Hanbell Rtm-090 User manual

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Magnetic Centrifugal Compressor

RTM-090

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Contents

.....................................................................................................................................................................

Contents...................................................................................................................................................................2

Chapter 1. Introduction............................................................................................................................................4

Features ...............................................................................................................................................................4

Ambience.............................................................................................................................................................4

Chapter 2. Basic design...........................................................................................................................................5

2.1 Compressor nomenclature.............................................................................................................................5

2.2 Application limits..........................................................................................................................................5

2.3 Compressor specifications.............................................................................................................................6

2.4 Compressor outline........................................................................................................................................7

2.5 Connections...................................................................................................................................................8

2.5.1 Suction/discharge/economizer flange size..............................................................................................8

2.5.2 Butterfly valve ......................................................................................................................................10

2.5.3 Check valve ..........................................................................................................................................11

3. Suction Structure...............................................................................................................................................12

3.1 Inlet Guide Vanes........................................................................................................................................12

3.1.1 Control of inlet guide vanes..................................................................................................................12

3.2 Vane actuator control ..................................................................................................................................13

3.2.1 Actuator data.........................................................................................................................................13

3.2.2 Electrical connections...........................................................................................................................14

3.2.3 Wiring...................................................................................................................................................14

3.2.4 Control info...........................................................................................................................................15

3.2.5 Troubleshooting....................................................................................................................................17

3.3 Capacity adjustment ....................................................................................................................................18

3.4

Equation of safety margin line...................................................................................................................18

3.5 Hot gas bypass (HGBP)...............................................................................................................................19

3.6 Middle pressure stop valve..........................................................................................................................20

4.1 Motor cooling..............................................................................................................................................21

4.1.1 Heater....................................................................................................................................................21

4.1.2 Pt100 Thermostat..................................................................................................................................21

4.2 Liquid returned from motor and bearings....................................................................................................22

4.3 Motor Temperature Control.........................................................................................................................23

4.4 Motor connection.........................................................................................................................................23

4.4.1 Voltage & Frequency............................................................................................................................23

4.4.2 Components of inverter ........................................................................................................................23

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4.4.3 Grounding.............................................................................................................................................24

4.4.4 Cable of main power input....................................................................................................................25

4.4.5 Connection notice.................................................................................................................................26

4.5 MCC (Maximum Continuous Current) of motor.........................................................................................26

5. Control line connection .....................................................................................................................................27

5.1 Magnetic Bearing Controller (MBC) info...................................................................................................28

5.2 MBC installation notice...............................................................................................................................28

5.4 MBC connection port..................................................................................................................................30

5.5 MBC connection data..................................................................................................................................31

5.5.1 Additional info. about connection port.................................................................................................31

5.5.2 Communication of MBC and PLC .......................................................................................................31

5.6 Total Harmonic Distortion (THD) info.......................................................................................................31

5.7 THD installation & fix.................................................................................................................................32

5.8 THD connector............................................................................................................................................33

5.9 Variable Frequency Drive (VFD) Connector..............................................................................................34

5.10 Parameter of inverter.................................................................................................................................34

6. Compressor lifting and installation....................................................................................................................35

6.1 Compressor lifting.......................................................................................................................................35

6.2 Compressor installation...............................................................................................................................35

7. Instructions........................................................................................................................................................37

7.1 Accessories..................................................................................................................................................37

7.2 Valves..........................................................................................................................................................37

7.3 Testing before power supply .......................................................................................................................37

7.4 System requirement.....................................................................................................................................38

7.5 Control requirement.....................................................................................................................................38

7.6 Others ..........................................................................................................................................................38

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Chapter 1. Introduction

This manual is intended as a guide for application engineers, consultants, sales engineers, and

HVAC designers to use Hanbell RTM series centrifugal compressors. The copyright of this technical

manual belongs to Hanbell Precise Machinery Co., Ltd.. Neither this publication nor any part of it may

be reproduced or transmitted in any form or by any means without the prior permission of Hanbell

Precise Machinery Co., Ltd..

Features

Refrigerant – R134a

Compressor – semi-hermetic design

Shaft –made of high-strength alloy

Impellers – closed type made of high-strength aluminum

Bearings – magnetic bearings

Motor –permanent magnet synchronous motor, independent cooling by liquid refrigerant

Enclosure - IP54 protection

Ambience

RTM series compressors should be stored and operated within the following ambient temperature.

