Hanbell RC2 Series Installation manual

5580 Enterprise Pkwy., Fort Myers, FL 33905 O󰀩ce [phone] Fax: [phone]






NO OIL is shipped in compressor.
Compressor must NEVER be run backwards.

These Safeties ARE Required at Startup to Maintain Hanbell Warranty
a) Motor Module Trip (INT69HBY): Open for 1 second
b) Low Oil Level Float Trip: Open for 30-60 seconds
c) Unsafe Suction: Less than 5 psi for 3 seconds
d) Low Differential Pressure: Less than 65 psi for 60 seconds (Oil Psi – Suction Psi)
e) Unsafe Differential Pressure: Less than 35 psi for 5 seconds (Oil Psi – Suction Psi)
f) Low Discharge Superheat: Less than 25°F for 300 seconds

COMPRESSOR INSTALLATION & START-UP GUIDE REVISION M
2
The MCS Commitment is to provide practical solutions for the industries
needs and to be both a leader and partner in the e󰀨ective use of
microprocessor controls.
Micro Control Systems, Inc.
5580 Enterprise Parkway
Fort Myers, Florida 33905
PH:[phone] FAX:[phone]
www.mcscontrols.com
All information contained within this document is considered to be proprietary information of Micro Control Systems, Inc.
No information or data from this document shall be published, used, reproduced, transmitted, or disclosed to others outside
your organization without the prior expressed written consent of Micro Control Systems, Inc. This document and the information
contained herein shall be treated as proprietary. Reasonable provisions shall be provided to ensure that this information remains
proprietary by your employees, agents, and other personnel that may have access to this document.
Copyright ©2020

COMPRESSOR INSTALLATION & START-UP GUIDE REVISION M
3

  ..........................................................
 ............................................................................
2.1. Compressor Safety Instructions...................................................................................................................5
2.2. Installation Procedures................................................................................................................................5
 .....................................................................
 .....................................................................
4.1. Electrical Power Terminals ........................................................................................................................10
 ...............................................................
 ...............................................................................
6.1. Description - INT69HBY DIAGNOSE .......................................................................................................12
6.2. Flash Codes ..............................................................................................................................................12
6.5. Flash Code Overview................................................................................................................................13
6.6. How to Wire INT69HBY Diagnose.............................................................................................................14
  ................................................................................
 ..............................................................................
 ..............................................................................
  ................................................................................
 ............................................................................................................
 .................................................................................................................
  ..................................................................................................
13.1. Oil Types....................................................................................................................................................22
6.3. HANBELL FLOODED TYPE WITH OIL SEPARATOR..............................................................................23
6.4. HANBELL FLOODED TYPE WITH OIL SEPARATOR & OIL COOLER....................................................24
  ...........................................................................................................
14.1. Recommended Safety Settings.................................................................................................................25
  ...............................................................................................................
15.1. Wiring & Controls Set Up...........................................................................................................................26
15.2. Compressor Set Up...................................................................................................................................26
15.3. Solenoids...................................................................................................................................................27
15.3.1 Solenoid Identication (Normally Open / Normally Closed) .............................................................27
15.3.2 Innite Capacity (Stepless) Minimum (50-100%).............................................................................28
15.3.3 Step Load 50%, 75%, 100%...........................................................................................................29
15.3.4 Step Load 25% 50%, 75% & 100% (Only 25% at Start-Up and Shut-Down) .................................29
15.3.5 Solenoid Alignment..........................................................................................................................30
 .....................................................................................................
16.1. Slide Amp Calculation through MCS-Connect...........................................................................................34
  ...........................................................................
 ..............................................................................................................
  ........................................................................................
19.1. Hanbell Warranty Startup Form.................................................................................................................40

COMPRESSOR INSTALLATION & START-UP GUIDE REVISION M
4
1. Inspect crate and compressor for anyshipping damage.
2. The compressor is in an easy open crate, cutstraps and lift off crate top
from base.
3. Use either steel cable or safety ropes to lift the compressor, see Figure
1. The cable shouldbe capable of holding up to a minimum of 2 tons.
Use caution while lifting the compressor
Figure 1
Lifting Compressor with Steel Cable
Make sure that the steel cable does not touch the Solenoid Valves, Capillary, Oil Heater, Discharge Temperature
Sensor and or Power Terminals, etc. to prevent damage.
 Use only steel cable or safety ropes to lift the compressor; make sure that the cable/rope has the proper strength to
lift the compressor.
Keep the compressor horizontal while lifting.
4. Check compressor nameplate for correct model and voltage designation.
5. Tofacilitate customer installation requirements, the parts listed in Table 1 are factory supplied in separate boxes located
in the compressor terminal box or packed in the compressor shipping container. Please verify that you have received all
accessory parts.
Table 1: Compressor Accessories & Service Valve Parts
Qty Description
1 Stop Valve Assembly
1 stop valve, 2 gaskets, 1 charging valve, 4 bolts, 1 half union connector, 1 flare nut, 1 flare seal
bonnet
1 Discharge bushing connector
1 Suction bushing connector
1 Motor Terminal Junction Box Assembly
1 terminal box, 1 motor protection, 2 plastic terminal plugs, 1 reset button, 4 wires
(refer to Figure 4-B)
 

