RC2 Technical Manual PDF
RC2 Technical Manual PDF
1
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 4-step capacity control system................................................................................. 8
2.8 Continuous (stepless) capacity control system ............................................................. 9
2.9 Dual capacity control system (optional)........................................................................ 11
2.10 Compressor volume ratio (Vi) ...................................................................................... 12
2.11 Application limits........................................................................................................... 12
2.12 MCC and LRA................................................................................................................ 14
3. Lubricants ................................................................................................................................. 16
3.1 Lubricants table ............................................................................................................... 17
3.2 Pre-cautions of changing oil .......................................................................................... 17
3.3 Oil change ........................................................................................................................ 17
4. Compressor handling and installation ................................................................................... 18
4.1 Compressor lifting........................................................................................................... 18
4.2 Mounting the compressor .............................................................................................. 19
4.3 RC2 compressor outline drawings .............................................................................. 20
4.4 Compressors accessories .............................................................................................. 43
4.5 Installation and connection of compressor .................................................................. 56
5. Electrical data and design ....................................................................................................... 59
5.1 Motor design .................................................................................................................... 59
5.2 Compressor protection devices ..................................................................................... 62
5.3 Power supply ................................................................................................................... 62
5.4 Grounding ........................................................................................................................ 63
6. Operation and maintenance .................................................................................................... 64
6.1 Compressor start-up ....................................................................................................... 64
6.2 Troubleshooting .............................................................................................................. 65
6.3 Compressor checking list ............................................................................................... 66
7. Applications .............................................................................................................................. 67
7.1 Additional cooling ........................................................................................................... 67
7.2 Economizer applications ................................................................................................ 70
7.3 Parallel system applications .......................................................................................... 71
7.4 Oil pump application ....................................................................................................... 72
7.5 Important note of applications of compressor ............................................................. 72
8 Selection software ..................................................................................................................... 73
9. Warranty .................................................................................................................................... 75
Appendix. RC2 Compressor noise level .................................................................................... 76
1. General
HANBELL RC2 series semi-hermetic screw compressor is developed especially for applications in air-conditioning and
refrigeration. With high operating load design, each HANBELL compressor is of high efficiency and reliability in all
operating conditions such as thermal storage, heat pump system & refrigeration. 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. Each HANBELL
compressor follows ISO 9001 quality system. This certification assures that its quality is controlled under severe quality
procedures and good service to all customers.
RC2 series compressor is equipped with separated radial and axial bearings, liquid injection and economizer connection,
PTC motor temperature thermistors and discharge temperature thermistors, a motor protector, and oil level switch and
oil pressure differential switch connector and other accessories. The complete accessories and their new designs
guarantee the compressor has the best reliability, longest bearing life during heavy duty running and strict operating
conditions.
This Technical Manual contains information about lifting, dimensions, installation, operation, applications and basic
trouble-shooting. 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.
RC 2 – x x x x x
1
2.2 Compressor specifications
a. RC2-A
COMPRESSOR MOTOR Lubricant Oil
Hydrostatic
Pressure WEIGHT
MODEL Displacement Rated Nominal
charge Heater
Test
Cap. Control (%) Voltage (V)
60 / 50Hz Speed VI Type Hp Starting Insulation Protection
m3/hr 60 / 50Hz STEP STEPLESS 60Hz 50Hz 60Hz 50Hz L W Kg/cm2G kg
DOL
RC2-340A 407/339 35, 50, 75, 100 35~100 77 64 16 600
3 Phase, 2 Pole, Squirrel Cage, Induction Motor
PTC Protection
2.2
RC2-430A 509/423 2.6 25, 50, 75, 100 25~100 93 78 16 735
Class F
380
3550/2950 3.0 150/300 42
400
3.5 25, 50, 75, 100
RC2-470A 567/471
4.8
25~100 108 90 415 18 800
RC2-550A 660/549 25, 50, 75, 100 25~100 126 105 23 820
RC2-580A 702/583 35, 50, 75, 100 35~100 131 109 20 805
RC2-620A 745/619 35, 50, 75, 100 35~100 137 114 380 23 850
440
460
RC2-710A 858/713 35, 50, 75, 100 35~100 158 131
480
28 1099
575
RC2-790A 952/791 30, 50, 75, 100 30~100 175 146 28 1140
RC2-830A 993/825 30, 50, 75, 100 30~100 183 152 28 1150
Y-△
RC2-930A 1117/929 35, 50, 75, 100 35~100 212 176 28 1180
DOL
RC2-1020A 1223/1017 25, 50, 75, 100 25~100 227 189 40 1500
RC2-1130A 1350/1122 25, 50, 75, 100 25~100 248 206 40 1520
RC2-1270A 1521/1268 25, 50, 75, 100 25~100 286 238 53 2100
RC2-1530A 1847/1539 25, 50, 75, 100 25~100 331 275 53 2200
2
b. RC2-B
COMPRESSOR MOTOR Oil Hydrostatic
Lubricant
Pressure WEIGHT
Displacement Rated charge
MODEL Cap. Control (%) Nominal Hp Voltage (V) Heater Test
60 / 50Hz Speed
VI Type Starting Insulation Protection
3
m /hr 60 / 50Hz STEP STEPLESS 60Hz 50Hz 60Hz 50Hz L W Kg/cm2G kg
RC2-320B 384/320 25, 50, 75, 100 25~100 114 94 DOL 16 600
3 Phase, 2 Pole, Squirrel Cage, Induction Motor
RC2-340B 407/339 35, 50, 75, 100 35~100 121 101 16 620
RC2-370B 440/366 35, 50, 75, 100 35~100 130 108 16 640
PTC Protection
RC2-410B 490/407 2.2 25, 50, 75, 100 25~100 146 121 16 740
2.6
Class F
380
3.0
RC2-470B 567/471 3550/2950
3.5
25, 50, 75, 100 25~100 170 141 400 18 150/300 42 810
415
4.8
RC2-510B 611/508 35, 50, 75, 100 35~100 183 152 20 780
RC2-550B 660/549 25, 50, 75, 100 25~100 195 162 23 850
RC2-580B 702/583 35, 50, 75, 100 35~100 210 175 20 840
RC2-620B 745/619 35, 50, 75, 100 35~100 220 183 23 880
380
RC2-710B 858/713 35, 50, 75, 100 35~100 250 208 440 28 1099
460
480
RC2-790B 952/791 30, 50, 75, 100 30~100 276 230 575 28 1180
RC2-830B 993/825 30, 50, 75, 100 30~100 290 234 Y-△ 28 1215
RC2-930B 1117/929 35, 50, 75, 100 35~100 334 278 DOL 28 1240
RC2-1020B 1223/1017 25, 50, 75, 100 25~100 357 297 40 1540
RC2-1130B 1350/1122 25, 50, 75, 100 25~100 393 327 40 1560
RC2-1270B 1521/1268 25, 50, 75, 100 25~100 471 392 53 2200
RC2-1530B 1847/1539 25, 50, 75, 100 25~100 534 443 53 2300
3
2.3 RC2 series compressor construction
Figure 1
Item Description Item Description Item Description Item Description
1 Compressor casing 9 Oil separator cartridge 17 Discharge fixed ring 25 Refrigeration Lubricant
2 Motor casing 10 Piston 18 Disc spring 26 Suction flange
3 Oil separator 11 Piston spring 19 Bearing lock nut 27 Discharge flange
4 Motor rotor assembly 12 Piston rod 20 Male rotor 28 Cable box
5 Motor stator assembly 13 Bearing seat’s cover plate 21 Suction bearings 29 Power bolt
6 Motor rotor washer 14 Modulation slide valve 22 Oil filler cartridge 30 Motor cable cover plate
7 Motor rotor spacer ring 15 Slide valve key 23 Suction filter 31 Discharge check valve
8 Oil separator baffle 16 Discharge bearings 24 Oil heater
RC2-200, RC2-230, RC2-260, RC2-300, RC2-310, RC2-320, RC2-340, RC2-370, RC2-410, RC2-430, RC2-470,
RC2-510, RC2-580 Construction
29 34 32 31 30 1 2
3 8 9 1110 12161514
13 33 45 6
20
1918 17 27 21 26 242223 7 25
Figure 2
Item Description Item Description Item Description Item Description
1 Compressor casing 10 Piston 19 Disc spring 28 Suction flange
2 Motor casing 11 Piston spring 20 Bearing lock nut 29 Discharge flange
3 Oil separator 12 Piston rod 21 Male rotor 30 Cable box
4 Motor rotor assembly 13 Bearing seat’s cover plate 22 Suction bearings 31 Power bolt
Suction bearings inner/outer spacer
5 Motor stator assembly 14 Modulation solenoid valve 23 32 Thermostat terminals
ring
6 Motor rotor washer 15 Modulation slide valve 24 Oil guiding ring 33 Motor cable cover plate
7 Motor rotor spacer ring 16 Slide valve key 25 Suction filter 34 Discharge check valve
8 Oil separator baffle 17 Discharge bearings 26 Oil heater
9 Oil separator cartridge 18 Discharge fixed ring 27 Refrigeration Lubricant
Figure 3
Item Description Item Description Item Description Item Description
1 Compressor casing 10 Piston 19 Disc spring 28 Suction flange
2 Motor casing 11 Piston spring 20 Bearing lock nut 29 Discharge flange
3 Oil separator 12 Piston rod 21 Male rotor 30 Cable box
4 Motor rotor assembly 13 Bearing seat’s cover plate 22 Suction bearings 31 Power bolt
5 Motor stator assembly 14 Modulation solenoid valve 23 Suction bearings inner/outer spacer ring 32 Thermostat terminals
6 Motor rotor washer 15 Modulation slide valve 24 Oil guiding ring 33 Motor cable cover plate
7 Motor rotor spacer ring 16 Slide valve key 25 Suction filter 34 Discharge check valve
8 Oil separator baffle 17 Discharge bearings 26 Oil heater
9 Oil separator cartridge 18 Discharge fixed ring 27 Refrigeration Lubricant
4
RC2-710, RC2-790, RC2-830, RC2-930 Construction
Figure 4
Item Description Item Description Item Description Item Description
1 Compressor casing 11 Piston spring 21 Bearing lock nut 31 Suction flange
2 Motor casing 12 Piston rod 22 Male rotor 32 Discharge flange
3 Oil separator 13 Bearing seat cover plate 23 Suction bearings 33 Cable box
4 Motor rotor assembly 14 Modulation solenoid valve 24 Suction bearings inner/outer spacer ring 34 Power bolt
5 Motor stator assembly 15 Modulation slide valve 25 Oil guiding ring 35 Thermostat terminals
6 Motor rotor washer 16 Slide valve key 26 Oil level sight glass 36 Motor cable cover plate
7 Motor rotor spacer ring 17 Discharge bearings 27 Oil filler cartridge 37 Discharge check valve
8 Oil separator baffle 18 Discharge fixed ring 28 Suction filter
9 Oil separator cartridge 19 Disc spring 29 Oil heater
10 Piston 20 α-Balance piston 30 Refrigeration Lubricant
Figure 5
5
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.