Storage

：

-25℃~55℃

Operation(Water-cooled)

：

2℃~14℃；CT：15℃~55℃

Note：

Please refer to “Application limits” in chapter 2 for allowable operating conditions and Hanbell

selection software for detailed performance data.

2. For special application limits, please contact Hanbell.

3. Chapter 7 contains instructions for the use of other AC electrical components.

4. In a humid environment, the compressor housing and piping should be insulated to prevent

condensation.

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Chapter 2. Basic design

2.1 Compressor nomenclature

0：Air-Condition，△T=SCT-SST=30℃

1：Heat-Pump，△T=SCT-SST=40℃

RTM- X X X

Model

Magnetic Bearing Centrifugal Compressor

2.2 Application limits

0 2 4 6 8 10 12 14 16 18 20 22

Saturated Condensation Temperature (℃

℃

℃)

Saturated Evaporation Temperature (℃

℃℃

℃)

Pr=3.0

Pr=2.5

Pr=2.0

Pr=1.5

Figure 2.1 RTM-090 application limits

Note: Please refer to the latest compressor selection software for specific compressor capacity.

Note: This range represents the range of FLA at

380V, and the limits for maximum condensation

temperature (SCT) and evaporation temperature

(SST) depend on the full load current and the

axial thrust of the compressor.

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2.3 Compressor specifications

Model RTM-090

Refrigerant R134a

Nominal cooling capacity USRT 400~450

Compressor

Type

Two-stage compression

Axial guide vane

control IGV 20~100% continuous

Frequency Hz 225

Motor

Type

3 Phase, 2 Pole, Permanent magnet

Starting

VFD

Voltage V 380~460±5%

Insulation

Class H

Protection

PT100*6

Transmission

Type

Direct-driven

Lubrication

Oil free

Dimension (LxWxH) m 1.3 X 0.8 x 0.7

Weight kg 1050

Hydrostatic pressure test kg/cm²g 22

Refrigerant heater kW 1x 0.3

Table 2.1 Compressor specifications

RTM-090 Performance

USRT RPM COP IPLV

400 13,000 6.53 11.0

450 13,500 6.33 10.5

Table 2.2 Compressor performance

Note: The performance is based on AHRI condition assuming a discharge check valve is installed.

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2.4 Compressor outline

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2.5 Connections

2.5.1 Suction/discharge/economizer flange size

Figure 2.3 Flange

Position Size

A B D E F G Piping

thick.

(JIS)

(GB)

RTM-090

Suction 8" 218

221.5

305 350 30 12 25 11

Discharge

6" 167

170.5

260 305 28 12 25 10.5

Mid.-

press.

(Eco.)

2 1/2"

77.5

140 175 20 8 19 7

Remarks ※Material- standard JIS 20kg/cm²g steel

unit: mm

※Thickness must be equal to the standard or larger

Table 2.2 Flange dimensions

Note：

1. Please weld steel pipes onto flanges by butt-welding and make sure debris has been cleaned,

otherwise the compressor might be damaged during running. Flow velocity in the discharge

side of the compressor could be as high as 15~20 m/sec. High-speed discharge gas will

make noise in discharge connection. In order to decrease the noise level, it’s recommended

to round sharp edges of joints of piping as shown in Figure 2.4

2. The discharge and suction piping is recommended to be one size larger to reduce pressure

drop and noise level. If the noise level is high in discharge side, it is suggested to increase

the piping thickness or enclose with acoustic foam shown in Figure 2.5.

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Figure 2.4 Discharge and suction piping

Note: Residue from welding might damage the compressor seriously.

1防熱橡膠

2鉛板層(2~3mm)

3隔音棉

4表層膠帶

Figure 2.5 Enclosure of piping connection

Heatproof rubber

Laminated lead

(2~3mm)

Acoustic foam

Gummed tape

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2.5.2 Butterfly valve

For easy maintenance, the butterfly valve can be installed in condenser inlet and liquid line before

expansion valve. When installing butterfly valve, the pipe must also be enlarged one size to effectively

reduce the pressure drop.

