Summary of Contents for J&E Hall 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 HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual © 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.
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Page 3: Safety
HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual Safety In common with most other forms of mechanical and electrical equipment, there are a number of potential hazards associated with operating and servicing refrigeration plant. In writing this instruction manual every emphasis has been given to safe methods of working. -
Page 4: Examination Of Pressure Systems
HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual Examination of Pressure Systems Within the United Kingdom, statutory regulations require the user to prepare a ‘written scheme of examination’ to cover all parts of the plant subject to pressure. It is a requirement that the scheme be introduced before the plant is put into operation for the first time. -
Page 5: Lubricating Oils
HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual Lubricating Oils Refrigeration oils are unlikely to present any significant health and safety hazard provided they are used properly, and good standards of industrial and personal hygiene are maintained. The following general precautions are recommended: •... -
Page 6: Hydrochlorofluorocarbon And Hydrofluorocarbon Refrigerants
HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual Exits and gangways from areas where ammonia is used or stored must be kept clear and free from obstructions to permit rapid evacuation if there is a serious escape of ammonia. Locations from which evacuation can only be carried out with difficulty must be designated ‘gas mask areas’. -
Page 7: Table Of Contents
HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual Contents Safety ............................ 3 Personnel Permitted to Install, Commission and Maintain the Plant ........3 Mechanical ..........................3 Examination of Pressure Systems ..................4 Noise Hazard ........................... 4 Electrical ..........................4 Lubricating Oils ........................ - Page 8 HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual 5.1.1. Capacity Control Actuation ....................32 5.1.2. Bearing Lubrication ......................32 5.1.3. Shaft Seal Lubrication, Sealing and Cooling ..............32 5.1.4. Oil Injection for Sealing and Cooling ................... 32 Oil Support System ....................34 6.1.
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Page 9: List Of Figures
HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual 12.6. Re-instating the Compressor ....................55 Maintenance ......................57 13.1. Spare Parts......................... 57 13.2. Filters and Strainers ......................57 13.3. Running-in .......................... 58 13.4. Maintenance Schedule ....................... 58 13.5. Maintenance Intervals ......................58 13.5.1. -
Page 10: About This Publication
HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual About this Publication These instructions have been prepared according to the following standards: BS 4884 : Technical Manuals: Part 1 : 1992 Specification for Presentation of Essential Information. Part 2 : 1993 Guide to Content. Part 3 : 1993 Guide to Presentation. -
Page 11: Misuses That Invalidate Guarantee
HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual Misuses that Invalidate Guarantee Please note that the installer is responsible for the correct installation and commissioning of equipment and, on completion, the owner and/or user is responsible for its safe operation and maintenance. Failure to comply with the following provisions will invalidate the guarantee as set out in J &... -
Page 12: Prolonged Storage
HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual Under no circumstances should the compressor be operated with cut-outs or other safety devices short-circuited or rendered inoperative by mechanical or electrical means. The plant controller is required to supply load/unload pulses to the capacity control solenoid valves;... -
Page 13: General Description
HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual General Description The J & E Hall International HSO 2000 series of open drive compressors form part of the HallScrew family of positive displacement, oil injected, single screw compressors. These compressors have been specially developed for refrigeration, air conditioning and heat pump applications, and can be applied to single stage and multi-stage systems using all normal refrigerants as well as many other process gases. -
Page 14: The Compression Process
HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual The main rotor and star rotors are housed inside a one-piece, cast-iron main casing. The inside of the casing has a somewhat complex shape, but essentially consists of a cylindrical annulus which encloses the main rotor leaving a small clearance. - Page 15 HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual The movement of the slide valves is effected by oil pressure acting on a piston which is connected to the valves by a yoke. Pressurised oil is taken from the lubrication system and fed through solenoid valves which respond to signals from the plant control system.