Screw rotors are precisely installed with roller bearings, i.e. radial bearings at both suction and discharge ends as well
as angular contact ball bearings i.e. axial bearings at discharge end. A three-phase, two-pole squirrel-cage induction
motor drives the compressor. The motor rotor is located on the shaft of the male screw rotor. Cooling of the motor is
achieved with suction refrigerant vapor.
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 high-efficiency screw rotors- The new 5:6 high efficiency screw rotor profile is patented in
Taiwan, UK, US, and China. This new large-volume, high-efficiency rotor profile is designed especially for modern
refrigerant characteristics. High-efficiency screw rotors are accomplished by using precision CNC machining centers,
rotor milling machines, rotor grinding machines. Strict ISO 9001 process controlling and the application of precise
inspection equipments, such as ZEISS 3D coordinate measuring machines, ensure high-efficiency, high-quality, low-
noise and low-vibration HANBELL RC2 series screw compressors.
High efficiency motor- Premium grade low-loss core steel with special motor cooling slot and refrigerant guide vane
which pilot the cold suction refrigerant gas through the motor provides the highest operating efficiency possible no
matter how strict operating conditions are.
Long life bearings and high reliability- The screw compressors utilize a combination of 10 axial and radial bearings
and α axial balance piston to ensure longer bearing life and higher compressor reliability.
Double-walled rotor housing- Double casing structure with high strength inner ribs has been designed to minimize
noise and ensure rigidity. The rotor housing is made of high-strength gray cast iron FC25 that is extremely stable,
therefore no expansion will occur even at high-pressure condition. These casings are machined by computer aided
machining centers and inspected by precision measuring machines to enhance reliability.
Direct flange-on oil separator- A vessel made of ductile material FC 500 specially designed to withstand high
pressure and provide the highest efficiency of oil separation. Simple oil management, three-staged oil
separator(models above RC2-1020), low-pressure-drop demister to ensure the minimum refrigerant dilution in the oil
and maintain high oil viscosity.
Precise capacity control- The slide valve for capacity control is located in the compressor chamber. The slide valve is
actuated by injection of pressurized oil into the cylinder from the oil sump as well as bypass of oil through solenoid
valves in each oil lines with pressure differential.
Perceptive protection modules- RC2 series screw compressors are equipped with PTC thermistors and motor
protection module which could monitor discharge and motor coil temperatures as well as phase sequence and phase
loss. Accessories also include oil level switch to monitor the level of oil, pressure differential switch, and pressure relief
valve for optional application.
Adaptable with additional cooling- Liquid injection connection port located at the motor casing and in the
compression chamber, oil cooler connection port, and middle pressure economizer connection port for customer’s
desired application.
RC2 series compressors not only continue RC series compressors’ characteristics of high efficiency & reliability design
mentioned above, but are also designed with the following newly added advantages to meet customers’ needs more
adequately:
1. Design the fittest high-efficiency motor for respective refrigerant, operation condition and electrical power.
2. Dual capacity control of steps or continuous create more accurate and reliable mechanism (Option)
3. Part load effective economizer application.
Detailed description of new design features are given in the following chapters.
6
2.5 Compression process
The RC2 series screw compressors are equipped with either 3-step/4-step 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. The slide valve and the piston are connected by a piston rod. The principle of
operation is using the oil pressure to drive the piston in the cylinder. See Figure 7, the lubrication oil flows from the oil
sump through the oil filter cartridge and capillary then fills into the cylinder due to the positive oil pressure bigger than
the right side of spring force plus the high pressure gas. The positive pressure differential causes the piston to move
toward the right side in the cylinder. When the slide valve moves toward the right side, the effective compression
volume in the compression chamber increases. This means the displacement of refrigerant gas also increases, as a
result the refrigeration capacity also increases. However, when any of the step solenoid valve (for 3-step/4-step
capacity control system) is opened, the high pressure oil in the cylinder bypasses to the suction side, which causes the
piston and the slide valve to move toward the left side, and then some of the refrigerant gas bypasses from the
compression chamber back to the suction end. As a result, the refrigeration capacity decreases because of the
reduction of displacement of refrigerant gas flowing in the system.
The piston spring is used to push the piston back to its original position, i.e. minimum load position in order to reduce
the starting current for the next starting. If the compressor started at full load capacity it may result in over current start.
The capillary is used to maintain and restrain a suitable amount of oil flow into the cylinder. The modulation (stepless)
solenoid valves (SV1 and SV2) are controlled by a micro controller or temperature switch to modulate the piston
position smoothly with stable output of capacity.
If the oil filter cartridge, capillary, or modulation solenoid valves are not working well in the capacity control system, this
may result in the abnormality and ineffectiveness of the capacity control system. Before stopping the compressor,
HANBELL strongly recommends that the unloading solenoid valve of stepless control system or minimum
load solenoid valve of 3/4-step control system should be kept opened for 60~90 seconds so that oil pressure
in the cylinder could be released. When starting the compressor again, it is in unloading position for light duty
start.
7
2.7 3 or 4-step capacity control system
There are two (For RC2-100, RC2-140, RC2-180) or three (for the rest 23 models) solenoid valves installed on the
compressor that control the compressor capacity from minimum capacity (please refer to chapter 2.2 for different
minimum capacity of each model) to full load (100%). There are two / three normally closed (NC) solenoid valves used
to control the various required capacity. For the compressor with 3-step / 4-step capacity control system, it is usual to
use the sequence of min.%-66%-100% / min.%-50%-75%-100% to load the capacity of compressor and to use the
sequence of 100%-66%-min.%/100%-75%-50%-min% to unload the capacity. If min% capacity is kept for a long time,
the problem of oil return, motor cooling, high discharge temperature need to be solved by adding accessories such as
oil level switch for monitoring the oil level, liquid injection devices for cooling motor coil and reducing discharge
temperature.(Figure 8). Min% is recommended for start and stop only, not for long-termed operation.
RC2-200~1530 capacity
RC2-100,140,180 capacity SV25%(NC) SV75%(NC) SV50%(NC)
SV33%(NC) SV66%(NC) control system
control system
100 of full load not energized not energized 100 full load not energized not energized not energized
66% of full load not energized energized 75 of full load not energized energized not energized
33%(for start) energized not energized 50 of full load not energized not energized energized
25(for start) Energized not energized not energized
Note: For 3-step or 4-step capacity control system, Hanbell equips normally-closed (NC) solenoid valves as standard
accessory. If normally-opened (NO) solenoid valves are preferred instead, please specify it to Hanbell when placing
order.
SV 50% OFF
a. min% capacity
When starting the compressor, SV25%/33% solenoid valve is SV75% OFF
energized and the piston is in min% capacity position, so even the oil
coming from the oil sump is continuously injecting into the cylinder
through the capillary, the high-pressured oil in the cylinder bypasses
directly into the suction port, so the piston is kept in its initial position.
SV25%/33% ON
SV25%/33% OFF
8
c. 75%/66% capacity SV50% OFF
When SV75%/66% solenoid valve is energized, SV50% solenoid valve (omitted for RC2-100, 140 & 180)
will be de-energized simultaneously, the high pressure oil will push the
piston toward the position where a hole at exactly 75%/66% position
drains the oil back to the suction side and the piston will be held on SV75%/66% ON
that position.
SV25%/33% OFF
SV 25%/33% OFF
Set point + 2T
Set point + T
In continuous (stepless) capacity control system, solenoid valve SV2 (for loading) and solenoid valve SV1 (for
unloading) are equipped to inlet and outlet of piston cylinder respectively. These two solenoid valves are controlled by
chiller temperature controller or micro controller so refrigeration capacity can be modulated anywhere within min% ~
100%. Min% is recommended for start and stop only, not for long-termed operation.
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.
9
No. Component No. Component No. Component
1 Suction filter 7 Discharge bearings 13 Capillary
Gas in(low
2 8 Oil separator baffle 14 Solenoid valve, SV2
pressure)
Gas out(high pressure
3 Motor 9 15 Solenoid valve, SV1
with oil)
4 Oil filter cartridge 10 Lubricant 16 Orifice
5 Suction bearings 11 Oil separator cartridge 17 Slide valve
Gas out (high pressure
6 Male rotor 12
without oil)
Option: When both NO SV2 and (N.C. / ON; Oil bypasses) (N.C. / ON; Oil bypasses)
10
c. Stable/Holding
Standard: When both NC SV2
and NC SV1 are not energized,
piston can be held in
stable/holding position.
SV1 SV1
Option: When NO SV2 is (N.C. / OFF;Oil bypasses) (N.C. / OFF;Oil bypasses)
energized but NC SV1 is not
SV2 SV2
energized, piston can be held in (N.C. / OFF; Oil injection stops) (N.O. / ON; Oil injection stops)
stable/holding position.
STABLE/HOLDING STABLE/HOLDING
Set point + T
Set point (target) Time
Set point - T’
U L S U S L S U S L S U
1~3min 60~90sec
Note: 1. Above T. & T' should be determined by system designer’s experience and end user’s application.
2. Capacity control must be kept at unloading for 1~3 min before start and for 60~90 sec before stop.
Loading/unloading functions
Loading (L)
SV2 Open t2
SV2 Close
t3
t1 Stable (S)
Unloading (U)
SV1 Close
SV1 Open t4
Time
6 Male rotor 12 Gas out (high pressure without oil) 18 Solenoid valve
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). Low Vi corresponds to low Pi and high Vi corresponds to high Pi. In
the equation below, in order to prevent over or under compression, the system compression ratio (CR) should be equal
to compressor’s internal compression ratio (Pi). Please refer to P-V (pressure – volume) diagram below to figure out
this relation.
2
1 2 1 Ps 1 2
Ps Ps
V V V
Under compression (CR > Pi) CR = Pi Over compression (CR < Pi)
Application limits of the compressor vary significantly with the type of refrigerant used. The operating limits shown
below are based on saturated suction and discharge operating 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, and operating at extra high
saturated condensing temperature will shorten the compressor life due to insufficient motor and compressor chamber
cooling.
