Hanbell RC2 Series User manual

Contents
1. General ........................................................................................................................................ 1
2. Specifications and concept of design ...................................................................................... 1
2.1 Compressor nomenclature............................................................................................... 1
2.2 High Voltage compressor specifications ........................................................................ 2
2.3 Compressor construction................................................................................................. 2
2.4 Design features ................................................................................................................. 3
2.5 Compression process....................................................................................................... 4
2.6 Capacity control system ................................................................................................... 4
2.6.1 4-step capacity control system .............................................................................. 4
2.6.2 Continuous (step-less) capacity control system.................................................. 5
2.6.3 Dual capacity control system (optional)................................................................ 6
2.7 Compressor volume ratio (Vi) .......................................................................................... 6
2.8 Application limits............................................................................................................... 6
2.9 MCC & LRA ........................................................................................................................ 8
3. Lubricants ................................................................................................................................... 9
3.1 Lubricant table................................................................................................................... 9
3.2 Pre-cautions of changing oil ............................................................................................ 9
3.3 Oil change ........................................................................................................................ 10
4. Compressor lifting and installation ........................................................................................ 11
4.1 Compressor lifting........................................................................................................... 11
4.2 Compressor mountings .................................................................................................. 12
4.3 Piping work ...................................................................................................................... 12
4.4 Installing the compressor in a sloping position ........................................................... 13
4.5 Compressor outline drawings....................................................................................... 14
4.6 Compressors accessories.............................................................................................. 17
4.7 Installation and connection of the compressor............................................................ 27
5. Electrical data and design ....................................................................................................... 29
5.1 Direct-on-line start for High Voltage compressor......................................................... 29
5.1.1 Power supply wiring application.......................................................................... 29
5.2 Compressor protection devices..................................................................................... 30
5.2.1 Protection devices for High Voltage compressor .............................................. 31
5.3 Power supply ................................................................................................................... 31
5.4 Selection of magnetic contactors .................................................................................. 32
5.5 Grounding ........................................................................................................................ 33
6. Operation and maintenance ....................................................................................................33
6.1 Compressor starting ....................................................................................................... 33
6.2 Troubleshooting .............................................................................................................. 35
6.3 Compressor check list .................................................................................................... 36
7. Applications .............................................................................................................................. 37
7.1 Additional cooling ........................................................................................................... 37
7.2 Economizer applications ................................................................................................ 38
7.3 Parallel system applications .......................................................................................... 38
7.4 Oil pump application ....................................................................................................... 39
7.5 Important notes of compressor applications................................................................ 40
8. Warranty.................................................................................................................................... 40

1
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.
High Voltage 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 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 High Voltage RC2 compressor in order to prevent any accident or damage. Please
contact HANBELL or its local distributors/agents for more information or further assistance.
2. Specifications and concept of design
2.1 Compressor nomenclature
RC 2 – x x x x x
Refrigerant Code A = R134a
B = R22, R407C, R404A, R507A
Compressor’s Displacement at 50Hz (m3/hr)
RC model 2nd Version