Butterfly valve

size A B C D E F G H J K L

2 1/2〞

65mm 121 48 58 97 162 111 16 11 32 64 20

3〞80mm 133 48 73 104 168 111 16 11 32 64 20

4〞100mm 171 52 94 120 191 111 16 11 32 64 19

5〞125mm 191 57 122 129 191 130 19 13 32 114

6〞150mm 219 57 149 141 203 130 19 13 32 114

8〞200mm 273 61 198 176 241 130 22 16 32 114

10〞250mm 332 70 248 217 273 155 30 22 51 114

Remark

※Dimension C is minima size when the valve opened totally unit：mm

※Operation Temp.：-29℃~260℃；Operation Pressure：1480psi

※Material- ASTAM351 GR CF8M stainless steel. Pressure level: ASME 150

※The butterfly valve is of wafer plate valves. Use ANSI 150 standard flange

Table 2.3 Flange size

Figure 2.6 Outline of butterfly size

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2.5.3 Check valve

To avoid the reverse rotation caused by emergency shutdown and protect active magnetic bearing

(AMB), under high-speed compressing, installation of a check valve installed in the discharge side is

necessary.

Size A(mm) B(mm) C(mm) E(mm)

6〞150mm 222.2 120.7 95.3 70

8〞200mm 279.4 163.5 116.7 74.6

Remark

※Operating temp.：-260℃~810℃

Hydraulic pressure testing: 31.6kg/cm

(API-598)

※Material - ASTAM351 GR CF8M stainless steel. Pressure level : ASME 150

※The check valve is of wafer plate valve. Use ANSI 150 standard flange

Table 2.4 Check valve size

No. Name Material

1 Valve CF8M

2 Disc shield A351- CF8M

3 Spring SUS316

4 Alignment pin SUS316

5 Bearing PTFE

6 Bolt SUS316

7 O ring PTFE

8 Eye ring A105

Figure 2.7 Pendulum check valve outline

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3. Suction Structure

3.1 Inlet Guide Vanes

The cooling capacity of RTM Series centrifugal compressors is modulated with change in angles of

inlet guide vanes. As illustrated in Figure 3.1, Refrigerant gas from the evaporator outlet flows through

the suction nozzle to the compressor suction inlet. After the inlet nozzle, gas flow velocity increases

due to the narrow passage. By changing angles of IGV, velocity and volume are changed as well as

cooling capacity.

Figure 3.1 Compressor inlet

3.1.1 Control of inlet guide vanes

Angles of inlet guide vanes are automatically controlled through a vane actuator with a lever arm, and

IGV opening ranges from 20% (minimum load) to totally open.

Opening of the vane actuator in percentage (%) has a linear relation to the control signal voltage.

However, cooling capacity does not relate the angle changes of guide vanes. Therefore, vane actuator’s

opening in percentage (%) is not the same as the cooling capacity in percentage (%)

Note 1：When inlet guide vanes are completely closed, a small hole will be formed in the middle to

keep a basic amount of gas flow into the compressor. When inlet guide vanes are fully closed,

only Min. mass flow passes so the smallest cooling capacity will be established.

Note 2：The lower pressure ratio stands for the lower minimum unloading capacity.

Actuator

Inlet guide vane

Impeller Suction

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Remark：1. IGV should be fully opened before start up. When HGBP opened before stop，please keep

IGV fully opened.

2. IGV operating range is 20%~100%.

3. Actuator signal feedback window:

Figure 3.2 OPEN Figure 3.3 SHUT

3.2 Vane actuator control

3.2.1 Actuator data

RATED POWER 1Phase, AC 220V±10%(50/60Hz)

1Phase, AC 110V±10%(50/60Hz)

INPUT SIGNAL 4~20mA‧DC；1~5V‧DC

OUTPUT SIGNAL 4~20mA‧DC

OUTPUT TORQUE 49N‧m(5kgf‧m)

OPERATION SPEED 15sec(50Hz)；12.5 sec(60Hz)

TRAVEL ANGLE 0~90°

RATED OPERATION TIME Continuous (100%)

RESOLUTION Over 1/250

DEAD ZONE Max. 0.5%

PROTECTION Motor thermal protector (120ºC)

AMBIENT TEMPERATURE Ambient temperature within: -25~55ºC

RATED CURRENT 0.4A(220V)；0.7A(110V)

MOTOR 20W

INSULATION GRADE Class E

INSULATION RESISTANCE Between power terminal – case : 500V·DC / 100MΩ

WITHSTAND VOLTAGE Between power terminal – case : 1500V·AC / 1 minute

WIRE INLET

G1/2×2

ENCLOSURE PROTECTION

NEMA-4X (IP-66)

WEIGHT

4.5kg

Table 3.1 Actuator data

Note：When operating at ambient temperature under 0℃, optional space heater is required to keep the

actuator inside dry. Otherwise, moisture may condense under low temperature and high humidity or

parts may shrink at low temperature.