12
b. Application limits of of RC2-1020~RC2-1530 are described on the respective refrigerant charts.
13
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 :
(1) Oil cooler or (2) Liquid injection to chamber or (3) Liquid injection to motor.
Please refer to Hanbell selection software for application of additional cooling system.
2
Hanbell recommends monitoring oil pressure differential and keep it 4 kg / cm G over the suction pressure for
adequate seal, lubrication and capacity control by pressure differential switch passively or by additional oil pump or
minimum pressure valve actively. Especially under operation conditions with low condensing temperature and high
evaporating temperature like application in flooder water-cooled chillers, high-low pressure difference tends to be
2
less than 4 kg / cm G , installation of oil pump is recommended to ensure regular oil pressure.
Contact with Hanbell to verify potential operating conditions outside the limits shown.
2. If compressors run continuously at partial load below 50%, failure of motor coils might happen due to insufficient
cooling. Therefore, Hanbell emphasizes installation of liquid injection system to motor to make sure adequate
cooling of motor coils for safe running of compressors. According to EN12900, suction superheat is 10°k and liquid
sub-cooling is 0°k.
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.
14
Refrigerant : R134a (PWS)
50Hz 60Hz Unit: Ampere
380V 400V 415V 208V 220V 230V 380V 440V 460V 480V 575V
Model
LRA LRA LRA LRA LRA LRA LRA LRA LRA LRA LRA
MCC MCC MCC MCC MCC MCC MCC MCC MCC MCC MCC
(△/△△) (△/△△) (△/△△) (△/△△) (△/△△) (△/△△) (△/△△) (△/△△) (△/△△) (△/△△) (△/△△)
RC2-100A 53 79/165 50 84/175 49 74/155 115 170/355 109 156/325 104 166/345 63 86/190 55 79//165 52 84/175 50 74/155 42 62/130
RC2-140A 73 108/225 70 113/235 67 101/210 160 238/495 151 211/440 145 221/460 88 125/160 76 108/225 72 110/230 69 101/210 58 79/165
RC2-180A 97 155/310 92 163/325 89 145/290 213 338/675 202 305/610 193 320/640 117 185/370 101 155/310 96 163/325 92 145/290 77 118/235
RC2-200A 103 155/310 98 163/325 94 145/290 226 338/675 214 305/610 204 320/640 124 185/370 107 155/310 102 163/325 98 148/295 82 118/235
RC2-230A 124 303/505 117 285/475 113 267/445 270 645/1075 256 618/1030 244 573/955 148 360/600 128 303/505 122 285/475 117 267/445 98 237/395
RC2-260A 138 303/505 131 285/475 126 267/445 302 645/1075 286 618/1030 273 573/955 165 360/600 143 303/505 137 285/475 131 267/445 109 237/395
RC2-300A 155 350/565 147 329/530 142 322/520 340 822/1325 322 763/1230 308 704/1135 186 428/690 161 350/565 154 329/530 147 322/520 123 273/440
RC2-310A 163 350/565 155 329/530 149 322/520 360 822/1325 341 763/1230 326 704/1135 197 428/690 170 350/565 163 329/530 156 322/520 130 276/445
RC2-320A 167 350/565 158 329/530 153 322/520 366 822/1325 346 763/1230 331 704/1135 200 428/690 173 350/565 165 329/530 158 322/520 132 276/445
RC2-340A 178 462/710 169 423/650 163 410/630 388 943/1450 367 868/1335 351 920/1415 213 546/840 184 462/710 176 423/650 168 410/630 140 358/550
RC2-370A 194 462/710 185 423/650 178 410/630 426 943/1450 403 868/1335 386 920/1415 233 546/840 202 462/710 193 423/650 185 410/630 154 358/550
RC2-410A 216 475/730 205 497/765 198 429/660 - - - - - - 260 553/850 224 475/730 215 497/765 206 429/660 172 374/575
RC2-430A 230 475/730 218 497/765 211 429/660 - - - - - - 277 553/850 239 475/730 229 497/765 219 429/660 183 374/575
RC2-470A 248 571/840 236 598/880 227 513/755 - - - - - - 300 677/995 259 571/840 248 598/880 238 513/755 198 439/645
RC2-510A 271 571/840 258 598/880 248 513/755 - - - - - - 327 677/995 282 571/840 270 598/880 259 513/755 216 439/645
RC2-550A 292 615/905 277 646/950 267 596/875 - - - - - - 350 779/1145 302 615/905 289 646/950 277 595/875 231 476/700
RC2-580A 304 615/905 288 646/950 278 595/875 - - - - - - 365 779/1145 316 615/905 302 646/950 289 595/875 242 476/700
RC2-100B 69 77/230 65 80/240 63 73/220 151 175/525 142 153/460 136 160/480 82 97/290 71 77/230 68 80/240 65 73/220 54 63/190
RC2-140B 91 103/310 87 108/325 84 98/295 199 230/690 188 198/595 180 207/620 109 125/375 94 103/310 90 108/325 86 98/295 72 85/255
RC2-180B 121 155/465 115 162/485 110 148/445 263 362/1085 249 310/930 238 323/970 144 192/575 124 155/465 119 162/485 114 148/445 95 127/380
RC2-200B 128 155/465 122 162/485 117 148/445 282 362/1085 266 310/930 255 323/970 154 192/575 133 155/465 127 162/485 122 148/445 102 127/380
RC2-230B 153 230/690 146 240/720 140 218/655 336 503/1510 318 460/1380 304 480/1440 184 270/810 159 230/690 152 240/720 146 218/655 122 182/545
RC2-260B 171 230/690 163 240/720 157 218/655 376 503/1510 355 460/1380 340 480/1440 206 270/810 178 230/690 170 240/720 163 218/655 136 182/545
RC2-300B 193 260/780 183 272/815 177 263/790 424 653/1960 401 520/1560 384 543/1630 232 343/1030 200 260/780 192 272/815 184 263/790 153 223/670
RC2-310B 203 260/780 193 272/815 186 263/790 446 653/1960 421 520/1560 403 543/1630 244 343/1030 211 260/780 201 272/815 193 263/790 161 223/670
RC2-320B 207 260/780 196 272/815 189 263/790 456 653/1960 431 520/1560 413 543/1630 250 343/1030 216 260/780 206 272/815 198 263/790 165 223/670
RC2-340B 220 345/1035 209 360/1080 201 313/940 483 720/2160 457 662/1985 437 692/2075 264 407/1220 228 345/1035 218 360/1080 209 313/940 175 272/815
RC2-370B 241 345/1035 229 360/1080 221 313/940 529 720/2160 500 662/1985 478 692/2075 289 407/1220 250 345/1035 239 360/1080 229 313/940 191 272/815
RC2-410B 268 292/875 254 305/915 245 283/850 - - - - - - 323 372/1115 279 292/875 267 305/915 256 283/850 214 250/750
RC2-470B 310 407/1220 294 428/1285 284 387/1160 - - - - - - 372 482/1445 321 407/1220 307 428/1285 294 387/1160 246 323/970
RC2-510B 336 443/1330 319 463/1390 308 417/1250 - - - - - - 406 535/1605 350 443/1330 335 463/1390 321 417/1250 268 382/1145
RC2-550B 336 443/1330 319 463/1390 308 417/1250 - - - - - - 406 535/1605 350 443/1330 335 463/1390 321 417/1250 268 382/1145
RC2-580B 377 443/1330 358 463/1390 345 417/1250 - - - - - - 454 535/1605 392 443/1330 375 463/1390 359 417/1250 300 382/1145
RC2-620B 393 503/1510 374 527/1580 360 468/1405 - - - - - - 473 627/1880 409 503/1510 391 527/1580 375 468/1405 313 422/1265
RC2-710B 453 663/1990 430 693/2080 415 617/1850 - - - - - - 545 823/2470 471 663/1990 450 693/2080 432 617/1850 360 555/1665
RC2-790B 498 743/2230 473 777/2330 456 682/2045 - - - - - - 598 958/2875 516 743/2230 494 777/2330 473 682/2045 395 600/800
RC2-830B 534 785/2355 508 827/2480 489 863/2590 - - - - - - 643 1067/3200 555 785/2355 531 827/2480 509 863/2590 425 658/1975
RC2-930B 620 875/2625 589 915/2745 567 955/2865 - - - - - - 746 1247/3740 644 875/2625 616 915/2745 591 955/2865 493 765/2295
RC2-1020B(B1) 611 888/2665 580 935/2805 559 782/2345 735 1168/3505 635 888/2665 607 935/2805 582 782/2345 486 717/2150
RC2-1020B(B2) 684 1085/3255 650 1142/3425 626 920/2760 823 1290/3870 710 1085/3255 680 1142/3425 651 920/2760 544 868/2605
RC2-1130B(B1) 671 888/2665 637 935/2805 614 782/2345 806 1168/3505 697 888/2665 666 935/2805 638 782/2345 533 717/2150
RC2-1130B(B2) 766 1085/3255 728 1142/3425 702 920/2760 922 1290/3870 796 1085/3255 762 1142/3425 730 920/2760 609 868/2605
RC2-1270B(B1) 777 1085/3255 738 1142/3425 711 920/2760 934 1290/3870 807 1085/3255 772 1142/3425 740 920/2760 617 868/2605
RC2-1270B(B2) 864 1338/4015 820 1160/3480 791 1213/3640 1038 1573/4720 896 1338/4015 857 1160/3480 821 1213/3640 686 1292/3875
RC2-1530B(B1) 878 1085/3255 834 1142/3425 804 920/2760 1056 1290/3870 912 1085/3255 873 1142/3425 836 920/2760 698 868/2605
RC2-1530B(B2) 996 1393/4180 946 1195/3585 912 1263/3790 1199 1633/4900 1035 1393/4180 990 1195/3585 949 1263/3790 792 957/2870
15
Refrigerant : R22, R407C, R404A, R507, R134a (PWS)
50Hz 60Hz Unit: Ampere
380V 400V 415V 208V 220V 230V 380V 440V 460V 480V 575V
Model
LRA LRA LRA LRA LRA LRA LRA LRA LRA LRA LRA
MCC MCC MCC MCC MCC MCC MCC MCC MCC MCC MCC
(△/△△) (△/△△) (△/△△) (△/△△) (△/△△) (△/△△) (△/△△) (△/△△) (△/△△) (△/△△) (△/△△)
RC2-100B 69 108/225 65 113/235 63 101/210 151 238/495 142 211/440 136 221/460 82 125/260 71 108/225 68 113/235 65 101/210 54 82/170
RC2-140B 91 155/310 87 163/325 84 145/290 199 338/675 188 305/610 180 320/640 109 185/370 94 155/310 90 163/325 86 145/290 72 118/235
RC2-180B 121 225/425 115 239/450 110 207/390 263 480/905 249 444/840 238 466/880 144 254/480 124 225/425 119 239/450 114 207/390 95 172/325
RC2-200B 128 225/425 122 239/450 117 207/390 282 480/905 266 445/840 255 466/880 154 254/480 133 225/425 127 239/450 122 207/390 102 172/325
RC2-230B 153 350/565 146 329/530 140 322/520 336 822/1325 318 763/1230 304 704/1135 184 428/690 159 350/565 152 329/530 146 322/520 122 273/440
RC2-260B 171 462/710 163 423/650 157 410/630 376 943/1450 355 868/1335 340 920/1415 206 546/840 178 462/710 170 423/650 163 410/630 136 358/550
RC2-300B 193 507/780 183 497/765 177 481/740 424 1260/1940 401 1121/1725 384 1004/1545 232 614/945 200 507/780 192 497/765 184 481/740 153 403/620
RC2-310B 203 507/780 193 497/765 186 481/740 446 1261/1940 421 1121/1725 403 1004/1545 244 614/945 211 507/780 201 497/765 193 481/740 161 403/620
RC2-320B 207 507/780 196 497/765 189 481/740 456 1261/1940 431 1121/1725 413 1004/1545 250 614/945 216 507/780 206 497/765 198 481/740 165 403/620
RC2-340B 220 663/1020 209 640/985 201 608/935 483 1628/2505 457 1342/2065 437 1495/2300 264 777/1195 228 663/1020 218 640/985 209 608/935 175 527/810
RC2-370B 241 663/1020 229 640/985 221 608/935 529 1628/2505 500 1342/2065 478 1495/2300 289 777/1195 250 663/1020 239 640/985 229 608/935 191 527/810
RC2-410B 268 615/905 254 646/950 245 595/875 - - - - - - 323 779/1145 279 615/905 267 646/950 256 595/875 214 476/700
RC2-470B 310 870/1280 294 915/1345 284 826/1215 - - - - - - 372 1030/1515 321 870/1280 307 915/1345 294 826/1215 246 690/1015
RC2-510B 336 952/1400 319 996/1465 308 891/1310 - - - - - - 406 1142/1680 350 952/1400 335 996/1465 321 891/1310 268 816/1200
RC2-550B 336 952/1400 319 996/1465 308 891/1310 - - - - - - 406 1142/1680 350 952/1400 335 996/1465 321 891/1310 268 816/1200
RC2-580B 377 952/1400 358 996/1465 345 891/1310 - - - - - - 454 1142/1680 392 952/1400 375 996/1465 359 891/1310 300 816/1200
3. Lubricants
The main functions of lubrication oil in screw compressors are lubrication, internal sealing, cooling and capacity control.