2
2.2 High Voltage compressor specifications
a. RC2-A
COMPRESSOR MOTOR
Displacement
60 / 50Hz Cap. Control (%) Nominal Hp Voltage (V)
Hydrostatic
Pressure
Test
WEIGHT
MODEL
m3/hr
Rated
Speed
60 / 50Hz
VI
STEP STEPLESS
Type
60Hz 50Hz
Starting
60Hz 50Hz
Insulation Protection
kg/cm2g kg
RC2-1090A 1310/1089 35, 50, 75, 100 35~100 247 205 1710
RC2-1280A 1535/1276 30, 50, 75, 100 30~100 286 238 1890
RC2-1520A 1832/1523
3550/2950
2.2
2.6
3.0
3.5
25, 50, 75, 100 25~100
3 Phase, 2 Pole,
Squirrel Cage,
Induction Motor
331 275
DOL
3300
4160
6600
6000
10000
Class F
PTC Protection
42
1940
b. RC2-B
COMPRESSOR MOTOR
Displacement
60 / 50Hz Cap. Control (%) Nominal Hp Voltage (V)
Hydrostatic
Pressure
Test
WEIGHT
MODEL
m3/hr
Rated
Speed
60 / 50Hz
VI
STEP STEPLESS
Type
60Hz 50Hz
Starting
60Hz 50Hz
Insulation Protection
kg/cm2g kg
RC2-1090B 1310/1089 35, 50, 75, 100 35~100 402 335 1710
RC2-1280B 1535/1276 30, 50, 75, 100 30~100 471 392 1890
RC2-1520B 1832/1523
3550/2950
2.2
2.6
3.0
3.5
25, 50, 75, 100 25~100
3 Phase, 2 Pole,
Squirrel Cage,
Induction Motor
534 443
DOL
3300
4160
6600
6000
10000
Class F
PTC Protection
42
1940
Compressor weight kg
Model 380V 6000V 10000V
RC2-1090 1430 1710 ---
RC2-1280 1580 1890 ---
RC2-1520 1630 1940 ---
Nominal Horse Power:
All the above Nominal Hp’s are not equal to the maximum compressor Hp. Please refer to Hanbell selection software’s
output for rated current and Maximum Continuous Current-M.C.C according to various operating conditions while
selecting sizes of contactor, cable, fuse and wire, etc…
2.3 Compressor construction
High Voltage RC2- 1090, RC2-1280, RC2-1520 construction
30 9
125
18
10
11 17
19
16 15 20 21 25 22
678
23
27
13 14 426
129
2
28
24
3
Figure 1: Compressor construction
Item Description Item Description Item Description Item Description
1 Compressor casing 9 Motor rotor spacer ring 17 Discharge fixed ring 25 Suction bearing
inner/outer spacer ring
2 Motor casing 10 Piston 18 Disc spring 26 Discharge bearing
inner/outer spacer ring
3 Motor cover casing 11 Piston spring 19 Bearing lock nut 27 Seal plate
4 Bearing seat 12 Piston rod 20 Male rotor 28 Motor cooling inlet
5 Piston cylinder 13
Bearing seat cover
plate 21 Suction bearings 29 Oil inlet connection
6 Motor rotor assembly 14 Solenoid valve 22 Suction bearing fixed
ring 30 Piston cylinder cover
7 Motor stator assembly 15 Slide valve 23 Sight glass
8 Motor rotor washer 16 Discharge bearings 24 Power bolt

3
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 male screw rotor. Motor cooling is achieved by
independent motor cooling system.
Compressor technical features:
Full product range- Hanbell provides a variety of high voltage motors, 3300V, 4160V, 6600V, 6000V and 10000V, for
customer’s selection, which are compatible with R22, R134a, R404A, R507A and R407C. Other special working
voltage and frequency are available after consulting Hanbell.
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.
Precise capacity control- Slide valve for capacity control is located in the compressor cylinder. Slide valve is actuated
by oil with solenoid valves.
Wide range of operating conditions- Evaporating temperatures can be between -25℃ and 15℃while condensing
temperatures can be 65 maximum.℃
High-efficiency motors- Premium-grade low-loss core steel with special independent motor cooling design provides
the highest operating efficiency 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
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.
Perceptive electronics- High Voltage series screw compressors are equipped with PTC thermistors and motor
protection module which could monitor discharge and motor coil temperatures. The oil flow switch and oil temperature
thermistors are optional for your application.
Independent motor cooling and liquid injection- Independent motor cooling and liquid injection to chamber greatly
help heat dissipation in heavy-duty condition.
High Voltage series compressors not only inherit RC2 series compressors’ characteristics of high efficiency & reliability
design mentioned above, but are also designed with the following new advantages to meet customers’ needs:
1. Design the fittest high-efficiency motor for respective refrigerants, operating conditions and applicable power.
2. Dual capacity control provides flexibility in change of control (optional).
3. Floating ECO port design results in partial load effective economizer operation.

