Hanbell Screw Compressors Service Manual
Contents
1. i B H I L O O N Y 4 D S H z al J K OO easy Q 0 l L3 9 P TB IN pm Jj 9 x H N 7 L Y P q L N 49 H IN H E m i 2 H NS 1 11 1 H e 0 J D 4 LI N F H T 59 RC19 RC21 Outline Drawings i i Y 1 i aL Sy na IF 1 ror d d 1 1 L O O 115 j 5 L _ 6 DIMENSION UNIT mm NNERGEASEREANNE BUR ws mmus sus 265 sw 955 ms sr mes sus messo 252. Test Cm p so sidus 18 19 RC20 21 22 23 24 Displacement rc 735 598 952 774 1024 832 1310 1089 1536 1277 1832 1522 Rated Rated Speed rpm 3550 2950 Capacity 4 steps or 25 100 continuous capacity control system Lubrication Differential pressure feed lubricant Type 3 Phase 2 Pole Squirrel Cage Induction Motor ET nen no 2 Oil Heater Hydrostatic Pressure ke cm G 42 Test 1220 imo 1630 2 2 CONSTRUCTION HANBELL semi hermetic twin screw compressors are constructed with the following three major components the compressor compartment the hermetic motor compartment and the oil separator compartment The compressor compartment includes twin screw helical rotors bearings components for capacity control system B The hermetic motor compartment includes the motor stator motor rotor six terminal plugs for electric power connections an internal thermostat inserted into the stator coil to protect the motor from burning out two terminal plugs for the thermostat and a suction gas strainer C The oil separator compartment consists of demister and chambers to serve as an oil separator and an oil reservoir The rotor of the hermetic motor 15 connect
3. SCREW COMPRESSORS HANBELL SCREW COMPRESSORS Service Manual 26 March 2003 Web www hanbell com CONTENTS 1 SCOPE 2 DESCRIPTION OF DESIGN 2 1 Compressor Specification 2 2 Construction 3 OPERATIONS AND MAINTENANCE 3 1 Important Instruction 3 2 Pre start Checklist 3 3 Compressor Start up 3 3 1 Start up Limitations 3 3 2 Starting Current Continuous Current 3 3 3 Running Restraint of Compressor 3 4 Protective Devices 3 5 Troubleshooting and Maintenance Schedule 3 6 Tightening Torque Wrench and Tolerance 3 7 Lubricant 3 7 1 Precautions 3 7 2 Changing Oil 3 7 3 Oil Level 3 8 Maintenance Space 4 DISASSEMBLY PROCEDURES 4 1 Work Preparations 4 2 Oil Purges 4 3 Suction Sealed Flange Filter 4 4 Electrical Cover Plate 4 5 Motor Casing Motor Rotor 4 6 Oil Filter Oil Switch Cover 4 7 Oil Separator 4 8 Discharge Cover Plate Piston Spring Rod 4 9 Bearing Seat Bearing Slot Nut 4 10 Male and Female Suction Bearings 4 11 Slide Valve Solenoid Valve 4 12 Screw Rotor Discharge Bearings 4 13 Motor Stator 4 14 Cleaning of Components 5 REASSEMBLY PROCEDURES 5 1 Bearing Seat Rotor Discharge Bearings 5 2 Suction Bearings 5 3 Slide Valve Solenoid Valve 5 4 Compressor Casing 5 5 Piston Rod Spring Cover Plate 5 6 Motor Rotor 5 7 Motor 5 8 Terminal Cover 5 9 Oil Separator 5 10 Oil Filter Oil Switch 5 11 Suction Sealed Flange Filter 5 12 Oil Charge 6 LIST
4. 9 wi Un gt 7 M9 BEARING SLOT NUT MALE DISCHARGE BEARING AXIAL MALE ROTOR ALANCE PISTON ALE ROTOR OTOR ROTOR KEY IL GUIDING RING MALE ROTOR UCTION BEARING MALE ROTOR INNER SPACER RING OF SUCTION BEARING MALE ROTOR OUTER SPACER RING OF SUCTION BEARING MALE ROTOR UCTION BEARING MALE ROTOR OTOR ROTOR OTOR ROTOR SPACER RING OTOR ROTOR WASHER PRING WASHER OLT FOR MOTOR ROTOR FIXED 41 DISC SPRING FEMALE ROTOR 42 DISCHARGE FIXED RING FEMALE ROTOR 43 M6 BEARING SLOT NUT FEMALE ROTOR DISCHARGE BEARING OF FEMALE ROTOR AXIAL NNER SPACER RING OF FEMALE ROTOR OUTER SPACER RING OF FEMALE ROTOR 45 zioizzimgEEZxEEZsEssos5szzsoESSSOOGO Un Un e e 22 A A les wasi gt lt 22 5 R gt gt gt gt 5 RC12 15L PARTS LIST PART NAME DISCHARGE BEARING OF FEMALE ROTOR RADIAL EMALE ROTOR IL GUIDING RING FEMALE ROTOR UCTION BEARING FEMALE ROTOR EARING SEAT ASKET OF DISCHARGE EXHAUST TUBE OLT FOR BEARING SEAT IX PIN LUG OLT FOR SLIDE VALVE KEY LIDE VALVE KEY LIDE VALVE OLT ERVICE FLANGE ASKET OF SERVICE FLANGE AGNETICS OMPRESSOR CASING IL FILTER NNER GASKET OF OIL FILTER FLANGE UTER GASKET OF OIL FILTER FLANGE IL FILTER FLANGE OLT IL HEATER 220V OWER BOLT OWER BOLT O RING OPPER NUT FOR POWER BOLT PRING WASHER OPPER NUT CREW FOR PTC WIRING T
5. 93 _ 94 _ 95 _ 96 _ 98 _ p 100 101 102 103 104 105 106 107 _ 108 109 110 75 RC 12 RC17 EXPLODED DRAWING 76 19 21 EXPLODED DRAWING 77