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3.2.2 Electrical connections

When using standard wire wiring, cable diameter should be Φ9 ~ Φ11; if other wire is used, please

select the appropriate cable diameter, otherwise the water may penetrate.

Figure 3.2 Wiring diagram (220/110V)

Remark：1. 5A fuse or breaker should be installed in main power supply. Voltage stabilizer is required

to avoid the damage caused by the imbalance of voltage. (within 10%)

2. Signal wires for control should be shielded to prevent them from interference.

3. The actuator wiring shall not be parallel to the power cables.

3.2.3 Wiring

Make effective water proof if vinyl tubes or conduits are used：

Figure 3.3 Wiring

Cable gland

Protection cable

Single phase power source

(220/110V, 50/60Hz)

Output signal

4~20mA DC

Input signal

4~20mA DC

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3.2.4 Control info.

Figure 3.4 Control pack

Figure 3.5 Switcher

Select switch for off mode

Select switch for action mode

External terminal block

SPAN volume

Zero volume

Sensitivity volume

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※Direction mode

Either direct or reverse action is selectable at this switch.

※Selection of a mode during signal interruption：

A mode among open/stop/close is selectable at this switch in case of signal interruption

Note：When the input signal is less than 2mA, the actuator is judged to be interrupted and transferred

to the specified state, so the control device and signal 4~20mA must be adjusted correctly.

Select switch for action mode

Select switch for off mode

1 = Direct action

Input signal 20mA → Close

Input signal 4mA → Open

3 = Reverse action

Input signal 4mA → Open

Input signal 20mA → Close

Select switch 1 = Close action

Select switch 2 = Stop action

Select switch 3 = Open action

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※

Sensitivity volume：

※

ZERO/SPAN Setting：

Remark：

1. Before the compressor is shipped out from the factory, the zero and span knobs have been adjusted

to the best position. Do not adjust if not necessary. If adjustment is required, please use a small

screwdriver to turn gently (excessive force will cause damage in the knob).

2. When adjusting IGV, turn to the fully-close position and then do fully-open position adjustment.

※Note：Because the forward turn of the actuator is opposite to the IGV connecting rod’s, the zero

knob is fully opened while the span knob is fully closed. To avoid risk, this adjustment should be done

by qualified personnel.

3.2.5 Troubleshooting

TROUBLE

PROBABLE CAUSE

SOLUTION

Motor does not start up

Power failed or dropped

Signal failed or dropped

Wire broken or disconnected

Thermal protector functioned

Limit switches functioned at an intermediate

position

Motor advancer defective

Control pack defective

Check and supply power

Check and input signals

Change the wire or re-connect the

terminal

Lower the ambient temperature

Decrease duty rate

Eliminate overload at valve

Re-adjust the limit cam

Change advancer (condenser)

Change control pack

Sensitivity volume

* Sensitivity volume

Clockwise for higher

Counter clockwise for lower

* Max. sensitivity:

Resolution = 1/400

* Min. sensitivity:

Resolution = 1/100

SPAN Setting

ZERO Setting

* ZERO volume

CW = To increase (to OPEN direction)

Adjustable range - 25 ~ +25 %

* SPAN volume

CW = To increase (to OPEN direction)

Adjustable range - 50 ~ +200 %

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Aperture unfixable

(Hunting)

Noise on signal line

Noise on potentiometer

Potentiometer and opening gear loose

Check input signal

Change potentiometer

Check the fixing screws

Aperture does not match

input signal

A wrong signal input

Improper adjustment of ZERO/SPAN

Potentiometer slipped

Check the input signals

Re-adjust ZERO/SPAN

Re-adjust the aperture on the

potentiometer

Aperture signal does not

output

The opening signal is broken or poorly

connected Check the wiring connection

3.3 Capacity adjustment

According to AHRI standard, the capacity control range is 100%~25%. To achieve the best

performance, please follow the equation of safety margin line (refer chapter 3.4). The compressor

loading/unloading will work with the control of IGV：

1. Speed control：In general, cooling capacity will change about 2% by adjusting 1 Hz, or 2% of

leaving chilled water temp. change (approx. 0.1℃). Please refer to the following table：