Positive oil pressure in the cylinder pushes the piston together with the slide valve that is connected by a piston rod to
move forward and backward in the compression chamber. The design of positive pressure differential lubrication
system makes RC2 series normally omit an extra oil pump which is necessary for reciprocating compressors. However,
in some special applications, it is still necessary to install an extra oil pump to screw compressors for safety.
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. In order to separate oil from refrigerant gas, an external oil separator is required to
ensure the least amount of oil carried into the system.
Please pay more attention to the oil temperature, which is crucial to compressor bearings’ life. Oil is with much lower
viscosity at high temperatures. Too low viscosity of oil will result in poor lubrication and heat dissipation in the
compressor. Viscosity is recommended to keep over 10mm2/s at any temperatures for oil. Oil temperature in the oil
sump should be kept above the saturated condensing temperature to prevent refrigerant migration into lubrication
system. Oil has a higher viscosity in low ambient temperature circumstances. When viscosity is too high, slow flow
speed of oil into the cylinder may result in too slow loading of the compressor. To solve this problem, use of oil heaters
can warm up oil before starting.
If the compressor operates under critical operating conditions, an extra oil cooler is required – please refer to Hanbell
selection software for the required capacity and oil flow of the extra oil cooler. High-viscosity oil is recommended to
apply in high operating conditions because high discharge temperature will make viscosity of oil lower. Oil return from
the evaporator may be insufficient in refrigeration systems, flooded chillers…etc., in which it’s difficult for oil to be
carried back and it may cause oil loss in the compressor. If the system encounters the oil return problem then an extra
2nd oil separator is recommended to be installed between the compressor discharge tube and condenser.
Each of HANBELL RC2-230 ~ RC2-930 compressors is equipped with two oil sight glasses as a standard (the second
sight glass is optional for the models RC2-100 ~ RC2-200), one is the high-level sight glass, and the other is the low-
level sight glass (RC2-230~RC2-510, RC2-580 and RC2-1020~RC2-1530) or internal oil line sight glass (RC2-550 &
RC2-620~RC2-930). The function of internal oil line sight glass is to monitor lubricant flow to capacity control system
and 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. It is strongly recommended to install the oil level switch (optional
accessory) to prevent the failure results from lose of oil.
16
3.1 Lubricants table
Applicable oil types (R22)
SPECIFICATION UNITS HBR -B10 HBR -A02 HBR -A04 HBR -B09 HBR -B02 HBR -B01
SPECIFICATION UNITS HBR -B05 HBR -B08 HBR -B09 HBR -B04
COLOR, ASTM
SPECIFIC GRAVITY 0.945 0.94 0.95 0.95
40℃ 64 131 175 215.9
VISCOSITY 2
100℃ mm /s (cSt) 8.9 14.53 16.5 20.8
FLASH POINT ℃ 266 254 265 271
POUR POINT ℃ -43 -36.5 -30 -25
T.A.N mg KOH/g
COPPER STRIP
100℃/3hr
MOISTURE ppm
FLOC POINT ℃
DIELETRIC STRENGTH
KV 46.6
2.5mm
Note: For other applicable oil types, please consult HANBELL firstly for approval.
2. When using polyester oil for chiller systems, please make sure not to expose oil to the atmosphere for prevention
of change in its property. Therefore, it is necessary to vacuum the system completely when installing the compressor.
3. In order to ensure no moisture inside the system, it is suggested to clean the system by charging it with dry Nitrogen
and then vacuum it repeatedly as long as possible.
4. It is a must to change the oil in motor burned out case, because acid debris may still remain inside the system.
Please follow the procedures mentioned above to change oil in the system. Check acidity of oil after 72 hours of
operation and then change it again until acidity of oil becomes normal.
5. Please contact Hanbell local distributors/agents for selection of oil.
2. Avoid clogging in oil filter with debris or swarf which may cause failure in bearings. An optional oil pressure
differential switch is recommended to be installed. The switch will trip when the oil pressure differential between the
primary and secondary sides reaches the critical point and then the compressor will automatically shut down to prevent
the bearings from damage due to oil loss.
17
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.
When lifting the compressor, it is recommended to use a steel chain or steel cable which can be used for loading
capacity of 3000kgf as shown in the figure below. Make sure that chains, cables or other lifting equipments are properly
positioned to protect the compressor and its accessories from damaging. Keep the compressor in horizontal position
when lifting, and prevent it from crashing or falling on the ground, hitting the wall or any other accident that may
damage it or its accessories.
Figure 18 Lift the compressor with steel Figure 19 Lift the compressor with safety ropes
chain or steel cable
The installation of the compressor in the refrigeration system should be accessible and make sure that the chiller base
or site is far enough from the heat source to prevent heat radiation. The compressor should also be installed as close
as possible to the electrical power supply for easier connection and must keep good ventilation and low humidity
condition in the site. Make sure that the frame or supporter is strong enough to prevent excessive vibration and noise
while the compressor is running and must reserve enough space for compressors’ future overhauling work.
The compressor must be installed horizontally and in order to prevent excessive vibration transferred by the structure
and piping of the chiller while in operation, the cushion or anti-vibration pad should be installed. The installation of the
anti-vibration pad is shown in Figure 22. The screws should only be tightened until slight deformation of the rubber pad
is visible.
※It is strongly recommended to position the compressor higher than the evaporator
The unsuitable piping works done to the compressor could cause abnormal vibration and noise that might damage the
compressor. Take notice of the following pointers to prevent this situation from happening:
1. Cleanliness of the system should be kept after welding the piping to avoid any swarf or debris contained inside the
system as it may cause serious damage to the compressor during operation.
2. In order to reduce the vibration on the piping tubes, it is recommended to use copper tube to be the suction and
discharge piping tubes. Copper tubes are better to minimize the vibration in the piping while the compressor is in
operation. In case steel tubes are used in piping system, the suitable welding works are very important to avoid any
stress in the piping. This inner stress can cause harmonic vibration and noise that can reduce the life of the
compressor. If a large-caliber 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.
4. The material of suction and discharge flange bushing is forged steel and it can be welded directly with piping
connectors. After welding the flange bushing and pipes, it must be cooled down by ambient air. Do not use water to
cool it down because water quenching is prohibited.
Figure 23 shows a 15° limit of oblique angle for installation of compressor. In case the oblique angle is higher than the
limit, compressor will be shut down easily. For special applications like the installation in ships, fishing boats, etc…,
where the oblique angle might exceed the limit, external oil separators, oil tanks and related accessories are
recommended to be installed. Please contact HANBELL or local distributors for further layout recommendation.
19
Figure 23 Limits of oblique angle for the installation of the compressor
UNIT
SI: mm Imperial: (in)
20
UNIT
SI: mm Imperial: (in)
UNIT
SI: mm Imperial: (in)
21
UNIT
SI: mm Imperial: (in)
UNIT
SI: mm Imperial: (in)
22
UNIT
SI: mm Imperial: (in)
UNIT
SI: mm Imperial: (in)
23
UNIT
SI: mm Imperial: (in)
24
25
UNIT
SI: mm Imperial: (in)
26
27
28
29
30
UNIT:
SI: mm Imperial: (in)
31
2. RC2-B outline drawings
32
33
34
35
36
37
38
39
40
UNIT:
SI: mm Imperial: (in)
41
Note: For RC2-1020B, RC2-1130B, RC2-1270B and RC2-1530B outline drawing, please refer to those of RC2-1020A,
RC2-1130A, RC2-1270A, and RC2-1530A
42
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
● :Standard, △ :Optional
Model
RC2 -
&
Accessory 100 140 180 200 230 260 300 310 320 340 370 410 430 470 510 550 580 620 710 790 830 930 1020 1130 1270 1530
INT69HBY controller ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ●
Economizer △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △
Oil cooler △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △
Oil pump △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △
Safety valve △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △
Mounting pad △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △
Lubricant oil △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △
Micro controller △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △
Sound jacket △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △
Temperature sensors
△ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △ △
Pt100 or Pt1000 – for motor coil temp. monitoring
Note: The accessory table is just for reference only. Actual specification and accessories enclosed might vary with
different quotation and agreement respectively. If any optional accessory is required and out of above mentioned
standard accessory, please contact Hanbell for detailed specification and price.