6. necessary to check the oil acidity after 72 hours operation and changes it until the value 15 in the standard level Table 15 shows oil replacement standard Table 15 Oil replacement standards Total acid number Color ASTM Above 6 0 0 5 Particle matters mg 100 Copper strip 100 C 3hrs ADONE E Viscosity 40 Moisture ppm Above 100 3 7 2 Changing oil Lubrication 15 one of the most important factors in the compression system in order to maintain the good running condition of the compressor It used to lubricate the rotating element of the compressor and it also cools and seal the system it 1s the driving force of the piston to move back and forth Following 1s the problem that may exist 1n the system 1 Clogged oil filter caused by contaminated oil 1 e debris or swarf 2 Corroded motor caused by moisture acid inside 3 Spoiled oil due to the compressor running at long duration of high discharge temperature causing the bearing life to shorten Following 1s the time period for changing the oil 1 Change oil periodically Check oil for every 10 000 hrs running period Change the oil and clean the oil filter after 20 000 hrs running period It is recommended to check the oil after 2 500 hrs running period or year because of the piping debris and swarf that can accumulate inside the system 2 To prevent the debris and swarf to clog oil filter an oil pressure differ
7. w Y S pues Fig 2 3 3 1 Start up limitations A Lowest starting voltage The power voltage cannot be lower than 10 of the rated voltage during the starting up period of the compressor B Maximum discharge pressure 18kg cm2 G C Minimum suction pressure 6 8kg cm2 D Maximum designed discharge pressure 28kg cm2 G E Maximum designed discharge temperature 110 C 3 3 2 Starting current continuous current of compressor LRA MCC The current of motor coil stator energized with rated frequency and voltage during the motor rotor locked so the starting current 1s the same as the locked rotor ampere LRA Starting current of RC compressor LRA for R22 R404A R407C 507 380V 60Hz 380V 50Hz RC10 1030 RCI4 600 5 600 0 RCISL ao 0 Maximum continuous current RC compressor for R22 404 407 R507A Maximum continuous current RC compressor for R134a 380V 60Hz 380V 50Hz 380V 60Hz 380V 50Hz 5 5 5 5 5 5 510 425 24 30 39 42 42 42 42 NOTE Please refer to the latest HANBELL SELECTION PROGRAM for more information regarding the Electrical data Contact sales department e mail address sales hanbell com 3 3 3 Running restraint of compressor A The starting for the Y start 1s usually set at 4 1 second and the maximum allo
8. 4 7 f ix A 2 Z 2 A K B ES N 2 _ i E N Boles Tp SE za 112 109 109 5 55 59 76 105 6 34 60 75 105 18 105 212 134 14 5 85 89 111 125 6 55 90 10 140 18 140 3 153 153 5 95 99 122 135 6 66 100 120 M20x25 160 22 160 42 171 120 124 146 135 6 805 125 145 M20x25 185 22 185 Ne oT De 66 Specification and dimension of check valve B Ss NS Diameter 52 1 2 Body Guide seat Item Unit mm Dimension 176 150 10 7 M 16 bolt C clipper O ring Spring 3 4 5 Valve plate Rod Valve plate Gasket 67 7 5 CHECKLIST MODEL COMPRESSOR TESTING CHECK LIST NEN TEST Between Phase U Z V X W Y 1221 Protector 0 W USED 1000DCV 2000Mega ohms the reading be greater than 100 2 check if the compressor have sufficient oil before testing FOR TESTIN 3 When using Generator be sure that the voltage frequency are the same as compressor specs Be sure the compress
9. IT PART NAME 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 3l 32 33 34 35 36 37 38 39 lt TY ASHER ISTON OPPER WASHER ISTON S O RING ISTON RING ISTON ROD ALID PISTON SPRING INNER ALID PISTON SPRING OUTTER ISC SPRING MALE ROTOR ISCHARGE FIXED RING MALE ROTOR r3 gt w 7 ea Un p 7 lt gt e ISCHARGE BEARING AXIAL MALE ROTOR ISCHARGE BEARING RADIAL MALE ROTOR ALANCE PISTON MALE ALE ROTOR EY OF MOTOR ROTOR IL GUIDING RING MALE ROTOR UCTION BEARING MALE ROTOR UTER SPACER RING OF SUCTION BEARING MALE ROTOR NNER SPACER RING OF SUCTION BEARING MALE ROTOR UCTION BEARING MALE ROTOR OTOR ROTOR OTOR ROTOR SPACER RING OTOR ROTOR WASHER PRING WASHER OLT FOR MOTOR ROTOR FIXED ISC SPRING FEMALE ROTOR ISCHARGE FIXED RING FEMALE ROTOR un 41 42 43 lt EN gt 7 e Un 7 e lt gt am 77 Z 45 ISCHARGE BEARING OF FEMALE ROTOR LONGITUDINAL ISCHARGE BEARING TRANSVERSE FEMALE ROTOR ALANCE PISTON FEMALE EMALE ROTOR IL GUIDING RING FEMALE ROTOR UCTION BEARING OF FEMALE ROTOR TRANSVERSE EARING SEAT ASKET OF DISCHARGE EXHAUST TUBE OLT FOR BEARING SEAT IX PIN LUG OLT FOR SLIDE VALVE KEY LIDE VALVE KEY LIDE VALVE 47 50 51 52 53 54 55 56 57 58 IL LEVEL SWITCH SET ASKET OF SERVICE F
10. for loosening bearings 4 CRAAAB44 12 1 5 Tool for Bearing assembly 2 CRAAABIA 50 RC12 RC13 RC14 15 RC16 17 RC19 21 6 Male Rotor Assembly Fixed Gauge CRAAAAI10 Model B 60 WWE NM M RCI4 ISL 80 RCI9 21 105 83 223 6 516 550 7 Plate Tool for loosening bearings CRAAAB20 51 NU B 30 __60_ 7313 210 200 55 65 8 Trumpet Shape tool for Tiehtenino Suction bearines CRAAAB30 38 12 13 PRESS RCI4 15L PRESS 16 17 PRESS RC19 21 PRESS 19 si 9 7 D 160 160 160 160 160 160 160 160 _ s ss 957 es os 9 B TYPE NU tool for loosening NU Bearings CRAAAB31 32 59 m 10 Tool for tightening NU bearing inner CRAAAB90 RCI921Male 330 70 60 2 11 Tool for tightening NU bearing inner ring 91 53 12 Slot Nut Tightening Gauge for Male Rotor CRAAAB60 0 1 0 0 02 CN 0 0 05 5 mum SS 0 05 SG 3 4 ENS BE Zk A ES TET ETE 0 0 05 mw wee ey 5 6F 55 maa as dda ad