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Page 16: The Compression Process
HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual 1. S UCTION 2. S UCTION Fig 1 Compression Process 3.4. The Compression Process As the HallScrew is a positive displacement compressor, there are three separate stages in the compression cycle: suction, compression and discharge. -
Page 17: Compression
HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual 3. C OMPRESSION 4. D ISCHARGE Fig 1 (continued) Compression Process 3.4.2. Compression As the main rotor turns, the volume of gas trapped within the flute is reduced as the length of the flute shortens and compression occurs. 3.4.3. -
Page 18: Capacity Control And Volume Ratio
HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual Capacity Control and Volume Ratio Since the HallScrew compressor utilises fixed intake and discharge ports instead of valves, the overall compression ratio is determined by the configuration of these ports. The degree of compression is governed by the ratio between the flute volume when it is sealed off by the star tooth at the beginning of the compression process, to that immediately before the delivery port is uncovered. -
Page 19: Slide Valve Actuation
HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual The best part load characteristics are achieved if the design full load V maintained as the compressor’s capacity is reduced. The HallScrew 2000 series compressor is fitted with a pair of sliding valves, one for each half of the symmetrical compression process. -
Page 20: Capacity Control Solenoid Valve Arrangements
HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual 4.2. Capacity Control Solenoid Valve Arrangements As discussed in 7. Oil Circulation, if the system suction/discharge pressure differential is sufficient to generate oil pressure for injection and lubrication, an oil circulation pump can be dispensed with altogether. However, as there is no other oil pressure source, special precautions must be taken to automatically return the capacity control piston to the minimum load position when the compressor stops to provide a... -
Page 21: Flow Control Valves
HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual 4.3.4. Flow Control Valves The capacity control piston and slide valves speed of travel, and hence how quickly the compressor loads and unloads, is determined by flow control valves fitted in the load and unload oil lines to the capacity control cylinder. -
Page 22: Fig 3 Capacity Control Arrangement Using Separate Pairs Of Solenoid Valves
HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual Load Line Load Flow Drain Feed Unload Line Control Valve Unload Flow Control Valve OMPRESSOR OADING Load Line Load Flow Drain Feed Unload Line Control Valve Unload Flow Control Valve OMPRESSOR NLOADING (NC) -
Page 23: Capacity Control Arrangement Using A 4-Way Solenoid Valve
HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual 4.4. Capacity Control Arrangement Using a 4-Way Solenoid Valve This arrangement, shown in Fig 4, provides continuously variable capacity control between minimum and maximum load. The solenoids on the 4-way valve are normally closed, energise to open. 4.4.1. -
Page 24: Fig 4 Capacity Control Arrangement Using A 4-Way Solenoid Valve
HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual SOLENOID B SOLENOID A Unload Flow Control Valve Feed Unload Line Load Line Drain OMPRESSOR OADING SOLENOID B SOLENOID A Unload Flow Control Valve Feed Unload Line Load Line Drain OMPRESSOR NLOADING APACITY... -
Page 25: Capacity Control By Inverter Drive
HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual 4.5. Capacity Control by Inverter Drive Instead of using the slide valves, compressor capacity can be controlled using a frequency inverter (also known as Variable Speed Drive or Variable Frequency Drive). If an inverter is used, the load/unload solenoid valves need to be controlled to allow the compressor to start at minimum load but load to full load when the compressor is running. -
Page 26: Linear Variable Displacement Transducer (Lvdt)
HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual 4.6. Linear Variable Displacement Transducer (LVDT) The LVDT provides a continuous 4 to 20 mA slide valve position signal between minimum load (25 %) and maximum load (100 %). The LVDT operates on the principle of using a coil (inductance element) to produce an electrical output proportional to the displacement of a separate movable indicator rod. -
Page 27: To 20 Ma Calibration - Compressor Running
HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual Cable DIN Plug Screw Cap Covering Calibration Entry IP65 Buttons and LEDs Slide valves at maximum Discharge load = 20 mA End Cover Slide valves at minimum load = 4 mA Head Module Indicator Rod... -
Page 28: Fig 6 Hblvdt External Wiring Connections For Explosion-Proof Version
HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual Cable DIN Plug Screw Cap Covering Calibration Entry IP65 Buttons and LEDs Slide valves Electronics at maximum Discharge Module load = 20 mA CE 0158 Ex II 2G End Cover DEMKO 04 ATEX 135657 Slide valves EEx 1b IIC T5... -