43
2. Description of accessories
Dimension unit: mm
Dia.
A B C D E F G H I
2” 102 6 53 69 91 65 90 85 5
No. 1 2 3 4 5 6 7 8
2 1/2 122 6 69 89 111 85 110 97 5
Dimension unit: mm
Dia.
A B C D E F G H I J K L M N P
44
Figure 26 Discharge check valve outline drawing (Horizontal type)
Dimension unit: mm
Dia.
A B C D E F G H I J
1 1/2 86 4 55 59 76 42 60 75 80.5 6
2” 102 4 65 69 91 53 70 90 85 6
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. If non-standard bushing is needed, please double-check with Hanbell sales
representatives when placing order for compressors.
45
Specification and dimension of optional flange bushing
Dimension of flanges bushing
Model Discharge / Suction port Materials and Sizes of pipes A B C D E
1 5/8" 41.6 52
Copper
Discharge 2 1/8" 52 75 35 54.3 65
RC2-100 Steel 1 1/2"
1 5/8"
49.3
41.6
64
55
RC2-140 Suction
Copper 2 1/8"
50 90 30
54.3 65
2 5/8" 67 74
Steel 2" 61.3 74
15/8” 41.6 52
Copper
Discharge 2 1/8" 52 75 35 54.3 65
RC2-180 Steel 1 1/2"
2 1/8"
49.3
54.3
64
65
RC2-200 Suction
Copper 2 5/8"
60 110 35
67 77
3 1/8" 79.8 90
Steel 2 1/2" 77.2 90
1 5/8" 41.6 55
RC2-230 Discharge
Copper 2 1/8"
50 90 30
54.3 65
RC2-260 Steel
2 5/8"
2"
67
61.3
74
74
RC2-300 2 1/8"
2 5/8"
54.3
67
65
77
Copper
RC2-310 Suction 3 1/8" 66 120 45 79.8 90
2 1/2" 77.2 92
RC2-320 Steel
3 90.2 103
2 1/8" 54.3 65
RC2-340 Discharge
Copper 2 5/8"
3 1/8"
60 110 35
67
79.8
77
90
RC2-370 Steel 2 1/2" 77.2 90
3 1/8" 79.8 90
RC2-410 Copper 3 5/8" 92.4 103
RC2-430 Suction
4 1/8"
3"
76 145 50
105.1
90.2
116
105
RC2-470 Steel 3 1/2" 102.8 117
4" 115.6 128
2 1/8" 54.3 65
Copper 2 5/8" 67 77
Discharge 3 1/8" 66 120 45 79.8 90
RC2-510 Steel
2 1/2"
3"
77.2
90.2
92
103
RC2-550 Copper
3 1/8"
3 5/8"
79.8
92.4
90
103
RC2-580 Suction
4 1/8"
76 145 50
105.1 116
3" 90.2 105
Steel 3 1/2" 102.8 117
4" 115.6 128
2 1/8" 54.3 65
Copper 2 5/8" 67 77
Discharge 3 1/8" 66 120 45 79.8 90
2 1/2" 77.2 92
RC2-620 Steel
3" 90.2 103
4 1/8" 80 105.1 121.2
Suction Copper
5 1/8" 75 174 35 130.5 146.5
Steel 5" 75 141.3 154
3 1/8" 79.8 90
Copper 3 5/8" 92.4 103
RC2-710 4 1/8" 105.1 116
Discharge 76 145 50
RC2-790 Steel
3"
3 1/2"
90.2
102.8
105
117
RC2-830 4" 115.6 128
4 1/8" 80 105.1 121.2
RC2-930 Suction
Copper
5 1/8" 75 174 35 130.5 146.5
Steel 5" 75 141.3 154
3 1/8” 79.8 90
Copper 3 5/8” 92.4 103
RC2-1020 Discharge
4 1/8”
3”
76 145 50
105.1
90.2
116
105
RC2-1130 Steel 3 1/2" 102.8 117
4" 115.6 128
Suction Steel 6" 75 215 40 166.7 196
46
e. Suction and discharge stop valves
For maintenance and service of compressor, it is recommended to install the suction and discharge stop valves.
Please refer to following detail of Hanbell stop valves.
Stop Valve Size Model Stop Valve Size
Model
Discharge Suction Discharge Suction
RC2-100 1 1/2 2 RC2-470 2 1/2 4
RC2-140 1 1/2 2 RC2-510 3 4
RC2-180 1 1/2 2 1/2 RC2-550 3 4
RC2-200 1 1/2 2 1/2 RC2-580 3 4
RC2-230 2 3 RC2-620 3 5
RC2-260 2 3 RC2-710 4 5
RC2-300 2 3 RC2-790 4 5
RC2-310 2 3 RC2-830 4 5
RC2-320 2 3 RC2-930 4 5
RC2-340 2 1/2 4 RC2-1020 4 6
RC2-370 2 1/2 4 RC2-1130 4 6
RC2-410 2 1/2 4 RC2-1270 5 8
RC2-430 2 1/2 4 RC2-1530 5 8
Dimensions unit: mm
Dia.
A B C D E F G H I J K L
5 30 30 126 194 194 248 230 230 214 338 474 161
A B
U/1 Z/7
V/2 X/8
W/3 Y/9
A Set:PTC
B Set:Pt100Ω/Pt1000Ω(Optional)
47
Other major functional descriptions are as follow:
1. After the supply voltage has been connected, a three second initialization period follows. Provide the PTC chain
resistance is below the reset threshold (2.75kΩ), the relay trips after these 3 seconds have expired.
2. 1 to 9 PTC thermistors with different nominal response temperature may be connected serially to the PTC input.
3. If any thermistor resistance increases above trip level the relay drops out. This failure results in a lockout. (5 minutes
delay for 1st PTC failure, 60 minutes delay for 2nd failure, lockout for 3rd failure.)
4. If a rapid temperature increase is detected (locked rotor condition), the output relay drops out. This failure results in
a lockout.
5. The phase monitoring of the three phase motor voltage becomes active 1 second after motor has started, for
duration of 10 seconds. In case of a wrong phase sequence or a phase failure, the relay switches of and locks.
6. The Lock-out and delay time may be lifted by cycling the power off for approx. 5 seconds.
7. To avoid nuisance tripping due to reverse running after shutdown (pressure equalization), the phase monitoring
function is only re-enabled approx. 20 seconds after motor stop.
8. A dual LED (red / green) provides additional information about the motor protector and compressor status.
9. The relay is fed out as a N/O dry contact, which is closed under good conditions.
10. Sensor and supply circuits are galvanic isolated.
11. The motor protector is not suitable for application of frequency converters.
Technical data:
●Supply voltage ●Relay output
AC 50/60 Hz 115/120V-15 …+10% 3VA max. AC 240V, max. 2.5A, C300
AC 50/60 Hz 230/240V-15…+10% 3VA min. > 24V AC/DC, >20 mA
●Ambient temperature ●Phase monitor
-30 … +70 ℃ 3 AC, 50/60Hz, 200 ~ 575 V ± 10%
Blink code display& diagram:
Phase failure
Motor
Power Internal error
Short Long
A Set: Motor PTC Terminal interruption interruption
48
h. Oil level switch
There are 2 wires for the interlock to main control circuit or any micro controller’s independent circuit. To prevent from
oil level switch trip caused by oil foaming or surging in the sump, a time delay around 10 ~ 15 seconds is
recommended before shut down the compressor.
Figure 33 Oil level switch on a compressor Figure 34 Oil level switch on an external oil separator
Hanbell designs and makes the cable box which meets IP54 protection degree.
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
RC2-100, RC2-140, RC2-180 cable box (Figure 36) RC2-200, RC2-230, RC2-260, RC2-300, RC2-310, RC2-
320, RC2-340, RC2-370, RC2-410, RC2-430, RC2-470, RC2-
510, RC2-550, RC2-580, RC2-620 cable box (Figure 37)
49
RC2-710, RC2-790, RC2-830, RC2-930 cable box RC2-1020, RC1130, RC1270, RC2-1530 cable box
(Figure 38) ( Figure 39)
Stop valve
Gasket
Check valve
Gasket
Length
Figure 41 Dimensions and installation of horizontal check valve
50
(Ⅰ) Technical data:
Oil Volume (Liter) Range of application based on
3
Model Type Displacement (m /hr) Shell Diameter
High level Low level
(Recommended)
OS40 Vertical 17 9 205 14”
OS50 Vertical 22 12 206~270 16”
OS65 Vertical 31 18 271~440 18”
OS80 Horizontal 33 20 441~705 20”
OS100 Horizontal 40 27 706~1120 20”
OS125 Horizontal 50 30 1121~1310 24”
OS150 Horizontal 60 36 1311~1835 24”
(Ⅱ) Accessories:
No. Description OS40 OS50 OS65 OS80 OS100 OS125 OS150
1 Refrigerant inlet 1 1/2” 2” 2 1/2” 3” 4” 5” 6”
2 Refrigerant outlet 1 1/2” 2” 2 1/2” 3” 4” 5” 6”
3 Oil outlet 5/8” Flare 5/8” Flare 5/8” Flare 1” PF 1” PF 1 1/4” PF 1 1/4” PF
4 Oil charge valve 1/4” Flare
5 High oil S.G. 1 PCS
6 Low oil S.G. 1 PCS
7 Oil level switch 1 PCS
8 Oil heater 150W 150W 150W 150W 150W 300W 300W
9 Oil drain valve 1/4” Flare
10 Oil temp. protection (option) 1/8” NPTF
11 Safety valve (option) 1/2” 1/2” 1/2” 1” 1” 1 1/2” 1 1/2”
(Ⅲ) Dimensions:
No. OS40 OS50 OS65 OS80 OS100 OS125 OS150
A 930 1050 1110 1297 1637 1829 2229
B 505 585 595 650 1000 1080 1480
C 240 275 300 359 354 409 409
D 300 350 350 300 300 400 400
E 18 22 22 23 23 23 23
F 320 360 360 688 698 830 830
(Ⅳ) Drawing:
51
Horizontal OS80, OS100, OS125, OS150 (Figure 43)
52
(1)Tolerance: ±0.3l/min
(2)Media temperature: max 110 ℃
(3)Average pressure loss: 0.4 bar at Qmax
(4)Hysteresis:depending on switch value minimum 0.4 l/min
Note: Switch value is indicated for horizontally decreasing flow
From compressor
Figure 45 Outline of oil flow switch discharge port
B
D
E
A
Figure 48 Compressor mounting pad (optional)
Model Part No. A B C D E Thickness Req. Q’ty
RC2-100, RC2-140, RC2-180, RC2-200, RC2-230, RC2-260, RC2-300, RC2-310, RC2-320 3131-9815B 20 55 50 20 22 20 mm 4
RC2-340, RC2-370, RC2-410, RC2-430, RC2-470, RC2-510, RC2-550, RC2-580 3136-9815B 26 100 70 25 22 20 mm 4
RC2-620, RC2-710, RC2-790, RC2-830, RC2-930 3139-9815B 25 100 80 25 22 20 mm 4
RC2-1020, RC2-1130, RC2-1270, RC2-1530 3142-9815B 40 100 80 40 22 20 mm 4
53
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.