11. heat absorption in compressor as well The oil viscosity is recommended to keep over 15 mm s at any temperature If the compressor operated under the critical condition then extra oil cooler 15 required Some high viscosity oil 15 recommended to apply to the high working condition It happens more often that the return oil from evaporator 15 insufficient due to the high viscosity of oil which 15 difficult to be carried back that causes the loss of oil In the compressor If the system encounters the oil return problem then an extra 2 oil separator is recommended to installed between the compressor discharge tube and condenser 3 7 1 Precautions A Use only HANBELL s recommended oil brand and do not mixed together oil with a different brand Different kinds of refrigerant have different kind of oil required note that some synthetic oil are not compatible with mineral oil The screw compressor should be fill with clean oil before and after initial operation B For the chiller system that uses synthetic oil be sure that the oil 15 not exposed to atmosphere for a long time It is necessary to vacuum the system when installing the compressor C It 1s suggested to heat first the system in order to vaporized any moisture and then vacuum the system It 1s essential for the changing of new oil in the system especially after the motor burned out the acidity debris are still remain inside the piping so follow the procedure mention above It 1s 16
12. s su y 21 62 Pen Dimension of standard flanges Coupling Sizes of PE B C 41 6 44 8 suitable for Discharge flange of RC10 RC13 Suitable for Discharge flange of 2 RCIA RCISL And Suitable for Suction flange of R10 1 2 5 1 543 4 Suitable for Discharge flange of RC16 RC17 And Suitable for 2 Suction flange of R12 RC13 2 71 2 Suitable for Discharge flange of RC18 RC19 And Suitable for Suction flange of RC14 RCISL 5 CA 43 3 49 3 44 3 51 1 54 3 9 64 5 6 6 7 1 64 7 52 5 6 6 74 64 1 6 6 7 74 4 6 87 513 7 1 2 92 90 2 103 766 9 suitable for Discharge flange of ER 105 RC20 RC21 And Suitable for Suction flange of RC16 18 T 1 116 90 2 105 1028 115 6 128 ON ON ON ON Ti ON O Co oo of standard flanges Coupling Tube Sizes of pipes L _ 1 4 1 8 105 1 121 51 8 130 5 147 RC22 RC24 And Suitable for a 1305 Suction flange of RC19 R21 4 115 6 134 1413 154 Suitable for suction flange of 141 3 RC22 1667 Suitable for suction flange of 166 7 i BE
13. 1 m 2 Height 1 2m 1 5m Sound Level Meter 1 2m 1 5m Ground dd Table 14 Compressor accessories and torque setting Standard screw bolt Torque value Kg cm Mosor terminat piate xe imm ww _ 1 flange M16 200 1 000 1 000 2 flange M16 400 2 000 1 000 3 flange M20 550 2 500 2 000 4 flange M20 800 3 000 2 000 Oil sight glass P1 P3 plug 200 15 3 7 LUBRICANT The main functions of the lubrication oil in screw compressor are lubrication internal sealing cooling and capacity control The positive oil pressure in the cylinder pushes the piston and the slide valve which 15 connected by a piston rod to move forward and backward In compression chamber The design with positive pressure differential lubrication system In RC series 1s available to omit an extra oil pump in the compressor The bearings used in RC compressor required a small but steady quantity of oil for lubrication The oil injection in the compression chamber creates an oil sealing film in the compression housing for increasing the efficiency and absorbed a part of heat of compression In order to separate the oil from the mixed refrigerant gas an oil separator 15 required to ensure the least amount of oil carried into the system Pay more attention to the oil temperature which has a significant factor to the compressor bearings life High oil temperature will reduce the oil viscosity and caused poor lubrication and