Page 29: Fitting A New Hblvdt Electronics Module
HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual Unscrew and remove the cap covering the calibration button and LEDs. Select ‘hand capacity control’. Move the capacity control slides to the minimum load position. The slides must remain at minimum load for the duration of step (e). -
Page 30: Msi Linear Variable Displacement Transducer (Msi Lvdt)
HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual 4.8. MSI Linear Variable Displacement Transducer (MSI LVDT) From the February 2008, all HS 2000 compressors are supplied with the MSI LVDT which replaces the HBLVDT previously fitted. • The MSI LVDT is a drop-in replacement for the HBLVDT. Adaptors, spacers etc., are not required;... -
Page 31: Fig 8 Signal Conditioning Module
HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual Pepperl & Fuchs Module KFU8-USC-1.D Suitable for DIN Rail Mounting Part Number 2848-601 Red 1 Black 2 LVDT White or Yellow 3 4 to 20 mA Output Power Supply 24 V dc (+IN) 2 8 (+OUT) Pepper &... -
Page 32: Compressor Lubrication, Sealing And Cooling
HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual Compressor Lubrication, Sealing and Cooling In common with other types of oil injected screw compressor, HSO 2000 series compressors do not possess a built-in oil reservoir (sump), oil circulation pump or oil filtration equipment. Instead, oil is supplied by a separate external oil support system. - Page 33 HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual Positioning the oil injection ports in the capacity control slide valves ensures that, at all slide valve positions, oil enters the main rotor flutes after the flute volume has been sealed, i.e. oil injection always occurs during the compression process over the whole capacity control range, thus ensuring maximum pumping efficiency.
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Page 34: Oil Support System
HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual Oil Support System HSO 2000 series compressors require an external oil separator and oil support system; refer to Appendix 2 Oil Support System Schematic Flow Diagrams. NOTE: the system into which the compressor is to be installed must fully comply with the recommendations in 6.1. -
Page 35: Oil Separation
HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual 6.3. Oil Separation All the oil injected into the compressor for lubrication, sealing and capacity control actuation, ultimately ends up in the discharge gas stream. During its passage through the compressor the oil is thoroughly mixed with the refrigerant, eventually ending up in the discharge gas stream as a fine mist of oil droplets. -
Page 36: Oil Return
HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual 6.4.1. Oil Return As already mentioned in 6.2, the separator must be positioned at a suitable height such that the standing oil level (compressor stopped) is significantly below the bottom of the compressor. For applications using a continuously running oil pump a drain line must be installed between the compressor casing and the oil separator. -
Page 37: Oil Circulation
HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual Oil Circulation An oil circulation pump can be dispensed with for most operating conditions using HSO 2000 series compressors or if a pump is necessary it is only required to run at start-up. For applications without an oil pump, oil circulation is maintained by the pressure difference generated between the high pressure side of the system and the pressure in the sealed main rotor flute at the point of oil... -
Page 38: Oil Differential Pressure 1 (Odp1)
HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual Each oil support system can be combined with two different oil feed types: • Common oil supply feeds to the compressor oil injection port and to the gland and bearings. •... -
Page 39: Oil Flow Switch
HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual The demand oil pump starts a few seconds before the compressor. After the minimum run time interval expires, Fridgewatch checks if system pressure difference is sufficient to maintain adequate oil supply without the oil pump running. -
Page 40: Oil Filter
HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual Suction CVPP Pilot Line Sensing Suction Pressure Danfoss PM 1 Main Valve + CVPP Pilot Valve Discharge Line Discharge Oil Separator/Reservoir Fig 9 Maintaining Discharge Pressure at Start up The differential pressure regulator allows discharge pressure to build up quickly on starting to achieve the necessary oil differential pressure before the start delay time expires (usually 30 seconds). -
Page 41: Lubricating Oils
HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual For further details refer 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 essential for compressor reliability and optimum system performance, this issue is discussed in detail in publication 2-59 Lubricating Oils. -
Page 42: Prolonged Storage
HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual Prolonged Storage In certain cases, it may be necessary to keep the compressor in store for several months before installation and commissioning takes place. In this event, the following precautions should be taken. 8.1. -
Page 43: Taking The Compressor Out Of Storage
HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual Suitably protect the compressor mainshaft extension from moisture and external damage by coating the shaft with Shell Enis Fluid MD or a thin film of grease, then covering with a plastic or rubber sleeve. -
Page 44: Installing The Compressor
HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual Installing the Compressor The following instructions apply to ‘bare’ compressors; adapt as necessary if the compressor forms part of a package unit. If the compressor has been in prolonged storage, carry out the instructions described under 8.2. -
Page 45: Electrical Wiring Connections And Interlocks
HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual Before running the compressor, the moving parts must receive some initial lubrication. • Remove the blank plug(s) or flange(s) from the oil injection connection(s), remove the blank plug from rear main bearing oil connection. -
Page 46: Commissioning And Operation
HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual Commissioning and Operation If the compressor is supplied as part of a package unit supplied by J & E Hall International, refer to Section 1 of the plant instruction manual for detailed installation and commissioning instructions. -
Page 47: Compressor Drive Motor
HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual Check that stop valves isolating pressure gauges, cut-outs or other pressure controls are fully open. These valves should be locked- open using circlips or equivalent locking devices. 10.3. Compressor Drive Motor The following general checks are applicable. -
Page 48: Lubrication System
HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual With the motor running, check that all safety controls operate at their correct settings and stop the drive motor. Stop the motor and isolate the electrical supply to prevent it accidentally restarting. - Page 49 HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual If liquid injection oil cooling is fitted, check that stop valves are open in the line supplying refrigerant to the liquid injection valve. With the solenoid valve in the line energised (open), the sight-glass in the line should be full of refrigerant.
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Page 50: Normal Starting And Running
HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual Demand Oil Pump The demand oil pump, controlled by the Fridgewatch 2000 Controller, enables the system to run for most of the time without an oil pump, but if system pressure difference falls the oil pump runs as necessary. -
Page 51: Adding Oil To The System
HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual WARNING The compressor must NEVER be started with the discharge stop valve closed or partially closed, nor must the discharge stop valve be throttled when the compressor is running. Check that the stop valves in the rest of the refrigeration system are in their correct running positions. -
Page 52: Running-In The Compressor
HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual Running-In the Compressor These procedures are carried out during the plant’s first 200 hours of operation. Depending on circumstances, this time period may need to be extended. 11.1. Filters and Strainers Refrigerant tends to have a scouring effect on the internal surfaces of the system. -
Page 53: Checking For Leaks
HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual During the running-in period, as oil is distributed throughout the system, it may be necessary to add extra oil from time to time until the overall oil content has stabilised. Afterwards, it should only be necessary to replace the small quantity of oil lost during maintenance exercises, for example, changing the oil filter element. -
Page 54: Pumping Down And Opening Up The Compressor
HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual Pumping Down and Opening Up the Compressor WARNING Before opening up any part of the system, all personnel concerned must be aware of the potential hazards involved. Because safety is such an important topic, personnel should be thoroughly acquainted with the principles laid down in Safety. -
Page 55: Removing The Residual Refrigerant Gas
HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual WARNING Withdraw the fuses from the motor starter and keep them on your person so that they cannot be accidentally refitted, place a warning notice on the panel next to the main isolator. - Page 56 HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual Check all joints for tightness, then check for leaks on the compressor and any other items disturbed during the maintenance operation. Once the leak test has proved satisfactory, evacuate and dehydrate the compressor and all other parts of the system open to atmosphere.
