Table of Contents
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1. General ........................................................................................................................................ 1
2. Specifications and description of design ................................................................................. 2
2.1 Compressor nomenclature ............................................................................................... 2
2.2 Compressor specifications .............................................................................................. 3
2.3 RC2-AV series compressor construction ........................................................................ 4
2.4 Design features.................................................................................................................. 6
2.5 Compression process ....................................................................................................... 7
2.6 Guide to VFD application .................................................................................................. 7
2.7 Capacity control system ................................................................................................... 8
2.8 Compressor volume ratio (Vi) .......................................................................................... 8
2.9 Application limits ............................................................................................................... 9
3. Lubricants ................................................................................................................................. 10
3.1 Lubricants table ............................................................................................................... 10
3.2 Pre-cautions of oil change .............................................................................................. 10
3.3 Oil change ........................................................................................................................ 11
4. Compressor lifting and installation......................................................................................... 12
4.1 Compressor lifting ........................................................................................................... 12
4.2 Mounting the compressor .............................................................................................. 12
4.3 RC2-AV series compressor outline drawings ............................................................... 14
4.4 Compressors accessories .............................................................................................. 37
5. Electrical data and design ....................................................................................................... 50
5.1 Motor design .................................................................................................................... 50
5.2 Electrical installation with VFD ...................................................................................... 50
5.3 V-F diagram ...................................................................................................................... 50
5.4 Compressor protection devices ..................................................................................... 51
5.5 Grounding ........................................................................................................................ 51
6. Operation and maintenance .................................................................................................... 52
6.1 Compressor start-up ....................................................................................................... 52
6.2 Troubleshooting .............................................................................................................. 53
7. Applications .............................................................................................................................. 55
7.1 Additional cooling ........................................................................................................... 55
7.2 Economizer applications ................................................................................................ 58
7.3 Parallel system applications .......................................................................................... 60
7.4 Oil pump applications ..................................................................................................... 60
7.5 Important notes about applications of compressor ..................................................... 61
Contents
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Related Manuals for Hanbell RC2-AV Series
Summary of Contents for Hanbell RC2-AV Series
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Page 1: Table Of Contents
4. Compressor lifting and installation..................12 4.1 Compressor lifting ......................12 4.2 Mounting the compressor ....................12 4.3 RC2-AV series compressor outline drawings ............... 14 4.4 Compressors accessories ....................37 5. Electrical data and design ....................... 50 5.1 Motor design ........................50 5.2 Electrical installation with VFD .................. -
Page 2: General
VFD applications. Each HANBELL compressor has the latest and advanced 5-to-6 Patented Screw Rotor Profile designed to ensure high capacity and efficiency in all operating conditions. Each unit is carefully manufactured and inspected by high precision THREAD SCREW ROTOR GRINDING MACHINE, CNC MACHINING CENTER, and 3D COORDINATE MEASURING MACHINE. -
Page 3: Specifications And Description Of Design
2. Specifications and description of design 2.1 Compressor nomenclature RC 2 – x x x x A V V for applications with variable frequency driver) Refrigerant Code A = R134a, R1234ze Compressor Displacement at 50Hz (m /hr) RC model 2 Version... -
Page 4: Compressor Specifications
2200 Nominal horse power: All the above Nominal Hp values are not the maximum compressor Hp. Please refer to Hanbell selection software for rated current according to various operating conditions while sizing inverter, AC reactor, contactor, cable, fuse and wirings, etc…... -
Page 5: Rc2-Av Series Compressor Construction
2.3 RC2-AV series compressor construction RC2-100AV, RC2-140AV, RC2-180AV construction Figure 1 Item Description Item Description Item Description Item Description Compressor casing Oil separator muffler Vi plug key Oil filler cartridge Motor casing Oil separator demister Discharge bearings Suction filter Oil separator... - Page 6 RC2-550AV, RC2-620AV construction Figure 3 Item Description Item Description Item Description Item Description Compressor casing Oil separator cartridge 17 Discharge bearings 25 Suction filter Motor casing 10 Discharge check valve 18 Discharge fixed ring 26 Oil heater Oil separator 11 Motor cable cover plate 19 Disc spring 27 Refrigeration Lubricant Motor rotor assembly...