14. 5 26 27 28 29 30 31 32 33 34 22 36 Disc spring Balance piston Bearing slot nut Male rotor Suction bearing Suction bearings inner outer spacer ring Oil guiding ring Oil level sight glass Oil filter cartridge Suction filter Oil heater Refrigeration lubricant Suction flange Discharge flange Cable box Power bolt Thermostat terminals Motor cable cover plate 3 OPERATIONS AND MAINTENANCE Before attempting to do some maintenance and troubleshooting the person in charge must have full knowledge and understanding of maintenance work of compressor or it should be an authorized technician from HANBELL 3 1 IMPORTANT INSTRUCTION A Before commencing any maintenance work the screw compressor unit must be put out of operation according to the operating instructions refrigerant should be removed and the unit must be depressurized B Preparations for maintenance work on the compressor are to be undertaken in such a manner that it is only necessary for the machine to be open for a short period C Utmost cleanliness during assembly is absolutely essential for continued trouble free operation D After maintenance and repair work has been completed the parts must be cleaned with an organically degreasing agent and treated with the refrigerating machinery lube oil of the same brand used in the plant 3 2 PRE START CHECKLIST Table 1 1 Oil level 1 Higher than the middle line of oil lev
15. 6 for the tool 5 Loosen the bearing slot nut of the male rotor and then the female rotor Then remove the rotor assembly fixed gauge Fig 13 3 13 4 6 Use an 2 screw bolt to separate the bearing seat from the compressor casing Fig 13 5 7 Put two eyebolt on top of the bearing seat then lift it slowly using an overhead crane Fig 13 6 TOOLS Hexagonal wrench spanner rotor assembly Fixed gauge overhead crane slot nut tightening gauge 4 10 MALE AND FEMALE SUCTION BEARINGS Refer to fig 14 14 3 1 Loosen the suction bearing fix ring of the male rotor Fig 14 2 Take out the suction bearing outer ring of male rotor by using the tool in page 51 item 7 Fig 14 1 3 Loosen the suction bearing fix bolt of the female rotor Fig 14 2 21 4 out the suction bearing outer ring of the female rotor Fig 14 3 TOOLS Hammer allen wrench trumpet shape tool 4 11 SLIDE VALVE SOLENOID VALVE Refer to Fig 15 15 2 1 Rotate the table with the discharge side in front Fig 15 2 Loosen the screw of slide valve key Fig 15 3 Pull out the slide valve Fig 15 1 4 Loosen the solenoid screw then remove the solenoid valve and the two O rings in the solenoid valve Fig 15 2 NOTE Replace all the O rings and gaskets after every dismantling or maintenance of the compressor 28 4 12 SCREW ROTORS BEARINGS Refer to Fig 16 16 7 1 Use a cylindrical drum and put it o
16. 8 2 Do the same procedure in cleaning the male and female rotors and the motor rotor Fig 18 1 18 2 3l 5 REASSEMBLY PROCEDURES 5 1 BEARING SEAT ROTORS BEARINGS Refer to Fig 19 19 30 Lift the compressor casing using an overhead crane and put it on the adjustable table with the suction side in front and screw the two base to fixed it temporarily Rotate the table to about 90 with the discharge side on top and clean the compression chamber using air Fig 19 2 Check the dimension of the male rotor neck and bearing seat neck to get the correct balanced piston size Fig 19 1 3 Check the dimension of the female rotor neck and bearing seat neck to get the correct inner and outer spacer ring Fig 19 2 CALCULATIONS ON HOW TO GET A BALANCE PISTON AND SPACER RING EQUATION D1 D2 C2 2 0 12mm BN balance C1 0 12mm T2 D1 C2 D2 0 12mm WHERE D is for balance piston DI is for inner spacer ring D2 is for outer spacer ring FOR BEARING SEAT FOR SCREW ROTORS Fig 19 C1 is for male hole T1 is for male rotor C2 is for female hole T2 is for female rotor Fig 19 1 Fig 19 2 4 Clean the male and female rotors using oilstone and wipe it with clean paper Fig 19 3 19 4 Fig 19 3 Fig 19 4 32 5 Lift the male rotor first and put it on the compressor casing and check the clearance of the rotor to the casing Fig 19 5 6 Put the female rotor in the compressor casi
17. C WIRING SCREW O RING OLT FOR MOTOR CABLE COVER PLATE OTOR CABLE COVER PLATE ASKET FOR MOTOR CABLE COVER PLATE ITE lt 47 50 51 52 53 54 55 56 57 58 59 61 62 63 65 67 70 71 72 73 74 75 76 77 QO 79 ASHER OLENOID COIL OLENOID VALVE STEP CONTROL OLENOID VALVE O RING OLT APILLARY 0 ELBOW LUG LUG O RING 8 CONNECTOR IL SIGHT GLASS O RING INCLUDED UCTION FIXED RING MALE ROTOR 81 82 83 85 87 88 ASHER PRING WASHER 91 gt RC12 15L PARTS LIST PART NAME OLT OLT FOR MOTOR STATOR GUIDE VANE OTOR STATOR GUIDE VANE OTOR STATOR IXED PIN OF MOTOR STATOR ASKET OF MOTOR CASING OTOR CASING OLT FOR MOTOR CASING 1 2 GASKET 3 FOR 14 151 UCTION FILTER ASKET 10 OPPER TUBE 106 SUCTION FLANGE 10 0 94 AD OF GUIDE VANE 96 98 99 9 9 9 9 1 1 7 2 a gt un nN ASHER 108 BOLT FOR SUCTION FLANGE X RC16 18 PARTS LIST PART NAME SKET NGLE VALVE OLT OLT SHER ISCHARGE FLANGE OPPER TUBE HECK VALVE IL SEPARATOR GASKET BOLT OIL SEPARATOR OLT END PLATE DISCHARGE COVER PLATE ASKET OF DISCHARGE COVER PLATE BOLT FOR SLIDE VALVE FIXED SPRING WASHER ASHER ISTON OPPER WASHER PISTON S O RING IS
