Hanbell RC2 Series Technical Manual
High-efficiency screw compressor
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- Page 1 TECHNICAL MANUAL VERSION 2.0 -10-18-2018 High-efficiency New generation of Model innovative design Screw compressor RC2 Series Screw Compressor 5580 Enterprise Pkwy., Fort Myers, FL 33905 Office (239) 694-0089 Fax: (239) 694-0031 www.mcscontrols.com...
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Page 2: Table Of Contents
2. Specifications and description of design ................. 1 2.1 Compressor nomenclature ....................1 2.2 Compressor specifications ....................2 2.3 RC2 series compressor construction ................4 2.4 Design features........................6 2.5 Compression process ....................... 7 2.6 Capacity control system ....................7 2.7 3 or 4step capacity control system ................. -
Page 3: General
It is strongly recommended that contents of this manual should be referred carefully prior to lifting, installation, and commissioning of RC2 series compressor in order to prevent any accident or damage. Please contact HANBELL or its local distributors/agents for more information or further assistance. -
Page 4: Compressor Specifications
2200 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 and Maximum Continuous CurrentM.C.C according to various operating conditions while selecting sizes of contactor, cable, fuse and wire, etc... - Page 5 2300 Nominal Horse Power: All above Nominal Hp are not equal to the maximum compressors Hp; Please refer to Hanbell selection software’s output for the rated current, Maximum Continuous CurrentM.C.C according to various working condition while selecting the contactor, cable, fuse and wire, etc...
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Page 6: Rc2 Series Compressor Construction
Technical Manual VERSION 2.0 -10-18-2018 2.3 RC2 series compressor construction RC2100, RC2140, RC2180 Construction Figure 1 Item Description Item Description Item Description Item Description Compressor casing Oil separator cartridge Discharge fixed ring Refrigeration Lubricant Motor casing Piston... - Page 7 Technical Manual VERSION 2.0 -10-18-2018 RC2710, RC2790, RC2830, RC2930 Construction Figure 4 Item Description Item Description Item Description Item Description Compressor casing Piston spring Bearing lock nut Suction flange Motor casing Piston rod Male rotor Discharge flange Oil separator Bearing seat cover plate Suction bearings Cable box...
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Page 8: Design Features
Compressor technical features: Full product range RC2 series compressor consists of 26 models with displacement ranging from 98/118 m3/hr up to 1539/1847 m3/hr (50/60Hz) compatible for different refrigerants and applications. Multinational patents of highefficiency screw rotors The new 5:6 high efficiency screw rotor profile is patented in Taiwan, UK, US, and China. -
Page 9: Compression Process
Figure 6 Compression process 2.6 Capacity control system The RC2 series screw compressors are equipped with either 3step/4step capacity control system or continuous (step less) capacity control system. Both of the capacity control systems consist of a modulation slide valve, piston rod, cylinder, piston and piston rings. -
Page 10: Or 4Step Capacity Control System
Energized not energized not energized 25%（for start） Note: For 3step or 4step capacity control system, Hanbell equips normallyclosed (NC) solenoid valves as standard accessory. If normallyopened (NO) solenoid valves are preferred instead, please specify it to Hanbell when placing order. -
Page 11: Continuous (Stepless) Capacity Control System
It is very important for any controller to control loading and unloading in stable condition. For a smooth modulation, HANBELL installs a capillary in loading oil line and an additional orifice valve in unloading oil line to avoid too fast loading and unloading. - Page 12 Figure 14 Stepless capacity control SV1(NC) SV2(NC) SV2(N0) Note: 1. In continuous (stepless) capacity control system, Hanbell installs two normally closed solenoid valves as standard Standard Standard Option accessory. If it is necessary to be equipped with other type of...