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Page 7: Design Features
27 Oil filler cartridge 2.4 Design features HANBELL screw compressors feature simple and robust construction by elimination of some components such as pistons, piston rings, valve plates, oil pumps which are found in reciprocating compressors. Without these components, screw compressors run with low noise level, minimized vibration, high reliability and durability. HANBELL screw compressors are of two-shaft rotary displacement design with the latest and advanced 5:6 patented screw rotors. -
Page 8: Compression Process
2. To run compressors out of working frequency mentioned above, e.g. powering a 380V/3P/70Hz motor between 20 and 80Hz, please consult Hanbell before running. Running at frequency out of designed range will result in lower efficiency or serious damage to the compressor and motor. -
Page 9: Capacity Control System
prevent interference. 9. To prevent reverse rotation caused by incorrect wiring, inspect high/low pressures by pressure switches or programming in commissioning. 10. High/low pressure differential of compressor should be kept above 4kg/cm , especially at low rotation speed. If there is external oil circuit, oil flow switch should be installed and oil pressure in the main oil return line should be monitored to ensure adequate lubrication of compressor. -
Page 10: Application Limits
Application limits of RC2-100AV~RC2-1530AV Note: 1. When Hanbell screw compressors operate at partial or full load within application limits, motor coil and discharge temperature will rise simultaneously. In order to keep compressor running safely and continuously, Hanbell recommends the following additional cooling devices:... -
Page 11: Lubricants
Every HANBELL RC2-AV compressors is equipped with oil sight glasses. The function of internal oil line sight glass is to monitor lubricant flow to bearings. While reverse running, it is unable to see the oil flow via 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. -
Page 12: Oil Change
3.3 Oil change 1. Change oil periodically: Check lubrication oil every 10,000 hours of continuous running. For the first operation of the compressor, it is recommended to change the oil and clean the external oil filter after 2,000 hours running. Check whether the system is clean or not and then change oil every 20,000 hours or after 3 years’... -
Page 13: 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 14 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 minimize vibration and noise.
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Page 15: Rc2-Av Series Compressor Outline Drawings
4.3 RC2-AV series compressor outline drawings... - Page 17 UNIT SI: mm Imperial: (in)
- Page 34 UNIT: SI: mm Imperial: (in)
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Page 38: Compressors Accessories
4.4 Compressors 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: ●： ： ： ： Standard, ：... - Page 39 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 40 8” Figure 15 Flange bushing dimensions Note：The above table lists specification of standard bushing for every model of RC2-AV 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 41 Specification and dimension of optional flange bushing: Dimension of flanges bushing Model Discharge / Suction port Materials and Sizes of pipes 1 5/8" 41.6 Copper Discharge 2 1/8" 54.3 Steel 1 1/2" 49.3 RC2-100 1 5/8" 41.6 RC2-140 Copper 2 1/8" 54.3 Suction 2 5/8"...
- Page 42 INT69HBY motor protector and PTC temperature sensor In order to protect compressors, every RC2-AV series compressor has four PTC temperature sensors (thermistors), three embedded in motor coil and one at the discharge port of the compressor. These sensors are connected to INT69HBY protection module to monitor the motor coil temperature and discharge temperature.
- Page 43 Hanbell also offers 300W oil heater to keep adequate lubricant oil temperature for large external oil separator and applications in areas where the ambient temperature is low.
- Page 44 Oil level switch There are 3 wires on Hanbell oil level switch. 2 of them are for the interlock to main control circuit or independent circuit for micro controller, the other one with green color for grounding. To prevent oil level switch from tripping caused by oil foaming or surging in the sump, a time delay of max 15 seconds is recommended.
- Page 45 Hanbell designs and makes the cable box Hanbell designs and makes the cable box which meets IP54 specification. Dimensions of cable box and the size of Dimensions of cable box and the size of opening in cable box (for motor power line...