Electric Plate
Controller
A B
Earth Bolt
U Z A: PTC
V X
W Y
A:PTC
B:Pt100 / Pt1000Ω(Optional)
s
Dryer Evaporator
B: Pt1000 or Pt100
Chiller Chiller
in out
1. Note: Hanbell suggests to control temperature of motor coil at 60℃ (not higher than 60℃)
2. On the terminal cover plates, “A” is PTC sensor, and “B” is Pt1000 or Pt100 temperature sensor.
3. The terminal cover plates for models RC2-710B, RC2-790B, RC2-830B, RC2-930A, RC2-930B are
shown above. The PTC sensor is on the top right side and Pt1000 or Pt100 is on the left bottom side of
terminal cover plate.
A B
connect to temperature controller for
U/1 Z/7
1.controlling the liquid injection solenoid valve
V/2 X/8 2. real motor coil temperature display
W/3 Y/9
3.Another motor coil protection
(for high temperature warming or tirp)
A Set:PTC
B Set:Pt100Ω/Pt1000Ω(Optional)
Note: Please specify Pt100 or Pt1000 sensor when placing orders to Hanbell.
54
t. Minimum pressure valve(MPV)
Minimum pressure valve is useful in cold start condition. During the cold start period, because the system’s condensing
temperature is still low, the discharge pressure will stay at a quite low level which means the pressure differential
between discharge and suction side will not be enough for compressor to act normally. Under such working condition,
compressor might have difficulties to load itself. Oil supply to bearings and internal cooling might be not enough which
will cause severe damage to those moving parts in the end. With minimum pressure valve, the pressure differential can
be built shortly after the start up, so the capacity control and oil supply to those moving parts won’t be a problem.
Therefore, the compressor protection can be achieved. In addition to protection function, it can also act as check valve
to reduce the reverse running time after compressor’s stopping.
Flange on minimum pressure valves are provided for the ease of installation. It can be installed on either compressor’s
discharge port or external oil separator’s discharge port (F type compressor only). The installation and specification are
shown as below:
55
4.5 Installation and connection of compressor
The diagrams below show the installation and connection of compressors
a. RC2-100 , RC2-140 , RC2-180
b. RC2-200, RC2-230, RC2-260, RC2-300, RC2-310, RC2-320, RC2-340, RC2-370, RC2-410, RC2-430, RC2-470,
RC2-510, RC2-550, RC2-580, RC2-620
56
c. RC2-710, RC2-790, RC2-830, RC2-930
Stop valve
Gasket
Bolt
Bushing
Gasket
◆ Soleniod valve description :
1. Solenoid valve ( only step-less )
Suction Filter ( motor)
2. Solenoid valve ( 25% ,30% ,35% ) Gasket
3. Solenoid valve ( 50% ) Check valve Liquid injection expansion valve
4. Solenoid valve ( 75% ) Liquid injection solenoid valve
Gasket
◆ Capacity control system module :
A. Step-less capacity control: 3 4 12
Gasket Oil cooler in Suction filter Flange
1 ( step-less ) + 2 ( 25% ,30% ,35%)
B. 4 step capacity control:
2 ( 25% ,30% ,35% ) + 3 ( 50% ) + 4 ( 75% )
C. Step-less+step capacity control: Bolt
1+2+3+4
Gasket
Stop pin
O-ring ( Only for application of oil cooler )
Plug
Discharge port
Suction port
Cable box
Power bolt
PTC terminal
PTC controller
connector
ECO stop valve
Refrigerant
service valve Oil heater
Angle valve
57
d. RC2-1020, RC2-1130, RC2-1270, RC2-1530
( Motor)
Bolt
Liquid injection expansion valve
Discharge Bolt Liquid injection solenoid valve
flange Stop valve
Bushing
◆ Soleniod valve description : Gasket In system
1. Solenoid valve ( only step-less )
2. Solenoid valve ( 25% ) Gasket
3. Solenoid valve ( 50% )
4. Solenoid valve ( 75% )
Check valve Suction Filte
◆ Capacity control system module : Bushing
A. Step-less capacity control: Oil cooler in Let
1 ( step-less ) + 2 ( 25% ) Gasket 3 4 21 Gasket
B. 4 step capacity control:
2 ( 25% ) + 3 ( 50% ) + 4 ( 75% ) Suction Filter
C. Dual capacity control:
1+2+3+4 Gasket
Discharge port
Terminal box
Power bolt
PTC terminal
Motor protector
Drain valve
Suction port Sight glass
Refrigerant
charging valve
58
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 RC2-100A ~ RC2-580A & RC2-100B ~ RC2-580B.
i.e. ●RC2-100A ~ RC2-580A & RC2-100B ~ RC2-580B both Y-∆ motor and ∆/∆∆ motor are available.
●RC2-620A ~ RC2-1530A & RC2-620B ~ RC2-1530B only Y-∆ motor are available.
Y-∆ Starting
Y-∆ motor connects motor coil by Y connection during starting therefore reducing voltage on coils to 1/√3 of input
voltage and reconnects motor coil by △ connection after starting. By doing so, we can decrease starting current
thorough voltage drop, i.e., so-called voltage-drop starting.
Y-∆ motor connection method is shown in the following motor wiring diagram:
In Y connection, MCM, MCS are inductive while motor leads Z,X,Y are tied together as a neutral connecting as Y
fashion. A few seconds later (3~5 sec is recommended), MCM, MCS become deductive. Around 0.25 sec later,
MCM,MCD are inductive, it turns out △ run connection.
I (AMP)
Starting
Current
Time
U Z
A
V X
B
Earth Bolt
W Y
A:PTC
B:Pt100Ω/ Pt1000Ω(Option)
59
∆/∆∆ (PW) starting
RC2-100A ~ RC2-580A & RC2-100B ~ RC2-580B 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.
I
(AMP)
Starting Current
sec
Time
1 7 A B
A
1 7
2 8 Earth Bolt
B
2 8
Earth Bolt
3 9
3 9
The selection of both of the motor contactors (k1 / k2) is each for approx. 60% of the max. running current. The
recommended time delay of the switching relay k1 is to be set at 0.5 second and not more than 1 second.
A B
1/U 7/Z
Earth Bolt
2/V 8/X
3/W 9/Y
A:PTC
B:Pt100Ω / Pt1000Ω
(Option)
60
A B
1/U 7/Z
Earth Bolt
2/V 8/X
3/W 9/Y
A:PTC
B:Pt100Ω / Pt1000Ω
(Option)
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.
61
Caution: Ensure the power supply wiring and output motor wiring are connected to the correct terminals.
Any mistake could cause catastrophic failure to compressor motor.
Note: when any protection device trips, please do troubleshooting and reset manually. Do not let the compressor reset
automatically after abnormal trip!
Note: In the region where the electricity power is unstable, install an additional hi-low voltage protector with ± 5%
tolerance of normal voltage to ensure safe operating of the compressor.
2. Unbalanced voltages :
Unbalanced voltages usually occur because of variations in the load. When the load on one or more of the phases are
different from the other(s), unbalanced voltages will appear. This can be due to different impedances, or type and value
of loading in each phase. Unbalanced voltages can cause serious problems, particularly to the motor.
NEMA defines voltage unbalance as follows :
(maximum voltage deviation from average voltage)
Percent voltage unbalance = 100 x (average voltage)
NEMA states that poly-phase motors shall operate successfully under running conditions at rated load when voltage
unbalance at the motor terminals does not exceed 1%. Furthermore, operation of a motor with over 5% unbalance is
not recommended for it probably results in motor damage.
Unbalanced voltages at motor terminals cause phase current unbalance ranging from 6 to 10 times the percent of
voltage unbalance for a fully loaded motor. This causes motor over current resulting in excessive heat that shortens
motor life, and hence, eventual motor burnout. If the voltage unbalance is great enough, the reduced torque capability
might not be adequate for the application and the motor will not attain rated speed.
Some of the more common causes of unbalance voltages are :
●Unbalanced incoming utility supply
●Open delta connected transformer banks
●Large single phase distribution transformer in the system
●Open phase on the primary 3-phase transformer in the distribution system
●Blow fuse on 3 phase bank of power factor improvement capacitors
●Unequal impedance in conductors of power supply wiring
●Unbalanced distribution of single phase loads such as lighting
●Unequal transformer tap settings
62
●Faults or grounds in power transformer
●Heavy reactive single phase loads such as welders
A 3-phase 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.
Suggestion:
a. The regular setting of electric leak protection should be greater than 50mA; for a humid location, 25mA is better.
b. Grounding voltage of casing should be no greater than 50V; for a humid location, the limit is 25V.
c. Grounding resistance should be no greater than 500 Ohm.
d. Air cut board (ACB) is regularly equipped with electric leak protection. Please refer to related settings for its normal
action.
e. If electric leak protection is active, please check if insulation of equipments is normal and if its wiring and setting are
correct.
U Z A B
A
V X
1 7
Earth Bolt
B
2 8
Earth Bolt
W Y
3 9
PW1:1,2,3 A:PTC
A:PTC PW2:7,8,9 B:Pt100Ω / Pt1000Ω
B:Pt100Ω / Pt1000Ω(Option) (Optional)
Please make sure nothing is wrong before turning on the power. If there are any questions, please contact the
supplier of equipments.