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Page 57: Maintenance
HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual Maintenance Routine maintenance is essential for the optimum availability and performance of all mechanical equipment, however, in this respect, refrigeration plant is in a somewhat different category since it is particularly susceptible to the presence of air and moisture inside the system. -
Page 58: Running-In
HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual Compressor suction line. Compressor liquid injection line - liquid injection cooling fitted. Economiser (subcooler) line before the solenoid valve and thermostatic expansion valve - if economiser fitted. Compressor discharge line - if separate secondary oil separator fitted. Oil line before oil pump suction - if continuously running or demand oil pump fitted. -
Page 59: Weekly
HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual The specimen log sheet illustrated in Appendix 5 Plant Performance Record shows the minimum number of readings which should be taken to enable an accurate assessment of the plant’s performance to be made. In the case of a very large plant, many more readings need to be logged to complete the overall picture. -
Page 60: Every Year, Or At Intervals Of 5,000 Operating Hours
HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual 13.5.4. Every Year, or at Intervals of 5,000 Operating Hours Pump down the compressor and isolate the compressor and oil separator/reservoir. The procedure to follow is described under 12. Pumping Down and Opening Up the Compressor. Take a sample of oil from the oil separator/reservoir. -
Page 61: Every 3 Years, Or At Intervals Of 15,000 Operating Hours
HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual Check more frequently if operating conditions are such that the pressure in the suction line is below atmospheric. 13.5.5. Every 3 Years, or at Intervals of 15,000 Operating Hours Pump down the compressor and isolate the compressor and oil separator/reservoir. -
Page 62: Every 24 Years, Or At Intervals Of 100,000 Operating Hours
HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual Open up the compressor for inspection in the presence of J & E Hall International or our appointed representative. Remove the side covers and examine the star shaft bearings and main bearings with a view to replacement. -
Page 63: Table 6 Maintenance Check List
HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual AILY Check the oil separator/reservoir oil level. 13.5.1 Check and record system temperatures, pressures and flow rates. EEKLY Check for leakage of refrigerant and oil. Inspect the exterior of the plant for damage or corrosion. Check valve caps are in place. -
Page 64: Oil Acid Content Record
HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual 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. IGNATURE RINTED ONTENT Table 7 Oil Acid Content Record - Plants Charged with Refrigerant other than Ammonia (R717) Page 64 of 94 Publication 2-119... -
Page 65: Appendix 1 Compressor Data
HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual 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 Operation. •... - Page 66 HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual HSO 2000 Series: Compressor Model Nomenclature Application Open drive Compressor Series 2000 Twin Star 24, 28, 31 or 35 Capacity Control Slide V 1.85 V 2.2 V 3.5 V 4.9 V 2.6 V Lubricant Ester oil...
- Page 67 HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual HSO 2000 Series: Physical Data Compressor Type Single screw, open drive. Compressor Rotation Anticlockwise looking on the motor (driven) end. Under no circumstances should the compressor run in the reverse direction. For gas engine drive applications, an intermediate gearbox is required to reverse the rotation of the prime mover.
- Page 68 HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual HSO 2000 Series: Starting Torque Characteristics Starting torque characteristics are shown for different system pressure ration, in tabular form and as a graph. Does not include accelerating torque ORQUE PEED YSTEM RESSURE ATIO...
- Page 69 HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual HSO 2000 Series: Limits of Operation Pressure Limits Detailed below are the test pressures applied to HallScrew compressors during the course of manufacture. These limits MUST NOT be exceeded during installation, commissioning or operation of the plant.