- Page 46 Figure 27 Dimensions and installation of horizontal check valve l. External oil separator For improvement of oil return in flooded-type, low-temperature and parallel systems, system with long piping, Hanbell specially designs a complete series of external oil separators – OS series with characteristics of high separation efficiency and low pressure drop.
- Page 47 Ⅲ ： ( ) Dimensions OS40 OS50 OS65 OS80 OS100 OS125 OS150 1050 1110 1227 1637 1829 2229 1000 1080 1480 Note：It is recommended to install a muffler before the external oil separator to avoid noise and vibration which is caused by resonance.
- Page 48 Specification: switch value l/min selectable Weight Type Qmax. Recom. l/min Qmax. Recom. l/min range for fixed switch G 1/2 FF-015GR012 0.4-12 G 3/4 FF-020GR025 0.6-25 FF-025GR040 1.5-40 Figure 30 Oil flow switch (1) Tolerance：+/- 0.3l/min (2) Media temperature: max 110℃ (3) Average pressure loss:0.4 bar at Qmax Average pressure loss:0.4 bar at Qmax (4) Hysteresis: depending on switch value minimum 0.4 l/min...
- Page 49 Temperature sensors Pt100 or Pt1000 To detect temperature of motor coil, Hanbell mounts Pt100 or Pt1000 sensor on motor coil as optional accessories. 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 50 Insulation test voltage U is – AC 1.5kV Compressors motor can be equipped with either Pt100 or Pt1000 sensor to precisely control liquid injection and maintain motor coil while running. Please specify Pt100 or Pt1000 sensor when placing orders to Hanbell. Their connection refers to Figure 37.
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Page 51: Electrical Data And Design
5.2 Electrical installation with VFD RC2-AV series compressors are compatible with any general inverters. The general connection diagram is as shown below in Figure 38. An AC reactor should be installed between the power supply and the inverter in order to prevent power system from serious breakdown. -
Page 52: Compressor 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 warranty of compressors if any action mentioned is found. -
Page 53: 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 is found. Regularly check the field according to national regulations and the following items also should be checked:... -
Page 54: Troubleshooting
●Operating data of the machine ●The lubrication/oil level ●All compressor protection devices ●Electrical cable wirings Procedures to operate RC2-AV compressors Start the compressor: 1. For loading and unloading the compressor with the inverter, it’s recommended to increase or decrease frequency 1Hz per 1~2 second. - Page 55 Check and reset for proper superheat Condensing temperature too low Check means for regulating condensing temperature Note: Replacements of compressor parts should be performed by a qualified / certified serviceman with full knowledge of HANBELL screw compressors or HANBELL service engineers.
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Page 56: 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 57 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 58 The basic water-cooled oil cooling system is shown in Figure 47. Figure 47 Oil cooling by water Note: 1. Please decide appropriate oil cooler capacity by referring to HANBELL selection software. 2. Maximum pressure drop allowed in external oil cooler is 1.5 kg/cm . When it exceeds 1.5kg/cm , clean or change oil filter.
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Page 59: Economizer Applications
External oil circuit application 7.2 Economizer applications HANBELL screw compressor can be fitted with an additional middle connection for economizer operation. With this HANBELL screw compressor can be fitted with an additional middle connection for economizer operation. With this HANBELL screw compressor can be fitted with an additional middle connection for economizer operation. With this... - Page 60 Figure 50 Installation of ECO muffler Figure 51 System with economizer (sub-cooler) Figure 52 System with economizer (flash type sub-cooler)
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Page 61: Parallel System Applications
Besides the installation of oil pumps, a high – low pressure differential switch is also recommended to apply to this kind of system. Please contact Hanbell for more detailed information of oil pump. Figure 54 Oil pump installation... -
Page 62: Important Notes About Applications Of Compressor
7.5 Important notes about applications of compressor 1. Pump down Do not pump down the compressor on the chiller as a routine operation. Only pump down for urgent maintenance or a long term shut down. Because pump down will cause extremely high temperature in the compression chamber and overheat of the motor as well due to less amount of refrigerant in the suction side.