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Page 13: Dual Capacity Control System (Optional)
Slide valve Male rotor Gas out (high pressure without oil) Solenoid valve Hanbell can provide compressors with capacity as shown in the figure 16, and its control logic is the same Figure 16 Dual capacity control as those shown in chapter 2.7 and 2.8. -
Page 14: Compressor Volume Ratio (Vi)
Technical Manual VERSION 2.0 -10-18-2018 2.10 Compressor volume ratio (Vi) The volume ratio (Vi) of the compressor can be defined as the ratio of suction volume to discharge volume in the compressor. The smaller the concavity of slide valve in the discharge end, the larger the volume ratio. The volume ratio directly affects the internal compression ratio (Pi). - Page 15 Technical Manual VERSION 2.0 -10-18-2018 additional cooling additional cooling Motor B Motor A Motor A With Min With Min pressure valve...
- Page 16 Note: 1. When Hanbell screw compressor operate in partial or full load within limits, temperature of motor coil and discharge will rise concurrently. In order to keep the safe running of compressor continuously , Hanbell recommend application of the following additional cooling devices :...
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Page 17: Mcc And Lra
Technical Manual VERSION 2.0 -10-18-2018 3. The minimum discharge superheat is recommended to be kept 10°k higher than the condensing temperature ( normally discharge superheat is around 20°K for R134a and 30°K for R22, R407C) to avoid liquid filling back to compressor and lubrication failure. - Page 18 Technical Manual VERSION 2.0 -10-18-2018 Refrigerant : R22, R407C, R404A, R507, R134a (Y-△) 50Hz 60Hz Unit: Ampere 380V 400V 415V 208V 220V 230V 380V 440V 460V 480V 575V (Y/△) (Y/△) (Y/△) (Y/△) (Y/△) (Y/△) (Y/△) (Y/△) (Y/△) (Y/△) (Y/△)
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Page 19: Lubricants
Bearings used in RC2 series compressors require a small and steady quantity of oil for lubrication. Oil injection into the compression chamber creates a film of oil for sealing in the compression housing to increase efficiency and also can dissipate part of compression heat. -
Page 20: PreCautions Of Changing Oil
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. -
Page 21: Compressor Handling And Installation
4. Compressor handling 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 reach 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 22: Mounting The Compressor
If a largecaliber copper tube is not easily accessible and a steel tube is used instead in suction port, Hanbell also recommends the use of a copper tube in discharge port to best minimize abnormal vibration and noise. 3. Remove the oxidized impurities, swarf or debris caused by welding in the piping tubes. If these materials fall into the compressor, the oil filter might be clogged and result in the malfunction of lubrication system, bearings and capacity control system. -
Page 23: Rc2 Compressor Outline Drawings
Technical Manual VERSION 2.0 -10-18-2018 Figure 23 Limits of oblique angle for the installation of the compressor 4.3 RC2 compressor outline drawings 1. RC2A outline drawings UNIT SI: mm Imperial: (in) ... - Page 24 Technical Manual VERSION 2.0 -10-18-2018 UNIT SI: mm Imperial: (in) UNIT SI: mm Imperial: (in) ...
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- Page 44 Technical Manual VERSION 2.0 -10-18-2018 UNIT: SI: mm Imperial: (in) ...
- Page 45 Technical Manual VERSION 2.0 -10-18-2018 Note: For RC21020B, RC21130B, RC21270B and RC21530B outline drawing, please refer to those of RC21020A, RC21130A, RC21270A, and RC21530A ...
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Page 46: Compressors Accessories
4.4 Compressors accessories To supply “Total Solution” to 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 47 Please refer to Chapter 2.6, 2.7, & 2.8 for further details. c. Suction and discharge check valve Hanbell standard check valve (vertical type) is gravitydriven with characteristics of large flow volume and low pressure differential. After shutdown of compressor, Teflon taper guider inside can simultaneously seal up the precisely machined base of check valve by gravity force to effectively prevent return of highpressured gas to...
- Page 48 8” Figure 27 Flange bushing dimensions Note: The above table lists specification of standard bushing for every model of Hanbell compressors. Their dimensions correspond to flange bushing dimensions and the table below. If bushing dimensions are not indicated in purchasing order, Hanbell will provide standard type. Suitable piping of customers’ choice is also shown in the table below.