Target leaving chilled water temp.: 7℃

Range ＜6.3℃6.3℃~6.8℃

6.8℃~7.2℃

7.2℃~7.8℃

＞7.8℃

Control mode Fast unloading

unloading Neutral Loading Fast loading

Inverter output -1Hz -0.5Hz 0 +0.5Hz +1Hz

2. IGV control：When the frequency reaches to surge line, the unloading will be controlled by IGV.

3. The control for target water temp. is based on input signal, and output signal is used for setting the

frequency and opening of IGV. It is suggested to install anti-interference devices on chiller unit.

3.4 Equation of safety margin line

Description of Surge：

When the centrifugal compressor is at part load, the angle of guide vane becomes smaller and

refrigerant volume entering compressor also reduces; when the volume flow decreases to a certain

extent, surge and stall may occur. As shown in Figure 3.6 Typical fixed-frequency compressor

performance map, when compressors operate above the Surge Line, stall or surge may occur. When

the compressor surges, discharge pressure drops suddenly lower than the pressure in condenser so

high-pressured gas flows reversely to the compressor; therefore, gas flows inside the compressor

turbulently and it causes higher vibration and noise. Meanwhile, heat cannot be dissipated and

refrigerant gas cannot be cooled down; high temperature inside the compressor may cause severe

damage to high-speed shaft. In addition, alternatively varied pressure due to reverse flow may

influence compressor’s moving parts so bearings may bear heavier load and be damaged. Therefore,

compressor’s operating map must be confined below the Surge Line. Please refer to Hanbell selection

software for more details of allowable compressor operating map to prevent surge.

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Equation of safety margin line is a polynomial of IGV actuator’s opening in percentage.

While operating, beware the pressure difference exceed the safety margin.

z= a+b/x+cy+d/x2+ey2+fy/x+g/x3+hy3+iy2/x+jy/x2

1. a、b、c、d、e、f、g、h、i、j are constant

2. z=Hz(minima operating frequency)；x= opening of IGV (%)/10；y= pressure ratio

Note：

1. When doing the minimum operation frequency calculation, 2~3Hz buffer will be considered.

2. Safety margin on each model is not the same, please contact HANBELL representatives.

3.5 Hot Gas By Pass (HGBP)

Hot gas bypass is to bypass gas refrigerant or liquid refrigerant from condenser into evaporator

through a proportional valve.

Function: When the load reaches certain value the surge would happen. To continue the low load

operation, the hot gas by pass valve can be opened to increase suction pressure and lower

discharge pressure as well as compression ratio.

Because hot gas bypass is to transfer compressed gas from the condenser (high-pressure side) to the

evaporator (low-pressure side), enormous noise may occur. It is recommended to enlarge the inner

diameter of piping after the HGBP valve to keep flow speed under 10 m/sec.

13500 rpm

13000 rpm

11700 rpm

10400 rpm

9100 rpm

7800 rpm

IGV 100%

13500 rpm operation

range at different IGV %

Operation range

IGV100% operation range

at different rpm

Pressure Ratio (Pr)

Cooling Capacity (kW)

Figure 3.6 Operating range

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In piping, the proportional valve should be installed as close as possible to the evaporator, and also at

another side of suction entry (motor side) to lower the noises.

Besides, a muffler or shield should be installed at the evaporator to prevent splashed liquid refrigerant,

which may damage the compressor.

Note1: The system with hot gas bypass is inefficient. It should be avoided whenever possible. Many

system applications still require hot gas bypass in order to avoid surge or maintain constant

chilled water temperatures from zero load to full load.

Note2: Required flow for HGBP depends on the difference between required minimum cooling

capacity and the minimum load compressor can reach. If the IGV is at minimum opening and

cooling capacity is 50%, and end user needs 20%. The pipe diameter and flow need to be

considered based on the 30% difference.

3.6 Middle pressure stop valve

Between the ECO port of the compressor and the economizer, it is recommended to install a stop valve

near the middle pressure port, it will avoid liquid goes back to compressor ECO port when compressor

running at partial loading. Under partial loading, liquid refrigerant entering the economizer might be

poured into the ECO port instead of the suction port.

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