18. CHARGE Before charging the compressor with refrigeration oil be sure to vacuum it first then filled it with dry nitrogen 0 3 0 5 Kg cm2 RC SERIES RCI4 15 RCISL 16 RCI8 RCI9 RC20 Lubricant 7 7 y 14 16 16 15 18 23 23 28 28 charge Lit 48 6 LIST OF TOOLS BEARINGS 6 1 LIST OF TOOLS RC SERIES COMPRESSOR 4 CRAAABA4 Circle Tool for loosening the bearings 4 CRAAABIA for Bearing assembly 2 CRAAAAI0 Male Rotor Assembly Fixed Gauge 7 CRAAAB20 Plate Tool for loosening the bearings CRAAAB30 Trumpet Shape tool for tightening Suction bearings 15 7 9 CRAAAB31 B TYPE NU tool for loosening NU Bearings 10 CRAAABOO Tool for tightening NU bearing inner ring CRAAABM Too for tightening NU bearing inner ring CRAAABOO Slot Nut Tightening Gauge for Rotor CRAAAB6L lot Nut Tightening Gauge for Female Rotor L H GRAAABT0 Press Tool for Piston Assembly 15 Motor Cable Cover Plate Lifter __16 ToolforPin s U Foo for Pin 10 11 12 13 14 15 16 7 1 Circle Tool for loosening the bearing 1 CRAAAB4I1 RC14 15F 2 Circle Tool for loosening the bearings 2 CRAAAB42 49 eco C D RC16 17 Male See er 164 3 Circle Tool for loosening the bearings 3 CRAAA B43 RC12 13M 73 aiia 38 4 Circle Tool
19. ER FLANGE IL FILTER FLANGE OLT IL HEATER 220V OWER BOLT OWER BOLT O RING OPPER NUT FOR POWER BOLT PRING WASHER OPPER NUT CREW FOR PTC WIRING TC WIRING SCREW O RING OLT FOR MOTOR CABLE COVER PLATE OTOR CABLE COVER PLATE ASKET FOR MOTOR CABLE COVER PLATE 50 51 52 53 54 55 56 57 58 59 155512 5 5 7 7 A m gt gt gt gt 77 7 wasi 7 7 ES gt gt gt gt gt gt gt lt gt gt S Vs un 61 62 63 65 70 71 72 73 74 75 6 7 J oc 79 ASHER NO RC16 18 PARTS LIST IT PART NAME un OLENOID COIL OLENOID VALVE STEP CONTROL PLUG O RING 1 1 1 0 101 20 102 103 104 105 106 107 108 W 81 eu x 80 _ MEE E 86 __ 89 _ 90 _ 94 96 _ 98 _ 9 10 RC19 21 PARTS LIST PART NAME 1 SEPARATOR 5 2 ANGLE VALVE 3 BOLT 4 5 WASHER 6 DISCHARGE FLANGE 7 COPPER TUBE 5 8 CHECK VALVE 9 SEPARATOR GASKET 10 BOLT OIL SEPARATOR 11 BOLT END COVER PLATE 12 DISCHARGE END COVER PLATE 13 GASKET OF DISCHARGE COVER PLATE 14 BOLT FOR SLIDE VALVE FIXED 2 3 5 7 10 11 12 13 14 15 SPRING WASHER RC19 21 PARTS LIST
20. LANGE AGNETICS OMPRESSOR CASING IL FILTER NNER GASKET OF OIL FILTER FLANGE ASKET OF SERVICE FLANGE IL FILTER FLANGE OLT OWER BOLT OWER BOLT O RING 61 62 63 65 e 7 70 E RC19 21 PARTS LIST IT PART NAME 71 OPPER NUT FOR POWER BOLT 72 PRING WASHER 73 OPPER NUT FOR POWER BOLT 74 CREW FOR PTC WIRING TC WIRING SCREW O RING OLT FOR MOTOR CABLE COVER PLATE OTOR CABLE COVER PLATE ASKET FOR MOTOR CABLE COVER PLATE 75 e 7 e J 9 WASHER OLENOID COIL OLENOID VALVE STEP CONTROL OLT APILLARY 0 ELBOW 8 CONNECTOR IL SIGHT GLASS O RING INCLUDED 7 PLUG O RING INCLUDED OWER BOLT O RING 4 CONNECTOR UCTION FIXED RING MALE ROTOR OLT ASHER PRING WASHER OLT FOR MOTOR STATOR GUIDE VANE OTOR STATOR ASKET OF MOTOR CASING OTOR CASING OLT FOR MOTOR CASING IXED BOLT OF MOTOR STATOR IXED BOLT O RING ASHER FOR FIXED BOLT OF MOTOR STATOR OLT un 81 82 83 85 QO 88 91 92 93 95 97 100 101 102 103 104 105 106 107 108 109 110 LANGE LANGE SHELF ASKET FOR 5 FLANGE ASKET FOR SUCTION FILTER UCTION FILTER PRING ASKET FOR SUCTION FILTER FLANGE UCTION FILTER FLANGE OLT FOR SUCTION FLANGE AAAA AAAA 2 7 gt Un un 74 ws 219261 80 _ _ 82 _ 83 _ 85 _ 86 __ 87 _ p 89 _ 90 _ 93
21. NE 29 gt 2 lt m i I N gt Y Pas i 1 ak PAM LAWN c QI gt Pe 221 Ne EAN 57 1 2 S we a pee Ne Ives 2 2527 m A N A PS Dimensions unit mm Dia TG piu 60 75 36 9 76 6 106 75 56 15 18 05 162 105 RV 65 212 90 67 89 6 5 137 95 307 153 18 140 MIG2 0 RV 80 3 100 120 80 99 121 6 5 154 117 398 177 22 160 M20x2 5 160_ RV 100 4 125 145 105 124 146 6 5 171 130 445 201 22 185 M20x2 5 185 28 kg 42 kg G 40 150 Specification and dimension of stop valve B F AE _ Dimensions unit mm Models RV 120 28 kg 42 kg G HFC HCFC 40 150 C 65 7 4 SPECIFICATION AND DIMENSION OF CHECK VALVES 2 A
22. OF TOOLS BEARINGS 6 1 List of Tools 6 2 List of Bearings 7 APPENDIX 7 1 Compressor Outline Drawings 7 2 Outline Dimension of Flange Coupling 7 3 Specification and Dimension of Stop Valves 7 4 Specification and Dimension of Check valves 7 5 Compressor Testing Checklist 7 6 Compressor Parts List 7 7 Exploded Drawing INTRODUCTION The HANBELL semi hermetic twin screw compressor is developed especially for applications in air conditioning and refrigeration With a built in high operating load design each compressor is high efficiency and reliability in all working conditions such as thermal storage and heat pump system Each compressor has the latest and advanced 5 to 6 Patented Profile design This service manual has been prepared for better maintenance performance by HANBELL semi hermetic twin screw refrigeration compressors This service manual provides maintenance policies and gives full details regarding the proper handling and maintenance of the screw compressors to the person in charge HANBELL semi hermetic twin screw refrigeration compressors have been developed by HANBELL s own technology and high precision made machines as compared to ordinary reciprocating compressors Therefore before starting the maintenance and overhaul of the compressor we suggest that proper preparation and handling of each components parts tools equipment and full knowledge of this manual are required Although proper maintenance procedures are