4
2.5 Compression process
As shown in Figure 2 below, during the rotation of the rotors, the meshing shifts from the suction side to the discharge
side. The meshing rotors enclose a working space, which is continuously reduced as it moves in the axial direction.
This causes a V-shaped lobe space between each male and female lobes. This lobe space is maximum at suction and
sealing process. As the rotors rotate further, the new meshing at the suction side closes the V-shaped lobe space. The
lobe space is then constantly reduced by continuous intermeshing of the lobes (compression process).
A reduction in lobe space takes places during its movement from the suction side of the rotors towards the discharge
side. The volume is steadily reduced and it is thereby compressed in the sealed condition. As soon as the peaks of the
rotor teeth are free to the outlet port, compressed vapor is discharged to the high-pressure side and flows to the oil
separator where the high-pressured gas is separated from lubrication oil. The size and geometry of the outlet port
determine the so-called “internal volume ratio (Vi)” of the compressor. This ratio must have a defined relationship with
operating pressure ratio to avoid losses in efficiency due to under or over compression.
Figure 2: Compression process
2.6 Capacity control system
High Voltage series screw compressors are equipped with either 4-step capacity control system or continuous (step-
less) capacity control system. Both of these capacity control systems consist of a modulation slide valve, a piston rod, a
cylinder, a piston and piston rings. The slide valve and the piston are connected by a piston rod. The principle of
operation is using oil pressure to drive the piston in the cylinder. For example, lubrication oil flows into the cylinder due
to oil pressure of which resultant is bigger than spring force plus the force of high-pressured gas in the other side of the
piston. Oil inside the cylinder pushes the piston toward the suction side. When the slide valve moves toward the
suction side, the effective compression volume is increased in the compression chamber. This means the displacement
of refrigerant gas is also increased; as a result, the refrigeration capacity is also increased. However, when any of
solenoid valves (for 4-step capacity control system) is opened, the high-pressured oil in the cylinder will be bypassed to
the suction side. In this way, the piston together with the slide valve will move toward partial load positions (either 25%,
or 50%, 0r 75% for 4-step capacity control system) and then some of the refrigerant gas will be bypassed from the
compression chamber back to the suction side. As a result, the refrigeration capacity is decreased because of
reduction in displacement of refrigerant gas flowing in the system.
A piston spring is used to push the piston back to its initial position, i.e. the minimum-load position, in order to reduce
starting current for the next start. If the compressor starts at full load, over current may happen. Orifices are used to
maintain a suitable amount of oil flow into the cylinder. Solenoid valves (SV1 and SV2) for step-less control are
controlled by a micro controller or a temperature switch to modulate the position of the piston smoothly for loading, or
unloading or stable.
If solenoid valves and the piston do not work well in the capacity control system, this may result in capacity control
failure. Before compressors stop, HANBELL strongly recommends that the unloading solenoid valve for step-less
control system or the minimum-load solenoid valve for step control system should be kept opened for 30~60 seconds
so the piston in the cylinder can approach the minimum-load position for lighter duty in next start.
2.6.1 4-step capacity control system
There are three solenoid valves equipped that control compressor capacity from the minimum load (please refer to 2.2
for different minimum capacity in each model) to full load (100%). In general, normally closed (NC) solenoid valves are
used to control variation of loads. For the compressor with 4-step capacity control system, usual use the sequence of
min%-50%-75%-100% to load the capacity of compressor and use the sequence of 100%-75%-50%-min% to unload
the capacity.
(A) Suction and sealing
(B) Compression
(C) Discharge