COMPRESSOR INSTALLATION & START-UP GUIDE REVISION M
5
 
1. Follow recognized safety procedures and practices.
2. In order to prevent the penetration of moisture, air or impurities, the compressor has been charged with Nitrogen
gas. Do not remove any compressor bolts or fittings until the factory supplied holding charge has been relieved
3. Do not apply any power to the compressor unless all valves are open and solenoids are energized (suction / discharge,
service valves, economizer and oil shut off valves).
4. Do not operate or provide any electrical power to the compressor unless the terminal box cover is in place and
secured. Measurements of the current and voltage during running conditions must be taken at other points in the
power supply.
5. Do not remove terminal box cover until all electrical sources have been disconnected.
WARNING: Failure to follow these instructions could result in serious personal injury.
 
1. Holding Charge: The screw compressor is factory supplied with 15 psig (0.5 bar) holding charge of nitrogen gas.
The internal pressure must be relieved before attempting to remove any compressor fittings or parts. Relieve the
holding charge by removing the threaded cap on the low pressure Schrader connection fitting and depressing the
internal Schrader stem.
CAUTION: This compressor may contain trace amounts of oil. Do not relieve the holding
charge or open the compressor ports until it is ready to be connected to a closed dry
system. Excessive moisture will shorten compressor life.
2. Installation of the Compressor Electrical Terminal Box: Four bolts located on the top of the electrical terminal
box cover mount the electrical terminal box; it is adjustable to the cable hole direction to meet the power cables’
optional connection direction from the chiller.
3. Oils: Adding and removing oil is done through the Drain valve located on the solenoid side of compressor.
The compressor has no oil and is not charged with oil. When adding or doing a complete change, use only the
listed Hanbell approved oils. POE oils readily absorb moisture and cause acid formation in the system. Keep oil
exposure to the atmosphere to a minimum.
4. Installation of the Service/Stop Valve: Unpack the service/stop valve’s box then check against the list on the out-
side of the box to ensure correct parts. Be sure that all parts inside the carton are clean. Use the four bolts to secure
the service/stop valve. Use PTFE sealer to seal the adapter while tightening it. Please refer to Figure 5-A for space
requirements for future service and maintenanceneeds.
5. Service/stop Valve Recommended Connection
Figure 3-A RC2-100, 140& 180 Figure 3-B RC2-170, 200~580 & 620 Figure 3-C RC2-610, 710~930
 

COMPRESSOR INSTALLATION & START-UP GUIDE REVISION M
6
1. Liquid Injection Solenoid Valve and Expansion Valve (Required, Not included with compressor): The liquid injection
system may be piped, but it is necessary to consider the required space for adjustment of the expansion valve while
testing or running the compressor. Please refer to installation guide in the following section for connection points.
Note A: It is necessary to adjust the Ball Valve to feed small amounts of liquid (drops) to the
compressor motor.
 

COMPRESSOR INSTALLATION & START-UP GUIDE REVISION M
7
1. If the compressor application is low voltage, the following items should be considered:
2. Use conduit to insulate and protect the main power cables between the control panel and compressors’ electrical
terminal box.
3. Press each main power cable connecting head with bolts firmly on each power terminal in electrical terminal box.
Keep enough space and distance between the main power cable heads.
4. Choose suitable electrical accessories to meet the required critical running conditions. An AC-3 contactor is
recommended to meet the rated capacity of power. Select an overload protector with a response time of 15 seconds
for overload.
5. Ensure the electricity voltage drop between each two phases is less than 2%. If unable to reduce the length of main
power cable then a larger diameter of main power cable should be chosen. Please refer to Figure 7-A shownbelow.
The chart below is an estimate for wire sizes based on maximum continuous current being used.
Local electrical codes should be followed prior to wiring the compressor and selecting a wire size.
Main power cable Size
AWG / MCM (mm2)8 awg (8 mm2)6 awg (14 mm2)4 awg (22 mm2)2 awg (30 mm2)1 awg (38 mm2)0 awg (50 mm2)00 awg (60 mm2)3/0 awg (80mm2)4/0 awg (100 mm2)4/0 awg (125 mm2)300 mcm (150 mm2)500 mcm (200 mm2)
Maximum continuous current
(Amp) 55 80 100 125 145 175 200 230 270 310 360 425
Table 7-A Main Power Cable Size vs MCC
Maximum main power cable temperature is at 60°C. Maximum ambient temperature is at 35°C.
6. To avoid any danger or accidents due to the shortage of electrical power, you are required to follow local Electrical
Regulations for the grounding of the electrical terminal box, heater and compressor body etc.
7. The motor PTC and discharge PTC are temperature sensors with a quick response in relation to the temperature
approach to their setpoint. The thermisters must be connected in series to a controller (INT69HBY – Kriwan provided
with the compressor) in the terminal box for protection of the compressor. An alarm for the motor protector is required to
be embedded on the control panel as an indicator. Do not bypass/jump-out the INT69HBY to start and run the compressor.
Warning: Reverse rotation of the compressor will cause compressor damage
and will void the compressor warranty.
 

