 Figure 2.1.2:RC2-260AVI, RC2-300AVI, RC2-340AVI, RC2-410AVI, RC2-470AVI, RC2-550AVI, RC2-620AVI, RC2-830AVI Construction Item Description Item Description Item Description Item Description Compressor casing Piston Disc spring Suction flange Motor casing Piston spring Bearing lock nut Discharge flange Oil separator Piston rod Male rotor Cable box Motor rotor assembly Bearing seat’s cover plate...
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Page 5: Design Features
Automatic variable volume ratio ensures no loss of work in various working condition. Variable frequency drive (VFD) Variable frequency drive efficiently adjusts motor speed to match output requirements and save energy. Full product range- RC2-AVI series compressor consists of 11 models with displacement ranging from 140 m /hr to 1775 m /hr. -
Page 6: Vfd Application
Figure 2.2: Compression process 2.6 VFD application The following are the instructions that explain the variable frequency drive (VFD) applied in RC2-AVI series screw compressor. Please read all of the instructions before commissioning. 1. Maximum rotation frequency must be within nominal rotation frequency of the motor; minimum rotation frequency is variable under specified working condition (please refer 2.9 Application Limits). -
Page 7: Volume Ratio (Vi)
Following the concept above, if the Vi varies with working condition, there will be less loss of work. High efficiency can be achieved. In RC2-AVI series, Vi 1.6-2.0-2.4 or Vi 2.4-3.0-3.5 is provided to correspond to various working condition. -
Page 8: Application Limits
Figure 2.5: Vi control (Water-cooled system) Figure 2.6: Vi control (Air-cooled system) 2.9 Application limits The application limits shown below are based on saturated suction and discharge operating conditions, for continuous operation over extended periods of time. It is important to operate within these limits to maintain proper compressor life. Operating at extra low saturated suction temperature, may cause oil management and motor cooling problems, while operating at extra high saturated condensing temperature will shorten the compressor life due to insufficient motor and compressor chamber cooling. -
Page 9: Lubricants
Bearings installed in RC2-AVI 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. -
Page 10: Lubricants Table
3.2 Suggestions of changing oil 1. Use Hanbell certified oil and do not mix different brands of oil together. Choice of oil should match characteristics of the refrigerant used. Oil remained in the compressor should be totally cleaned up before charging different brands of oil. -
Page 11: Compressor Lifting And Installation
4. Compressor lifting and installation 4.1 Compressor lifting Each HANBELL screw compressor has been carefully tested at the factory and every precautionary measures have been taken to make sure that compressors will keep in perfect condition when reaching customers’ work. After the compressor arrives at your warehouse, please check if its crate is kept in good condition and check all the compressor accessories with shipping documents to see if there is any discrepancy. - Page 12 If a large-caliber copper tube is not easily accessible and a steel tube is used instead in suction piping, Hanbell also recommends use of a copper tube in discharge piping to best minimize abnormal vibration and noise.
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Page 13: Compressor Outline
4.3 Compressor outline UNIT SI: mm Imperial: (in) - Page 14 UNIT SI: mm Imperial: (in)
- Page 17 UNIT: SI: mm Imperial: (in)
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Page 19: Accessories
4.4 Accessories To supply “Total Solution” for customers, Hanbell designs complete standard and optional accessories according to various application requirements for safe and steady running and best performance of compressors. 1. Compressors standard and optional accessories ● ： ： ： ：... - Page 20 Suction and discharge check valve Hanbell standard check valve is gravity-driven with characteristics of large flow volume and low pressure drop. After shut-down of the compressor, 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.
- Page 21 5” 8” Note: The above table lists specification of standard bushing for every model of RC2-AVI series compressors. Their dimensions refer to flange bushing dimensions and the table below. If bushing dimensions are not indicated in purchasing orders, Hanbell will provide standard type. Suitable piping of customers’ choice is also shown in the table below.
- Page 22 Suction and discharge stop valves Stop Valve Size For maintenance and service of compressors, it is recommended to install Model suction and discharge stop valves. Please refer to the following detail of Discharge Suction Hanbell stop valves. RC2-140AVI 1 1/2″ 2″ RC2-260AVI 2″ 3″...
- Page 23 INT69HBY diagnose motor protector and PTC temperature sensor In order to protect compressors, each RC2-AVI series compressor has been installed three PTC temperature sensors (thermistors) inside motor coil and another one at the discharge port of the compressor. These sensors are connected to an INT69HBY diagnose protection module to monitor the motor coil temperature and the discharge temperature as well.
- Page 24 In addition, Hanbell also offers 300W oil heater to keep adequate lubricant oil temperature for large external oil separator and applications in areas with low ambient temperature.
- Page 25 Figure 4.15: Oil drain valve h.IP54 cable box Hanbell designs and makes the cable box which meets IP54 specification. Dimensions of cable box and the size of opening in cable box (for motor power line and control power line) refer to the drawing below ...