63
6. Operation and maintenance
6.1 Compressor start-up
PRE-START CHECKING- Table below shows the required procedures and checkpoints before starting-up the
compressor during commissioning or initial operation of the unit.
Items Things to be checked States or standard values
1. Oil level 1. Higher than the middle line of oil level sight glass
2. Oil heater 2. Should be kept energizing after compressor shut
3. System valves status down.
1. Accessories
4. Solenoid valves 3. Opened
5. Capillary 4. Fixed
5. No serious distortion or damaged
1. Voltage of main power 1. Electricity voltage should be kept within 5 to the
2. Voltage of control circuit rated voltage, instant maximum voltage drop while
3. Insulation resistance value of the starting should be less than 10% to the rated
motor between phase to phase and voltage.
phase to ground. 2. Standard voltage is 220V. Maximum
4. Power terminals and wire cables’ voltage is 230V.
terminals connection. If there is other demand, contact HANBELL.
5. Grounded 3. Insulation resistance value should be above 5M.
2. Electrical system 6. Capacity of electrical accessories 4. Power terminals are firmly fixed on terminal block
7. Settings of switches, sensors and and well insulated. Keep wire cables away from
controllers. heat source and sharpened metal. Power terminals
are fixed firmly and well insulated. Terminal screw
and block are both required.
5. (Ruled by the local Electricity Regulations.)
6. Properly selected (or inquired by the system
designer.)
7. Properly set (or inquired by the system designer.)
1. Outer piping system 1. Fixed firmly.
3. Piping system 2. Leakage test 2. No leakage.
3. Bolts to fix the compressor. 3. Fix the compressor tightly.
1. Motor coil sensor (thermistor) 1. Connected in series with discharge sensor to
2. Discharge sensor (thermistor) controller.
4. Safety devices
3. Controller 2. Connected in series with motor sensor to controller.
3. Closed circuit with N.C. & N.O.
In addition to the pre-start checking given in the above table, please also consider the following:
a. It is necessary to pay more attention to the auxiliary facilities while the chiller is commissioning at the job-site and the
periodic maintenance after the initial start-up.
b. For a new chiller with compressor put in stock for a long time, it is recommended to add 1 to 1.5 liter of oil in the
motor casing to provide better screw rotor lubrication during compressor’s initial start-up.
c. In order to keep the capacity control smoothly under the low ambient temperature with the normal viscosity of oil, oil
heater should be kept energizing after compressor has been shut down for preparation for the next start-up.
d. Check that all the settings on each pressure switch are correct.
e. Check if all the stop valves in the system are already open.
f. Check the rotating direction of the compressor by starting the compressor for a split second (approx. 0.5…1 sec.) and
check the suction and discharge pressure gauges. The correct rotating direction is: suction pressure drops immediately
and the discharge pressure will go up.
g. Compressor’s lubrication oil should be checked immediately after starting. Oil level should be within sight glass
range or higher than the middle line of oil level sight glass.
h. Oil foaming can be generated during starting phase, but it should reduce when the compressor is under stable
operating conditions. Otherwise this can indicate excessive liquid in the suction gas.
i. The running condition of compressor after commissioning at the job-site should be adjusted as; the discharge
temperature will be at least 20K above the saturated condensing temperature and the suction vapor superheat should
be within 10K to the saturated evaporating temperature.
j. 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
●Check the lubrication/ oil level
●All compressor protection devices
●Check electrical cable connections and tightness
64
6.2 Troubleshooting
The table below shows some problem that might encounter in the jobsite during commissioning or upon operation of
compressor. This table will only serve as a guide for the Engineer to understand the situation once the problem
occurred in the site.
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.
65
6.3 Compressor checking list
Please fill out the compressor checking list and send it to Hanbell, if any failure of compressor happened. Hanbell will
reply and suggest the solution to resolve the failure.
66
7. Applications
When compressors operate in the following application conditions, installation of an additional auxiliary cooling
apparatus is recommended to lower discharge temperature, maintain proper temperature of lubricant and additional
cooling for motor coil… to ensure safe running of compressors with efficiency.
Air-cooled system
High compression ratio system such as heat pump, low temperature and refrigeration system
High discharge temperature system such as heat recovery system
If compressors have to run at partial load below 50% continuously in a long term.
Any other heavy duty application
There are two type of additional cooling of compressor that described separately as below.
In areas with high condensing temperature and/or low evaporating temperature as in the limitation diagram, additional
cooling is required in order for the compressor to work properly. A relatively simple method of additional cooling is
direct refrigerant injection in the compressor either in the motor side or compression chamber side.
The purpose of installing a liquid injection system is to prevent the compressor from overheat. The system installed a
liquid injection expansion valve between the liquid line and compressor for cooling down the compression chamber and
motor to ensure the continuous and safe running of the compressor. The suction superheat should be controlled
between 5K~10K for the application of air-cooled and heat pump chillers by means of expansion valve devices. These
devices can be adjusted by the stem of the expansion valve to control the suction superheat by means of refrigerant
flow rate. When the initial startup, the loading of the chiller is heavy due to the high temperature of chilled water, so the
liquid injection devices capacity should be selected or calculated enough to reduce the overheat of the compressor.
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.
When the compressor applied in the low temperature system (E.T. ≦ -10°C) the compression ratio is high at this
condition, also the discharge temperature will be very high. The design of the liquid injection system for low
temperature application is similar to the illustration shown in figure below. There are two connectors for the liquid
injection in the compressor, one is in the motor side to cool down the motor temperature and reduce the discharge
temperature. The other is in the compression chamber side and its function is to reduce the discharge temperature and
increase the compression efficiency. However, when additional cooling in compression chamber like economizer
operation, oil cooler application is used or when condensing temperature is low, discharge temperature will be kept low
and liquid injection may not be turned on, although motor load is severe and motor coil temperature is high. This may
lead to motor failure. Therefore, in application mentioned above Pt100 or Pt1000 for liquid injection to motor is
recommended instead.
Figure 59 Liquid injection connected to motor Figure 60 Liquid injection connected to compression chamber
67
Liquid injection applied with high temperature expansion valve
Select the high temperature expansion valve, which can sense the discharge temperature with its remote bulb. This
can control the opening of expansion valve proportionally, and can reach the best cooling effect; it will control the
compressor discharge temperature at an optimal situation of around 80C.
It can also be installed with an additional solenoid valve or service valve in front of the high temperature expansion
valve for the maintenance purposes. The solenoid valve will be opened while starting the compressor. The
equilibrium tube of high temperature expansion valve should be connected to the high-pressure side to counter the
internal pressure.
However, when additional cooling in compression chamber like economizer operation, oil cooler application is used,
or when condensing temperature is low, discharge temperature may be kept low and liquid injection may not be
turned on, although motor load is severe and motor coil temperature is high. This may lead to motor failure.
Therefore, in applications mentioned above, Pt100 or Pt1000 for liquid injection to motor is recommended instead.
Figure 61 Liquid injection (high temperature type) Figure 62 Liquid injection (high temperature type)
connected to motor to compression chamber
Cooling by refrigerant
The cooler uses refrigerant as the cooling medium. A basic
refrigerant-cooled oil cooling system is shown in Figure 63.
Figure 66 Internal oil circuit application Figure 67 External oil circuit application
69
7.2 Economizer applications
HANBELL screw compressor can be fitted with an additional middle connection for economizer operation. With this
form of operation, refrigeration capacity and also system efficiency can be improved by means of a sub-cooling circuit
or two-stage refrigerant expansion.
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.
Please refer to Hanbell selection software for calculation of economizer capacity at different operating conditions.
Principle of operation
As opposed to the reciprocating operation of a piston compressor, the compression in a screw compressor takes place
only with one flow direction. When the rotors turn, refrigerant vapor is pressed into the rotor grooves by the opposing
rotor teeth and transported to end wall of the corresponding working space. In this phase, the volume is steadily
reduced and the vapor is compressed from suction pressure to condensing pressure.
The pressure at the additional middle connection is at a similar level to the intermediate pressure with a two-stage
system. As a result of these features, a screw compressor of this design can be combined with an additional sub-
cooling circuit or an intermediate pressure vessel (flash type sub-cooler) for two-stage expansion. These measures
result in a clearly increased refrigeration capacity due to additional liquid sub-cooling, especially with high-pressure
ratios. The power consumption of the compressor increases slightly compare to the additional work that takes place at
a better level of efficiency.
Note:
1. When economizer is used, it is recommended to install a
muffler before middle-pressure returned gas port in
compression chamber to effectively mitigate pulsation noise in
middle pressure as shown in the drawing below.
70
Figure 69 System with economizer (sub-cooler) Figure 70 System with economizer (flash type sub-cooler)
In the rack or parallel system, it is possible to happen the unequal-distribution of returned oil from the evaporator that
could cause low oil level in one or more of the compressors. Be sure to install the oil level switch inside each
compressors and oil flow switch installed in each oil return line to ensure the returned oil in each compressor with
normal oil level.
The basic design of the system is shown in Figure 69, twin compressor parallel system connections. The accessories
installed are the basic and if there are more applications or protection required, contact HANBELL or local
distributor/agent for more information or further confirmation.
71
7.4 Oil pump application
An additional oil pump is recommended to install to the system when the differential pressure of oil pressure and
suction pressure is less than 4bar ( for example: water cooled flooder chiller). If compressor is operating at the
mentioned condition, the failure of modulation and lubrication will be happened and will seriously damage the
compressor. 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.
1. Pump down
Do not pump down the compressor on the chiller as a routine operation except only for temporary 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. When doing the pump down, be
sure to take notice of the items listed below :
a. Pump down should be done once each time, as it may be dangerous to the compressor, compression chamber for
pumping down repeatedly.
b. The minimum suction pressure when doing the pump down should be over 15 psig for R-134a and 25 psig for R22.
c. Take notice of compressor running noise. If there is any abnormal noise happened, then emergently stop the pump
down.
72
8 Selection software
Step:
1. Before operating our selection software, please
check any upgrade of selection software at Hanbell
website
The above window is the operating mode of a compressor, just key-in the following
condition and then click the「Calculate」button.
- Refrigerant type
- With economizer (yes/no)
- Compressor model
- Oil cooler or liquid injection
- Power supply (default is 380V 3 50Hz)
- Partial load percent (%)
- Evaporating SST (˚C,˚F)(default is 0 ˚C)
- Condensing SCT (˚C,˚F)( default is 40 ˚C)
In the lower part of the window, there are several kinds of buttons:
「Calculate」: Must click this key, to calculate the value.