COMPRESSOR INSTALLATION & START-UP GUIDE REVISION M
8
 

COMPRESSOR INSTALLATION & START-UP GUIDE REVISION M
9
Motor Terminals
The method to tell the terminals for wiring (V-Phase)
1. Star-Delta Motor - refer to Letter by terminal bolt.
2. PWS Motor - refer to Number by terminal bolt.
Terminal V2
Letter top, number under letter
Motor Terminals
Larger Compressors


New Style Motor
Terminals
Smaller Compressors
Terminal V2
Old Style Motor
Terminals
Smaller Compressors 

Number to right of Bolt
Letter to Left of Bolt

COMPRESSOR INSTALLATION & START-UP GUIDE REVISION M
10
Figure 5-A Motor Wiring

COMPRESSOR INSTALLATION & START-UP GUIDE REVISION M
11
 
The power terminals of Hanbell compressors are made from ceramic materials and are
insulated more than 1000MΩ. Be careful connecting the wiring and follow the list below.
The ceramic part on the power terminal should not be tighten by hitting otherwise the insulation
of the power terminal could be degraded.
Follow the drawing shown below for the wiring to prevent the power terminal from being damaged.
The setting of the torque wrench for tightening the copper nut of the terminal bolts should be
set less than 500 kg-cm (36 pound/inch)
Shut down the chiller first for service if the insulation value of the power terminal is lower
than 5MΩ.

COMPRESSOR INSTALLATION & START-UP GUIDE REVISION M
12
Photo shows extra nuts in󰀬alled under jumper bar
for clearance of power bolt Insulation
Connect line voltage directly on Terminal post
 

COMPRESSOR INSTALLATION & START-UP GUIDE REVISION M
13
 
Hanbell supplies INT69 HBY Diagnose for motor protection with monitoring functions of phase loss, phase sequence, motor
temperature, and discharge temperature. The module has built in flash codes that are helpful for diagnosing safety faults.
In order to protect the compressor, each RC2 series compressor has been built with three PTCtemperature sensors inside the
motor coil and one at the discharge port neck of the compressor.These sensors are connected to the motor module to monitor
coil temperature and discharge temperature. Up to 9 sensors can be connected in series and used with one module.
If the temperature in one of the positions monitored exceeds nominal response temperature of the respective PTC thermistor
(230° F, 4.5 ohms ±20%), the sensor resistance increases and the module trips (M1 and M2 open). The failure results in
a lockout. The module resets when the response temperature drops 3kΩ (when temp decreases below 212°F, 2.75 ohms
±20%). 5 min delay for the first PTC failure, 60 min delay for the 2nd failure, latching lockout for the 3rd within 24 hour period.
Monitoring is inactive for 20 seconds after motor stop to prevent nuisance trips from brief reverse rotation.
Phase failure (loss) and Phase sequence safety trips result in a first time lockout. Phase sequence monitoring is active
1 second after motor start for 10 seconds. Phase loss is monitored 1 second after motor start till motor stop.
Lockout and time delay can be canceled by interrupting power to the module for 5 seconds. An optional power supply reset
button can be added to electrical connection box.
 
RED ORANGE RED ORANGE
 

COMPRESSOR INSTALLATION & START-UP GUIDE REVISION M
14
 
Green lit Compressor Operational
Green flashing Compressor Running
Red/Orange flashing Error, Compressor is switched off; for description see
table below
1st flashing sequence
(Red LED) 2nd flashing sequence (Orange LED) Description
1 1 Motor temperature; Static switch
off, Permissible winding
temperature exceeded
3 Motor temperature;
Reset delay after static switch off
4 Motor temperature;
Sensor input detected
open circuit or short circuit
2 1 Motor voltage;
Incorrect phase sequence
2 Motor voltage;
Phase failure/asymmetry
3 1 General;
Supply voltage too low
5 General;
Reset delay after “General” error
Error Active Condition Time delay
Motor temperature
static trip Always Rtrip 4,5kΩ ±20%
Rreset 2,75kΩ ±20%
1. / 24h 5min 2. / 24h 60min
3. / 24h locked out
Time delay starts after cooling down
Operation cycle
limitation Always >3 switch off within 30s 5min
Phase sequence 1s after motor start for 10s Locked out
Phase loss failure 1s after motor start till motor stop,
monitoring is inactive for 20 seconds
after motor stop to prevent nuisance
trips from brief reverse rotation.
Locked out

COMPRESSOR INSTALLATION & START-UP GUIDE REVISION M
15
 
The following diagram shows the proper wiring connections for the module. The module is connected
to L1, L2 and L3 for phase monitoring. Stake on connectors at terminal “A” are connected in series with
the discharge PTC and wired back to S1 and S2.