- Page 26 Figure 4.16: IP54 cable box i. Liquid injection system (solenoid valve + expansion valve) Liquid injection system is an auxiliary mechanism to cool motor coil. RC2-AVI series’ motor is cooled by suction return gas. In high-condensing-temperature or low-evaporating-temperature applications, liquid injection system is recommended to cool motor coil auxiliary.
- Page 27 Ⅱ ： ( ) Accessories Description OS40 OS50 OS65 OS80 OS100 OS125 OS150 Refrigerant inlet 1 1/2” 2” 2 1/2” 3” 4” 5” 6” Refrigerant outlet 1 1/2” 2” 2 1/2” 3” 4” 5” 6” Oil outlet 5/8” Flare 5/8” Flare 5/8”...
- Page 28 l. External oil filter External oil filter is an optional accessory of external oil separator. It is suggested to install an external oil filter in oil return line before the suction port of compressor for safe running of compressors. *Flow Rate: max 50 (l/m) *Weight:1.4KG/Set *Working Pressure: 40 bar (the weight is not including element)
- Page 29 Temperature sensors Pt100 or Pt1000 To effectively detect temperature of motor coil, Hanbell specially mounts Pt100 or Pt1000 sensor on motor coil as optional accessory for customers. This temperature sensor along with controller of the system monitor motor coil temperature and then control on/off of liquid injection valve accordingly to provide suitable liquid injection as shown in the diagram below.
- Page 30 Insulation test voltage U is – AC 1.5kV Please specify Pt100 or Pt1000 sensor when placing orders to Hanbell. Compressors can also be equipped with Pt100 or Pt1000 sensor to adjust liquid injection to precisely control motor coil while running.
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Page 31: Electrical Data And Design
5. Electrical data and design 5.1 Motor design HANBELL RC2-AVI series screw compressors are equipped with Y-Δ motor for soft start with a frequency inverter, VFD. The motor winding is especially designed and its insulation is enhanced for a wide spectrum of rotation frequency. -
Page 32: Protection Devices
Alarm lamp for this protector is required to be embedded on control panel as indicator. Any intention to short controllers for starting of compressors is prohibited. It is beyond Hanbell’s warranty of compressors if there is any action above mentioned found. -
Page 33: Operation And Maintenance
The whole plant, especially the pipelines and capillary tubes must be checked for possible abnormal vibrations. Contact HANBELL or local distributors if any abnormal vibrations or noise found while the compressor is running. j. Regularly check the plant according to national regulations and the following items also should be checked: ●Operating data of the machine... -
Page 34: Troubleshooting
●Check electrical cable connections and tightness Procedures for RC2-AVI series’ operation Start the compressor: 1. For loading and unloading the compressor with the inverter, it’s recommended to increase or decrease its frequency by 1Hz at an interval of 1 to 2 seconds. - Page 35 Check and reset for proper superheat Condensing temperature too low Check means for regulating condensing temperature Note: The replacement of compressor parts should be performed only by a qualified / certified serviceman with full knowledge of HANBELL screw compressors or HANBELL service engineers.
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Page 36: Applications
Calculating the cooling capacity of liquid injection devices Liquid injection devices can be calculated with the HANBELL selection software or manually. For manual calculation, consider the most extreme conditions to be expected during actual operations i.e. minimum evaporating temperature, maximum suction gas super heat and condensing temperature. - Page 37 Oil cooler application can be classified into 3 types: cooling by refrigerant, cooling by ambient air, cooling by cooling water. Oil cooler capacity can be calculated manually or using HANBELL selection software. When calculating manually, worst case operating conditions must be considered: minimum evaporating temperature, maximum suction gas superheat, maximum condensing temperature and the operation mode.
- Page 38 Figure 7.7: Oil cooling by water Note: 1. Please decide appropriate oil cooler capacity by referring to HANBELL selection software. 2. The maximum pressure drop allowed in external oil cooler is 1.5 kg/cm 3. When applying an oil cooler with a compressor, please add appropriate refrigeration oil in accordance with the size...
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Page 39: Parallel System Applications
Besides the installation of additional oil pump, a high – low pressure differential switch is also recommended to install to this kind of system. Please contact Hanbell for more detailed information of oil pump. Figure 7.9 Additional oil pump... -
Page 40: Inverter Cooling
All the piping connected to the inverter should be covered completely with thermal insulation, especially the segment after the regulation valve. If outlet piping needs to be connected to other ports of the compressor such as ECO port, please consult Hanbell for further information. 7.5 Important notes of applications 1. -
Page 41: Selection Program
1. This program is suitable for the operating system of Windows 7 and above edition. 2. The monitor resolution shall be 1280 x720 or higher. 3. Double click the Hanbell Selection V5.0.4.exe file to start the setup. 4. Please follow the procedure and complete the installation. -
Page 42: Warranty
Click「 「 「 「 EXIT」 」 」 」 Leave current window 9. Warranty All HANBELL screw compressors pass strict quality and performance tests in our factory prior to delivery. The screw compressors are manufactured by quality materials and under warranty for: 1) One year after completion of installation and commissioning at jobsite.