「Tables」:Can calculate the coefficient of performance by means of polynomial.
「T.Data」:The technical data is the same with function key of technical data
「Print」: Copying the calculated performance data
「Vi selection」:After calculating, different Vi value can be chose by clicking this
button.
(3.2.1) Click「Tables」button and the window will appear right one (default
window), it can calculate the coefficient of performance using polynomial.
73
(3.3) 「SELECTION」by clicking this button, it will help the customer how to choose screw compressor model.
After clicking the 「SELECTION」button, the right window is customer's necessary operating mode. Just key-in the
following data.
- Refrigerant type
- Evaporating SST
- Cooling Capacity (KW)
- Condensing SCT
- Power supply
The data shown in the middle of the window is the compressor model and its
performance
「Calculate」: Must click this button, to calculate the value. After keying the
required data click this button and will show the compressor
model and the performance.
「T.Data」: The technical data is the same with function key of technical
data(3.4)
「Print」: Copying the calculated performance data
74
9. Warranty
All HANBELL screw compressors are put through strict quality and performance testing prior to shipping from the
factory. The screw compressors are manufactured from the finest quality material and are warranted for one year after
the completion of installation and commissioning at the jobsite or up to 18 months from the original date of sales by
HANBELL or designated sales agent, whichever comes first.
However, HANBELL will not be responsible if the compressor does not work properly for any of the following reasons:
1) damaged caused by others including shipping, natural disaster, war, etc.
2) damage caused by improper installation, operation or maintenance that is not in accordance with the HANBELL
Technical Manual or instruction,
3) damaged caused by modification of any part on or connected to the compressor, and/or
4) damage caused by the improper maintenance or repair by a non-authorized technician.
5) HANBELL will also not responsible for any accident, which may happen to personnel while installing, setting up,
operating, maintaining, and/or repairing the compressor.
75
Appendix. RC2 Compressor noise level
RC2 Series Screw Compressors’ Sound Pressure Level
Hz\Model RC2-100 RC2-140 RC2-180 RC2-200 RC2-230 RC2-260 RC2-300 RC2-310
50 55.0 55.6 56.5 59.7 60.1 60.4 60.8 61.0
63 51.9 52.4 53.3 56.3 56.7 57.0 57.3 57.6
80 56.9 57.4 58.4 61.7 62.1 62.4 62.8 63.1
100 54.0 54.5 55.5 58.6 59.0 59.3 59.6 59.9
125 53.6 54.1 55.0 58.1 58.5 58.8 59.2 59.4
160 53.1 53.6 54.5 57.6 58.0 58.3 58.6 58.8
200 51.0 51.5 52.4 55.4 55.8 56.0 56.3 56.6
250 60.4 61.0 62.1 65.6 66.1 66.3 66.7 67.0
315 56.1 56.6 57.6 60.9 61.3 61.6 61.9 62.2
400 53.2 53.7 54.7 57.8 58.2 58.4 58.8 59.0
500 57.6 58.2 59.2 62.5 62.9 63.3 63.6 63.9
630 55.5 56.0 57.0 60.2 60.6 60.9 61.3 61.6
800 64.8 65.4 66.6 70.3 70.8 71.1 71.5 71.9
1000 59.8 60.4 61.5 64.9 65.4 65.7 66.1 66.3
1250 66.9 67.5 68.7 72.6 73.1 73.4 73.9 74.2
1600 63.2 63.7 64.9 68.5 69.0 69.3 69.7 70.0
2000 62.0 62.6 63.7 67.3 67.8 68.1 68.5 68.8
2500 62.0 62.6 63.7 67.3 67.8 68.1 68.5 68.8
3150 59.5 60.1 61.1 64.6 65.1 65.3 65.7 66.0
4000 58.2 58.8 59.8 63.2 63.6 63.9 64.3 64.6
5000 53.1 53.6 54.6 57.7 58.1 58.3 58.7 58.9
6300 50.2 50.7 51.6 54.5 54.9 55.2 55.5 55.7
8000 45.2 45.6 46.4 49.0 49.3 49.6 49.9 50.1
10000 44.6 45.0 45.8 48.4 48.7 49.0 49.3 49.5
12500 39.4 39.8 40.5 42.8 43.1 43.2 43.5 43.7
16000 34.8 35.2 35.8 37.8 38.0 38.2 38.5 38.6
20000 34.5 34.8 35.4 37.4 37.6 37.8 38.1 38.2
Overall dB(A) 73.1 73.7 74.8 78.4 78.8 79.2 79.6 79.9
Hz\Model RC2-320 RC2-340 RC2-370 RC2-410 RC2-430 RC2-470 RC2-510 RC2-550 RC2-580
50 61.2 61.4 62.4 63.8 64.1 64.8 65.7 66.7 66.9
63 57.7 58.0 58.9 60.2 60.5 61.1 62.0 62.9 63.1
80 63.3 63.5 64.5 66.0 66.3 67.0 67.9 68.9 69.2
100 60.0 60.3 61.2 62.6 62.9 63.6 64.4 65.4 65.7
125 59.6 59.8 60.8 62.2 62.4 63.1 64.0 64.9 65.2
160 59.0 59.3 60.2 61.6 61.8 62.5 63.3 64.3 64.5
200 56.7 57.0 57.9 59.2 59.4 60.1 60.9 61.8 62.0
250 67.2 67.5 68.5 70.1 70.4 71.2 72.1 73.2 73.5
315 62.4 62.6 63.6 65.1 65.3 66.1 67.0 67.9 68.2
400 59.2 59.4 60.4 61.8 62.0 62.7 63.5 64.5 64.7
500 64.1 64.4 65.4 66.9 67.2 67.9 68.8 69.8 70.1
630 61.7 62.0 63.0 64.4 64.7 65.4 66.3 67.3 67.5
800 72.0 72.4 73.5 75.2 75.5 76.3 77.3 78.5 78.8
1000 66.5 66.8 67.9 69.4 69.7 70.5 71.4 72.5 72.7
1250 74.4 74.7 75.9 77.6 77.9 78.8 79.9 81.0 81.3
1600 70.2 70.5 71.6 73.3 73.6 74.4 75.4 76.5 76.8
2000 69.0 69.3 70.4 72.0 72.3 73.1 74.1 75.1 75.4
2500 69.0 69.3 70.4 72.0 72.3 73.1 74.1 75.1 75.4
3150 66.2 66.4 67.5 69.0 69.3 70.1 71.0 72.1 72.4
4000 64.7 65.0 66.0 67.5 67.8 68.6 69.5 70.5 70.8
5000 59.1 59.4 60.3 61.7 61.9 62.6 63.4 64.4 64.6
6300 55.9 56.1 57.0 58.3 58.5 59.2 60.0 60.9 61.1
8000 50.2 50.4 51.2 52.4 52.6 53.2 53.9 54.7 54.9
10000 49.6 49.8 50.6 51.7 52.0 52.5 53.2 54.0 54.2
12500 43.8 44.0 44.7 45.7 45.9 46.4 47.0 47.7 47.9
16000 38.7 38.9 39.5 40.4 40.6 41.0 41.6 42.2 42.3
20000 38.3 38.5 39.1 40.0 40.2 40.6 41.1 41.7 41.9
Overall dB(A dB(A) 80.1 80.4 81.5 83.1 83.4 84.2 85.2 86.3 86.6
Hz\Model RC2-620 RC2-710 RC2-790 RC2-830 RC2-930 RC2-1020 RC2-1130 RC2-1270 RC2-1530
50 67.2 67.4 67.5 67.8 68.5 70.0 70.3 70.6 70.9
63 63.4 63.5 63.7 63.9 64.6 66.0 66.3 66.6 66.9
80 69.4 69.6 69.8 70.1 70.8 72.3 72.7 73.0 73.3
100 65.9 66.1 66.3 66.5 67.2 68.7 69.0 69.3 69.6
125 65.4 65.6 65.8 66.0 66.7 68.1 68.5 68.7 69.1
160 64.8 65.0 65.1 65.4 66.0 67.5 67.8 68.1 68.4
200 62.3 62.4 62.6 62.8 63.5 64.9 65.2 65.4 65.8
250 73.8 74.0 74.1 74.4 75.2 76.8 77.2 77.5 77.9
315 68.5 68.7 68.8 69.1 69.8 71.3 71.7 72.0 72.3
400 65.0 65.2 65.3 65.6 66.2 67.7 68.0 68.3 68.6
500 70.4 70.6 70.7 71.0 71.7 73.3 73.7 73.9 74.3
630 67.8 68.0 68.1 68.4 69.1 70.6 70.9 71.2 71.6
800 79.1 79.3 79.5 79.8 80.6 82.4 82.8 83.1 83.5
1000 73.0 73.2 73.4 73.7 74.4 76.1 76.5 76.7 77.1
1250 81.7 81.9 82.1 82.4 83.2 85.1 85.5 85.8 86.2
1600 77.1 77.3 77.5 77.8 78.6 80.3 80.7 81.0 81.4
2000 75.7 75.9 76.1 76.4 77.2 78.9 79.3 79.6 80.0
2500 75.7 75.9 76.1 76.4 77.2 78.9 79.3 79.6 80.0
3150 72.6 72.8 73.0 73.3 74.0 75.7 76.1 76.3 76.7
4000 71.1 71.3 71.4 71.7 72.4 74.0 74.4 74.7 75.0
5000 64.9 65.1 65.2 65.5 66.1 67.6 67.9 68.2 68.5
6300 61.3 61.5 61.7 61.9 62.5 63.9 64.2 64.4 64.8
8000 55.1 55.3 55.4 55.6 56.2 57.4 57.7 57.9 58.2
10000 54.5 54.6 54.7 55.0 55.5 56.7 57.0 57.2 57.5
12500 48.1 48.2 48.3 48.5 49.0 50.1 50.3 50.5 50.8
16000 42.5 42.6 42.7 42.9 43.3 44.3 44.5 44.7 44.9
20000 42.1 42.2 42.3 42.5 42.9 43.8 44.1 44.2 44.4
Overall dB(A) 86.9 87.1 87.3 87.6 88.4 90.1 90.5 90.8 91.2
Note:
1. The above 1/3 octave spectrum datum is based on C/T 50°C,E/T 0°C, with R22.
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.
3. The above datum is based on ISO-2151 to be measured.
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