- Page 49 Technical Manual VERSION 2.0 -10-18-2018 Specification and dimension of optional flange bushing Dimension of flanges bushing Model Materials and Sizes of pipes Discharge / Suction port 1 5/8" 41.6 Copper Discharge 2 1/8" 54.3 RC2100 Steel 1 1/2" 49.3 1 5/8"...
- Page 50 INT69HBY control module and PTC temperature sensor In order to protect compressor, each RC2 series compressor has been installed three PTC temperature sensors inside motor coil and another one at the discharge side of compressor. These sensors are connected to an INT69HBY control module to monitor the motor and discharge temperature.
- Page 51 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 52 2. 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 ...
- Page 53 For improvement of oil return in floodedtype, lowtemperature and parallel systems, and system with long piping, Hanbell specially designs a complete series of external oil separators – OS series with characteristics of high filtration efficiency and low pressure drop. The following table shows details of OS series: Note : It is recommended to install a buffer before the external oil separator to avoid noise and vibration which caused by resonance.
- Page 54 Technical Manual VERSION 2.0 -10-18-2018 ( ) Technical data Ⅰ ： Oil Volume (Liter) Range of application based on Model Type Displacement (m /hr) Shell Diameter High level Low level (Recommended) OS40 Vertical 14” OS50 Vertical 206~270 16” OS65 Vertical 271~440...
- Page 55 Technical Manual VERSION 2.0 -10-18-2018 Horizontal OS80, OS100, OS125, OS150 (Figure 43) o. External oil filter External oil filter is optional accessory of external oil separator. It is suggested to install external oil filter in oil return line before oil inlet port of compressor for safe running of compressor.
- Page 56 Technical Manual VERSION 2.0 -10-18-2018 p. Oil flow switch Oil flow switch operates with external oil separator to prevent oil deficient compressor. Specification and installation of oil flow switch are shown as below: switch value l/min Qmax. Recom. Type selectable range for Weight kg...
- Page 57 RC2 models utilize suction return gas to cool down the motor coil. To effectively detect temperature of motor coil and adequately adjust volume of liquid injection by measured temperature, Hanbell specially mounts Pt100 or Pt1000 sensor on motor coil as an optional accessory. 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 58 Figure 52 Pt1000 sensor 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.
- Page 59 Opening Max. Working Pressure Model pressure pressure temperature drop 1 1/2" 2" 2 1/2 " <120℃ 3" 3.6±0.3Bar 28Bar <0.1Bar 4" 5" 6" Please consult Hanbell representatives for the detailed outline and application Figure 53 Installation of MPV...
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Page 60: Installation And Connection Of Compressor
Technical Manual VERSION 2.0 -10-18-2018... - Page 61 Technical Manual VERSION 2.0 -10-18-2018 c. RC2710, RC2790, RC2830, RC2930 Stop valve Gasket Bolt Bushing Bolt Bolt Bushing Stop valve Discharge Gasket flange Gasket Soleniod valve description ◆ 1. Solenoid valve ( only stepless ) Suction Filter ( motor) 2.
- Page 62 Technical Manual VERSION 2.0 -10-18-2018 d. RC21020, RC21130, RC21270, RC21530 ( Motor) Bolt Liquid injection expansion valve Bolt Liquid injection solenoid valve Discharge Stop valve flange Bushing In system Gasket Soleniod valve description ◆ 1. Solenoid valve ( only stepless ) 2.
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Page 63: Electrical Data And Design
5. Electrical data and design 5.1 Motor design HANBELL RC2 series screw compressors are fitted with Y∆ motor as standard. But ∆/∆∆ motor (Part Winding Starting – PWS) is also available for model RC2100A ~ RC2580A & RC2100B ~ RC2580B. - Page 64 Technical Manual VERSION 2.0 -10-18-2018 ∆/∆∆ (PW) starting RC2100A ~ RC2580A & RC2100B ~ RC2580B are available to be fitted with PWS motor for customer’s application as an optional accessory. Please refer to the follow diagram for the wiring of PWS motor. ...