5
Figure 3: 4-step capacity control
Note: For 4-step capacity control system, Hanbell equips
normally closed (NC) solenoid valves as standard
accessory. To equip normally open (NO) solenoid
valves, please specify it to Hanbell when placing
orders.
2.6.2 Continuous (step-less) capacity control system
In continuous (step-less) capacity control system, a normally closed solenoid valve SV1 (for loading) and a normally
closed solenoid valve SV2 (for unloading) are equipped respectively as shown in Figure 4. These two solenoid valves
are controlled by chiller temperature controller or micro controller, the refrigeration capacity hence can be modulated at
anywhere within min% ~ 100%
It is very important for any controller to control loading and unloading in moderate condition. For smooth modulation,
HANBELL installs an orifice in loading oil line to prevent too fast loading.
Figure 4: Step-less capacity control
Note: 1. For continuous(step-less) capacity control system, Hanbell installs
one normally closed solenoid valve for loading and another normally
closed solenoid valve for unloading as standard. If it is necessary to
install other type of solenoid valves, please specify it to Hanbell
when placing orders.
2. To equip loading orifice or not depends on system applications,
please discuss it with Hanbell when placing orders.
4-step capacity
control system SV2(NC) SV3(NC) SV4(NC)
100%full load
Not
energized
Not
energized
Not
energized
75%of partial load
Not
energized
Not
energized energized
50%of partial load
Not
energized energized Not
energized
min%（for starting）Energized Not
energized
Not
energized
SV1(NC) SV2(NC)
Start Not energized energized
Loading energized Not energized
Unloading Not energized energized
Stable Not energized Not energized
25% or 30% or 35 %
partial load
50 % partial load 75 % partial load 100 % full load

6
V
Pd
Pd'
V
Pd<Pd'
P
Pd, Pd'
V
Pd=Pd'
P
Pd>Pd'
Pd'
Pd
P
2.6.3 Dual capacity control system (optional)
Hanbell can provide dual capacity control system which is compatible for 4-step & step-less capacity control for
customers’ ease of change as shown in Figure 5, and its control logic is the same as explained in either 2.6.1 or 2.6.2.
2.7 Compressor volume ratio (Vi)
The volume ratio (Vi) of the compressor can be defined as the ratio of suction volume to discharge volume in the
compressor. The smaller the concavity of slide valve in the discharge end, the larger the volume ratio. The volume ratio
directly affects the internal compression ratio (Pi). 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.
CR =Pd/Ps
Pi = Vi k
Vi = Vs/Vd
CR: system compression ratio Pi: internal compression ratio
Vi: internal volume ratio Pd: system condensing pressure (absolute pressure)
Pd’: discharge pressure (absolute pressure) Ps: suction pressure (absolute pressure)
Vs: suction volume Vd: discharge volume
K: refrigerant specific heat ratio
2.8 Application limits
Compressor application limits vary significantly with types of refrigerant used. Application limits shown below are based
on operating conditions, i.e. saturated suction and discharge temperatures. For continuous long-term operation , it is
important to operate within these limits to maintain compressors’ life expectancy. Operating at extra low saturated
suction temperatures may cause oil management and motor cooling problems, while operating at extra high saturated
condensing temperatures may shorten compressors’ lifetime due to insufficient motor and compressor chamber cooling.
.
Under com
p
ression
(
CR > Pi
)
Over com
p
ression
(
CR < Pi
)
CR = Pi
Loss of work Loss of work
1 2
3
4
Ps
1 2
3
4
Ps
Ps
1
2
3
4
Figure 6: P-V Diagram
Fig. 5 Steps & Step-less control
Figure 5: Solenoid valves for dual
capacity control

7
R134a Application Limits R22 Application Limits
R407C Application Limits R404A&R507 Application Limits
Note:
1. Different types of motor, A1, A2, B1 and B2 applies to respective refrigerants and operating conditions as shown in
the above application limits.
2. When High Voltage series screw compressors operate under partial or full load within application limits, motor and
discharge temperatures will rise concurrently. In order to keep compressors’ continuous running safe, Hanbell
recommends using the following additional cooling devices :
(1) Oil cooler (2) Liquid injection to chamber
Please refer to Hanbell selection software for the application of additional cooling systems.
Hanbell recommends monitoring oil pressure differential and keeping it 4kg/cm2g over the suction pressure for
adequate seal, lubrication and capacity control by pressure differential switches passively or by additional oil pumps
actively. Especially under operating conditions with low condensing temperatures and high evaporating temperatures
like applications in water-cooled flooded chillers, high-low pressure differential tends to be less than 4kg/cm2g, The
installation of oil pumps is recommended to ensure regular oil supply.
Please contact Hanbell to verify potential operating conditions outside the application limits shown above.
3. The minimum discharge superheat is recommended to be kept 10K higher than the condensing temperature
(normally discharge superheat is around 20K for R134a and 30K for R22, R407C) to avoid liquid compression and
lubrication failure.