23. S RC10 RC11 Outline Drawings Li i Es 4 d So L I EO alk E AIV TE 9 ut N N Y 50 2 C Y N C Y D E LT H 5 HE 3 D n B Lu II H PA Y DIMENSION UNIT mm DIMENSION UNIT mm 57 RC12 RC17 Outline Drawings eei DIMENSION UNIT mm DIMENSION UNIT mm x JM N O P al R S RC 18 Outline Drawings
24. TON RING ISTON ROD ISTON INNER SPRING ISTON OUTER SPRING ISC SPRING MALE ROTOR ISCHARGE FIXED RING MALE ROTOR 25 M9 BEARING SLOT NUT MALE ROTOR 26 DISCHARGE BEARING AXIAL MALE ROTOR 27 DISCHARGE BEARING RADIAL MALE ROTOR gt RBS O O J 10 11 12 13 14 15 16 17 18 19 20 21 22 x V 23 24 p 4 6 7 8 _10_ 12 LU l4 15 16 _ s 18 19 20 22 s 23 24 _ 25 26 27 RC16 18 PARTS LIST IT PART NAME 28 9 30 3l 32 33 34 35 36 37 38 39 lt TY ALANCE PISTON ALE ROTOR OTOR ROTOR KEY IL GUIDING RING MALE ROTOR UCTION BEARING MALE ROTOR NNER SPACER RING OF SUCTION BEARING MALE ROTOR UTER SPACER RING OF SUCTION BEARING MALE ROTOR UCTION BEARING MALE ROTOR OTOR ROTOR OTOR ROTOR SPACER RING OTOR ROTOR WASHER PRING WASHER OLT FOR MOTOR ROTOR FIXED ISC SPRING FEMALE ROTOR ISCHARGE FIXED RING FEMALE ROTOR M6 BEARING SLOT NUT FEMALE ROTOR 41 42 43 45 SPACER RING OF FEMALE ROTOR UTER SPACER RING OF FEMALE ROTOR 47 EMALE ROTOR IL GUIDING RING FEMALE ROTOR UCTION BEARING FEMALE ROTOR EARING SEAT ASKET OF DISCHARGE EXHAUST TUBE OLT FOR BEARING SEAT IX PIN LUG OLT FOR SLIDE VALVE KEY LIDE VALVE KEY LIDE VALVE OLT ERVICE FLANGE ASKET OF SERVICE FLANGE AGNETICS OMPRESSOR CASING IL FILTER NNER GASKET OF OIL FILTER FLANGE UTER GASKET OF OIL FILT
25. a 7 8F e d cd dc al 7 8M 13 Slot Nut Tightening Gauge for Female Rotor CRAAABOI M30 1 5K M06 L2F 54 Lc 220209 0 05 10 05 0 05 0 02 0 1 Le me RDD sma ew e pw al ba 1 2 3 4F a ll d Press Tool for Piston Assembly CRAAAB70 E d 5 Lees peo Motor Cable Cover Plate Lifter 27412 92 16 Slide Pull Rod Lifter 55 N 1 2 13 90 477 RCI4 15L 100 17 Tool For Pin 035 Py SESI ______ zi xil E eL 6 2 LIST OF BEARINGS RC SERIES Table below shows the list of bearings for male and female suction and discharge side rotor shaft BEARING TYPE DISCHARGE BEARING TYPE SUCTION MALE FEMALE QTY MALE FEMALE TW7BUO 3 7306BUO RC10 11 55 35 NU307E NU2306E 7309800 3 7305800 RC12 13 NU2211E MODEL 0 30 NJ2206E NU309E NU2306E TMiBUO 3 7307BUO RC14 15L NU2213E 2 NJ2207E NUSE 1 NUINWIE TH3BUO 3 7309BUO RC16 17 NU2216E NJ2210E 1 NU313E NU2309E 7313800 7310BU0 RC18 NU2216E NJ2210E 1 NU313E NU2310E 31280 3 RC19 21 NU2217 NJ2308 1 NU312E NU2311E 313800 3 T73I5BUO RC22 24 NJ2310E NU2318E 1 NUBISE 1 NUGISE 56 1 1 1 7 7 1 RC SERIES OUTLINE DRAWING
26. alves clogged Piston ring worn out Insufficient lubricant 3 Compressor unable to unload Leakage on discharge cover plate Solenoid valves voltage misused Piston stucked up Capacity control circuit unsuitable 10 PROBLEMS PROBABLE CAUSES 1 Slide valve unable to go back to its 25 capacity position 2 Magnetic contactor failure Motor broken down Phase failure or phase reversal 4 Compressor starting failure or Y A switching Motor terminal protector trip failure Incorrect power supply connections Y A timer failure Discharge stop valve closed Improper connections between mode terminals of Y A wiring 1 Broken bearings 2 Phenomenon of liquid compression 3 Friction between rotors or between rotors and compression chamber 4 Insufficient lubricant oil 5 Abnormal vibration and noise of compressor 6 Electromagnetic sounds of the solenoid valves 7 System harmonic vibration caused by improper piping system 8 External debris into the compressor 1 Insufficient refrigerant 2 Condenser problem 3 System overcharged of refrigerant 6 High discharge temperature 4 Air refrigeration system 5 Insufficient lubricant oil 6 Damaged bearings Mutual friction of rotors 7 High compression ratio 11 3 6 TORQUE WRENCH AND TOLERANCE Below are the list of tables showing different setting value of torque wren