- Page 70 HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual Safety Requirements for Compressor Protection ARAMETER EVICE ETTING EMARKS Discharge pressure High HP cut-out According to the Connected to compressor operating discharge, refer to conditions. Discharge temperature High Cut-out or thermistor Temperature at the 100 °C compressor discharge.
- Page 71 HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual HSO 2000 Series: Physical Dimensions and Connections HSO 2024 HSO 2028 HSO 2031 HSO 3035 IMENSION Length 1130 1150 1305 Overall Height Width 1000 Centre of gravity 201.5 Holding-down bolt centres Holding-down bolt 4 x M22 4 x M26...
- Page 72 HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual Discharge Pressure Capacity Gauge Control ‘Unload’ Suction (Top – Standard) Gland Oil Feed Economiser Connection Capacity (Top) Control ‘Load’ Discharge (Top – Option) Liquid Injection Suction Main Oil Pressure Injection Gauge Main Oil Injection...
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Page 73: Appendix 2 Oil Support System Schematic Flow Diagrams
HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual Appendix 2 Oil Support System Schematic Flow Diagrams Normally Closed Normally Open Locked Open Normally Closed and Capped Valve, straight through Valve, right angle Ball valve Non-return valve Quick-acting drain valve, normally closed Control valve and capped Relief valve... -
Page 74: Fig 12 No Oil Pump
HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual Suction Discharge/Suction Bypass Evacuation Unload Load Oil Injection 4-Way Solenoid Valve (Subplate Oil Lubrication Shown) Discharge Oil Separator/Reservoir Sight-glass Oil Drain Oil Filling Connection HT (Oil) Purge Filter Circuit Completion When Using Liquid Injection Cooling Second Filter if... -
Page 75: Fig 13 Start-Up Oil Pump: Common Oil Lines For Injection And Lubrication
HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual Evacuation Suction Discharge/Suction Bypass Unload Load Oil Injection 4-Way Solenoid Valve (Subplate Oil Lubrication Shown) Discharge HT (Del) Oil Separator Reservoir Coalescing Elements for Oil Weir Separation Down to 5 ppm Oil Drain Integral Relief... -
Page 76: Fig 14 Continuously Running Or Demand Oil Pump: Common Oil Lines For Injection And Lubrication
HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual Evacuation Suction Discharge/Suction Bypass Unload Load Oil Injection 4-Way Solenoid Valve (Subplate Oil Lubrication Shown) HT (Del) Discharge Oil Drain Line Oil Separator Reservoir Coalescing Elements for Oil Weir Separation Down to 5 ppm Purge Oil Drain HT (Oil) -
Page 77: Appendix 3 Limits Of Operation Envelopes
HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual Appendix 3 Limits of Operation Envelopes Limits of Operation R22 Maximum suction pressure V Consult J & E Hall International when running at conditions below this line Suction Gauge ° ° ° ° C Continuously running oil pump Booster required below this line... - Page 78 HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual Limits of Operation R717 (Ammonia) Maximum suction pressure V Consult J & E Hall International when running at conditions below this line Suction Gauge ° ° ° ° C Continuously running oil pump Booster required below this line This diagram is approximate, for guidance only.
- Page 79 HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual Limits of Operation R134a Maximum suction pressure V Consult J & E Hall International when running at conditions below this line Suction Gauge ° ° ° ° C Continuously running oil pump Booster required below this line This diagram is approximate, for guidance only.
- Page 80 HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual Limits of Operation R404a and R507A Maximum suction pressure V Consult J & E Hall International when running at conditions below this line Suction Gauge ° ° ° ° C Continuously running oil pump Booster required below this line...
- Page 81 HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual Limits of Operation R407c Maximum suction pressure V Consult J & E Hall International when running at conditions below this line Suction Gauge ° ° ° ° C Continuously running oil pump Booster required below this line This diagram is approximate, for guidance only.