COMPRESSOR INSTALLATION & START-UP GUIDE REVISION M
16
 

COMPRESSOR INSTALLATION & START-UP GUIDE REVISION M
17
 

COMPRESSOR INSTALLATION & START-UP GUIDE REVISION M
18
 

COMPRESSOR INSTALLATION & START-UP GUIDE REVISION M
19
Please refer to the below tables for recommended minimum space requirements
RC2-100 RC2-140 RC2-180 RC2-170 RC2-200 RC2-230 RC2-260 RC2-300
A.(cm) 5.9” (15) 16.1” (41) 18.1” (46) 18.5” (47) 20.1” (51)
B.Outwards(cm) 11” (28)
C.(cm) 9.8” (25) 10.2 (26) 11.8” (30) 13” (33)
D.(cm) 5.9” (15)
E.Suction lter(mm) 3.7” (95) 4” (103) 5.6” (143)
F.Oil lter(mm) 7.8” (200)
RC2-310 RC2-320 RC2-340 RC2-370 RC2-410 RC2-470 RC2-510 RC2-550
A.(cm) 20” (51) 22” (56) 21.3” (54) 23.3” (59) 21.7” (55) 23.3” (59)
B.Outwards(cm) 11” (28)
C.(cm) 13” (33) 11.8” (30) 13.8” (35) 14.6” (37)
D.(cm) 5.9” (15)
E.Suction lter(mm) 5.6” (143 6” (153)
F.Oil lter(mm) 7.8” (200)
RC2-580 RC2-610 RC2-620 RC2-710 RC2-790 RC2-830 RC2-930
A.(cm) 21.7” (55) 23.6” (60) 23.6” (60) 25.6” (65) 31.5” (80)
B.Outwards(cm) 11” (28) 13.8” (35) 11” (28) 13.8” (35)
C.(cm) 13.8” (35) 14.6” (37) 17.7” (45)
D.(cm) 5.9” (15) --- 5.9” (15) ---
E.Suction lter(mm) 6” (153) 8.2” (210) 6” (153) 8.2” (210)
F.Oil lter(mm) 7.8” (200) 9.1” (232) 7.8” (200) 9.1” (232)
Table 7-A Compressor Recommended Space for Maintenance
1. Reserve enough space for connection and installation of the electrical terminal box, service/stop valves and sole-
noid valves on the compressor.
2. Consider the compressors’ future overhaul when determining space requirements. All compressors’ outside parts
and electrical controller lines and terminal connections etc should be spaced for easy dismantle and re-assemble.
 

COMPRESSOR INSTALLATION & START-UP GUIDE REVISION M
20
1. To avoid abnormal vibration and noise pay close attention to how the compressor is piped.
2. The welding for the compressor should contain at least 15% silver as an ingredient. Once all piping is completed,
perform a pressure test to ensure there are no leaks (maximum compressor pressure 350 psi or 24 bar). The cleanliness
of the system should be checked after pipe welding to help avoid any debris operating inside the system that can
cause compressor damage during operation. Nitrogen must be used to purge the refrigerant or oil lines when any solder
is being done.
3. To avoid compressor harmonic vibration transferred by the structure and piping to the chiller while in operation, a cushion
or shock absorber should be installed on the suction and discharge tube.
4. Refer to Figure 8-A showing a 6mm to 15mm.
5. Shock absorber installed under the compressor-mounting pad to isolate the vibration and noise transferred to other
portions.
Figure 8-AAbsorber Installation
6. In order to reduce vibration, copper tubes for suction and discharge pipes are recommended; copper suction and discharge
pipes will minimize the vibration from the piping while the compressor is running. In the case of steel piping, it is very
important for suitable welding to avoid the inner stress on piping due to harmonic vibration and noise, which will reduce
the compressor life.
7. Remove oxidized impurities, swarf or debris caused by welding on piping tubes, if these impurities, swarf or debris are
in the compressor, the oil lter will be clogged resulting in the lubrication system bearings and capacity control system
malfunctioning.
8. The suction and discharge anges are forged steel that can be welded directly with piping connectors (standard size
for copper piping, if connecting to steel piping contact your Hanbell representative) After welding the anges and pipes,
they should be cooled down by ambient air; water quenching is prohibited. Do not use water to cool down the pipes and
anges after welding.
 