27. and pull out the oil filter cartridge and oil level switch cover Fig 10 1 3 Remove the magnet and clean it Fig 10 2 TOOLS Air drive spanner or hexagonal wrench 4 7 OIL SEPARATOR Refer to 12 11 11 1 1 Use two eyebolts on top of the oil separator and hang it using an overhead crane to hold the oil separator Fig 11 2 Loosen and remove all the screws of oil separator Fig 11 3 Pull out the oil separator from the compressor Fig 11 1 Fig 11 1 TOOLS Eyebolts overhead crane air drive spanner or hexagonal wrench 4 8 DISCHARGE COVER PLATE PISTON SPRING ROD Refer to Fig 12 12 6 1 Loosen all the screws of discharge cover plate JW m then remove the cover plate and gasket 12 12 12 1 24 2 Remove the disc spring and the discharge fixed ring Fig 12 2 3 Loosen the screw bolt of the piston then remove the spacer ring washer and the piston 12 12 3 12 4 4 Loosen the connecting rod and remove it 12 12 5 12 6 25 TOOLS Air drive spanner or hexagonal wrench 4 9 BEARING SEAT BEARING SLOT NUT Ref to 12 13 13 6 1 Rotate the adjustable table with the discharge side on top Fig 13 2 Loosen all the screws of the bearing seat Fig 13 3 Remove the two guide pin from the bearing seat Fig 13 1 Refer to page 56 item no 17 for the tool 4 Install the rotor assembly fixed gauge on the male rotor shaft suction side Fig 13 2 Refer to page 51 item no
28. bly fixed gauge to the suction side of the male rotor so that it will not move when tightening the bearings Fig 19 21 Fig 19 21 35 20 Put loctite sealant on both male and female end side screw Fig 19 22 2 Put the bearing slot nut on both the male and female rotor Fig 19 23 22 Tighten the male rotor first using a torque wrench refer to Table 7 for the torque then the female rotor 12 19 24 23 Remove the rotor assembly fixed gauge and the two pin from the compressor casing 1 19 25 19 26 Fig 19 25 Fig 19 26 24 Lift the bearing assembly and check the clearance of the rotor to the bearing seat refer to Table 8 for the tolerance Fig 19 27 Fig 19 27 36 25 Heat the suction radial bearing inner ring and inner spacer ring of the male and female rotor Fig 19 28 26 Insert the inner ring and inner spacer ring on the male and female rotor Fig 19 29 27 Use a chisel and hammer it to prevent the ring from moving or falling Fig 19 30 5 2 SUCTION BEARING Refer to Fig 20 20 7 1 Install the oil guiding ring on the male and female hole Be sure that the oil hole in the ring 15 the same side as the oil hole in the casing Fig 20 2 Install the radial bearing male female outer ring on the casing and hammer Fig 20 1 20 2 37 Fig 20 3 Put the outer spacer ring the casing male 12 20 3 12 20 3 4 Install the radia
29. ch for different screw bolts torque wrench setting for different compressor accessories and torque wrench setting for discharge bearings male and female It also shows some of the tolerance Table 5 Compressor accessories and torque setting em mw Table 6 Compressor screw bolts torque setting Standard screw bolt Torque value Kg cm Setting value Table 7 Torque setting for male and female bearings discharge side Torque Value Ke m uw RC 14 15L RC 16 17 RC 18 21 12 Table 8 Discharge clearance of male and female rotor Standard mm 0 04 0 08 0 04 0 09 0 04 0 1 0 04 0 1 Table 9 Tolerance between slide valve and slide valve housing RC12 RC13 RC14 RC15 RC16 RC18 RC19 RC21 Model Tolerance mm 0 025 0 055 0 03 0 06 0 04 0 07 0 04 0 07 Slide valve housing Slide valve Table 10 Motor insulation standard Phase to wirin temperature protector Wiring U V W temperature U Z V X W Y U V W protector Should be more than 100 2000 amp 1000VDC 13 Table 11 Vibration standard Unit mm s Cas roren nene cea Between Rotors Around 300 Hz Motor Rotor Around 60 Hz Table 12 Allowable deflection of male rotor and motor rotor Unit mm Max allowed For male rotor combined with motor rotor Motor rotor Dial gauge Table 13 Standard sound level Unit dbm 14 Test standard 1 Horizontal
30. dar ________ sure that the compressor have been vacuum with pressure of 0 3 0 5 kglom2G __ 3 sure to put additional nut and washer in the sixpowerboltterminal 111 INSULATION To ground U V W Thermal protector __ o TEST BewemtephaseUZ L Protector U V W used 1000DCV 2000 ohms reading should be more than 100 __ 1 check if ali the cover in the accessories have been remove after painting FINAL 2 Check there is no oil leakages in all the flanges and connections 11110104 PROCEDURE 3 check if all the screw of cable box have been screwed and it should be the same model as the _ TT Also check if all the accessories and sticker are present 4 Check if there is anything wrong and fill up the production check table 5 Heater voltage 220V Solenoid valve coil 220V REMARKS 68 7 6 SCREW COMPRESSOR PARTS LIST RC12 15L PARTS LIST PART NAME IL SEPARATOR 1 2 GASKET 2 1 2 FOR RC 14 amp 15 NGLE VALVE OLT OLT SHER DISCHARGE FLANGE OPPER TUBE HECK VALVE IL SEPARATOR GASKET 10 BOLT OIL SEPARATOR 11 BOLT END PLATE 12 DISCHARGE COVER PLATE 13 GASKET OF DISCHARGE COVER PLATE 14 BOLT FOR SLIDE VALVE FIXED 15 SPRING WASHER 16 WASHER 17 PISTON 18 COPPER WASHER 19 PISTON S O RING 20 PISTON RING 21 PISTON ROD 22 PISTON SPRING 23 DISC SPRING MALE ROTOR 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39