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Page 82: Appendix 4 Hs 2000 Series Compressor Replacement Parts
HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual Appendix 4 HS 2000 Series Compressor Replacement Parts HSO 2024 Part Old Part Serial Number Serial Number Item Diagram Description Number Number 95154-4**-*** Begins with ‘C’ Survey Kit Survey Kit N33050009 95812-415 Gland Seal... - Page 83 HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual HSO 2028 Part Old Part Serial Number Serial Number Item Diagram Description Number Number 95154-5**-*** Begins with ‘C’ Survey Kit Survey Kit N33050011 95812-515 Gland Seal Gland Seal Kit (standard, for applications using R22 or R717 and N02020051 95812-520 mineral oil)
- Page 84 HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual HSO 2031 Part Old Part Serial Number Serial Number Item Diagram Description Number Number 95154-6**-*** Begins with ‘C’ Survey Kit Survey Kit N33050013 95812-615 Gland Seal Gland Seal Kit (standard, for applications using R22 or R717 and N02020053 95812-620 mineral oil)
- Page 85 HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual HSO 2035 Part Old Part Serial Number Serial Number Item Diagram Description Number Number 95154-7**-*** Begins with ‘C’ Survey Kit Survey Kit N33050014 95812-715 Gland Seal Gland Seal Kit (standard, for applications using R22 or R717 and N02020055 95812-720 mineral oil)
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Page 86: Appendix 5 Plant Performance Record
HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual Appendix 5 Plant Performance Record It cannot be too strongly emphasised that the regular and accurate logging of plant performance data makes an important contribution to safety, efficiency and reliability, by ensuring that the plant operates within the design conditions. - Page 87 HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual ..................................AKEN OMPRESSOR Hours Run ..........% Capacity ..........Net Oil Pressure at Compressor ....Oil Temperature (° C) ......... OMPRESSOR OTOR Speed (rpm) ..........Volt ..........................Amp ............
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Page 88: Appendix 6 Pepperl & Fuchs Signal Conditioning Module Kfu8-Usc-1.D Set-Up
HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual Appendix 6 Pepperl & Fuchs Signal Conditioning Module KFU8-USC-1.D Set-up Basic Set up for 4 mA and 20 mA Output Values at Minimum and Maximum Slide Valve Positions Refer to Table 8. The KFU8-USC-1.D module can be used simply to calibrate the output from the MSI LVDT to provide 4 mA and 20 mA signals, at the compressor minimum and maximum slide valve positions respectively, by... -
Page 89: Table 8 Basic Set Up For 4 Ma And 20 Ma Output Values At Minimum And Maximum Slide Valve Positions
HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual KFU8-USC-1.D Display Input Output Slide Valve Action Position Display Comment Value Comment Record value Minimum load 6.235 mA For example 6.235 mA Start displayed on unit Press buttons on Display: ESC + OK (together) Unit Input... - Page 90 HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual Input Output Slide Valve Action Position Display Comment Value Comment Record value Maximum load 15.76 mA For example 15.1mA Temporary value displayed on unit Press buttons on Display ESC + OK (together) Unit Input Output...
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Page 91: Table 9 Setting The Display To Read 0 At Minimum Load And 100 At Maximum Load
HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual This procedure is optional but recommended for easy set up of the relay switch point (if used); refer to Table 10 KFU8-USC-1.D Display Input Slide Valve Output Action Position Value Display Comment Min load... -
Page 92: Table 10 Setting The Relay Switch Value
HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual Set the display to read 0 at minimum load and 100 at maximum load before setting the relay switch value KFU8-USC-1.D Display Input Slide Valve Output Action Position Value Display Comment Min load 0.000... - Page 93 HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual This page intentionally blank Issue 1.2 : 03/10 Publication 2-119 Page 93 of 94...
- Page 94 HSO 2024 to HSO 2035 Installation, Operation and Maintenance Manual ©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.