- Page 65 Figure 57 Soft starting diagram Besides Y∆ and PWS start, if there were any inquiry of direct on line start、soft start、inverter start or series reactance reduced voltage start, please contact Hanbell for further information. Power supply wiring application (RC21270 and 1530 only)
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Page 66: 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’s warranty of compressors if there is any action above mentioned found. -
Page 67: Grounding
●Faults or grounds in power transformer ●Heavy reactive single phase loads such as welders A 3phase unbalanced voltages protector is upon request as optional accessory. Please contact Hanbell for more details. 5.4 Grounding There’s a grounding terminal inside cable box. Please accurately connect it to grounding of control panel for the system. -
Page 68: Operation And Maintenance
The whole plant, especially the pipelines and capillary tubes must be checked for abnormal vibrations. Please contact HANBELL or local distributor if any abnormal vibrations or noise found while compressor is running. k. Regularly check the plant according to national regulations and the following items should also be checked: ●Operating data of the machine... -
Page 69: Troubleshooting
Check means for regulating condensing temperature Note: The replacement of compressor internal parts should be perform only by a qualified / certified service technician with full knowledge of HANBELL screw compressor or it should be a Service Engineer from HANBELL. ... -
Page 70: Compressor Checking List
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 71: Additional Cooling
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 72 Figure 65 Oil cooling by water 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/cm 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.
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Page 73: Economizer Applications
Based on HANBELL extensive research a special design of the economizer connection has been developed so that the connection causes no additional back flow losses during compression. As a result of this, compressor capacity is fully retained in all operating conditions. - Page 74 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.
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Page 75: 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 with Hanbell for more detailed information of oil pump. Figure 72 Additional oil pump... -
Page 76: Selection Software
「 「 「 「 LB」 」 」 」 , 「 「 「 「 RC2AV」 」 」 」 , 「 「 「 「 RC2AVI」 」 」 」 , 「 「 「 「 RG」 」 」 」 , 「 「 「 「 RT」... - Page 77 Technical Manual VERSION 2.0 -10-18-2018 (3.3) 「 「 「 「 」 」 」 」 by clicking this button, it will help the customer how to choose screw compressor model. After clicking the 「 「 「 「 」 」 」 」 button, the right window is customer's necessary operating mode. Just keyin the following data.
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Page 78: Appendix. Rc2 Compressor Noise Level
2. For all compatible refrigerants of R22, R134a, R407C and the working conditions acceptable in limitation of Hanbell screw compressors, it has very similar value at all respective bars as above Sound Pressure Level chart with ±2dBA tolerance of OVERALL value at any working condition by any refrigerant. -
Page 79: Warranty
24 Month Warranty Suggestive Guidelines for Preventive Maintenance All HANBELL screw compressors are put through strict quality and performance testing prior to shipping from the factory. Provided that terms of payment are observed, a two year (24-month) warranty is offered from the date of installation or 27 months from date of shipment. - Page 80 In the case of being unable to do the oil analysis periodically, consult Hanbell oil change schedule because the interval of oil change varies by the oil type and compressor operating condition. Check the oil acidity periodically and change the oil if the oil acidity value measures lower than pH6.
- Page 81 Hanbell Maintenance Version 1.0 HANDLING POE OILS Please read as improper handling can cause compressor failure and void the compressor warranty. POE oils are more hygroscopic than mineral oils, so exposing POE oils to air will result in their absorbing moisture quicker than mineral oils. When POE oils are exposed to moisture and heat, they may react, forming acid that is harmful to the system.
- Page 82 Hanbell Maintenance Version 1.0 24 Month Maintenance Records Suggestive Guidelines for Preventive Maintenance Company _________________________________________________________________________________ Technician ______________________________________ Phone ____________________________________ Site Information Installation Site Name _________________________________________________________________________ Model Number Serial Number Type Oil Used Unit Maintenance Schedule Check Points 1000 2500 5000...
- Page 83 Technical Manual VERSION 2.0 -10-18-2018 NOTES...
- Page 84 HANBELL PRECISE MACHINERY CO., LTD. Providing HVAC/R Control Solutions Worldwide 5580 Enterprise Pkwy. Fort Myers, FL 33905 Office: (239) 694-0089 Fax: (239) 694-0031 www.mcscontrols.com...