31. de in front 2 Put loctite sealant in the piston rod and install it to the slide valve Fig 23 23 1 Fig 5 40 3 Fixed the piston to the piston gauge Fig 5 2 Fig 5 2 4 Put a copper washer on the piston rod and put some oil in copper washer the piston cylinder Fig 5 3 5 Put the piston and piston spring on the cylinder Fig 5 4 6 Use hexagonal screw and tighten it then check the piston by pushing it forward and backward Fig 5 5 7 Put the bearing fix ring and disc spring Fig 5 6 41 8 Put the gasket cover plate and put all the screws and tighten it Fig 5 7 5 8 Fig 5 7 Fig 5 8 TOOLS Spanner or hexagonal wrench oil loctite sealant piston gauge socket wrench 5 6 MOTOR ROTOR Refer to Fig 6 6 6 1 the shaft key on the male rotor shaft suction side Fig 6 Fig 6 2 Lift the motor rotor and install it to the compressor Fig 6 1 6 3 rotor number mark in inside position Fig 6 1 Fig 6 2 Fig 6 3 3 Put washer and spacer ring on the hexagonal screw and put loctite sealant then install it to the motor rotor and tighten it Fig 6 4 6 5 Fig 6 4 Fig 6 5 4 Check the motor rotors alignment using a dial gauge on top The reading should not exceed 0 15mm 12 6 6 Fig 6 6 TOOLS Overhead crane spanner or wrench loctite sealant dial gauge 5 7 MOTOR Refer to Fig 7 7 10 1 Put the motor stator on stator fixed jig Fig 7 2 Lift the mot
32. described in this service manual maintenance work of the screw compressors should be performed by the persons with full understanding of such work 1 SCOPE This HANBELL semi hermetic twin screw compressors service manual 15 applicable to RC series which is inclusive of RCIO RCII RCI2 RC21 22 24 2 DESCRIPTION OF DESIGN The HANBELL semi hermetic twin screw compressors have been developed by HANBELL s own technology including the basic research and development activities production engineering and system engineering HANBELL screw compressors used the simple and more reliable oil separator and unique types of bearing for axial and radial loads It also used the high precision CNC MACHINING CENTER THREAD GRINDING MACHINE to machine the compressor casing and screw rotors and it is tested in a 3 D MEASURING MACHINE to ensure its high quality performance 2 1 COMPRESSOR SPECIFICATIONS Displacement m RCIO RCI2 RC13 14 5 RCISL 6 RCI7 165 137 207 172 233 193 309 257 352 293 384 320 490 407 567 471 Rated S 3550 2950 Volume Ratio Volume Ratio 2 2 2 6 3 0 3 5 4 8 Capacity 3 steps or 33 100 A U 4 steps or 25 100 continuous capacity control system Differential pressure feed lubricant E 3 Phase 2 Pole Squirrel Cage Induction Motor s Yem Cmn ua DL D T T5 wf SS
33. e chiller shutdown besides the standard oil level NOTE In case a very long piping of the chiller system it 1s necessary to calculate the additional oil amount needed to keep the compressor running smoothly Table 16 Specification of applicable oil types R 22 TOTAL SUN CPI MOBIL LUNARIA SUNISO CP 4214 SHC UNITS s e sos sos x0 COLOR ASTM uo uo _ __ _ tos tos SPECIFIC GRAVITY ovia 095 oos 10s oss osas osi ied 0 POUR POINT 40 T A N COPPER STRIP 3hr 1009 la la la la MOISTURE 15 18 Table 17 Specification of applicable oil types R134a 404 407 CPI MOBIL ICI SOLEST EMKARATE E ta ni SPECIFIC GRAVITY POUR POINT COPPER STRIP 3hr 1009 MOISTURE UNITS 3 8 MAINTENANCE SPACE It 15 necessary to reserve enough space for the connection and installation of electrical box service valve and solenoid valve Fig 5 shows the recommended compressor installation space for future maintenance work in the job site B 19 RC compressor series RC10 RCI5 RCI3 RCIA RCISL 6 RCI7 RCIS RCI9 RC20 RC21 Ae spa
34. ed directly at the suction end of the male rotor shaft and drives the rotor shaft at rated speed of 2 950 rpm at 50 Hz and 3 550 rpm at 60 Hz respectively GO 1 ON Q Lm L oo Fig 1 Construction of screw compressor HHHH m RAN RE x ZZ 990000 1 5 S 7 H H 7 ji c MM Compressor casing Motor casing Oil separator Motor rotor assembly Motor stator assembly Motor rotor washer Motor rotor spacer ring separator baffle Oil separator cartridge Piston Piston spring Piston rod Bearing seat s Modulation solenoid valve Modulation slide valve Slide valve key Discharge bearings Discharge fixed ring 19 20 21 22 23 24 2
35. el sight glass 2 Time for heating the oil 2 Turn on the oil heater at least 8 hrs before starting 1 Accessories 3 System valves status 3 Opened 4 Solenoid valves 4 Fixed 5 Capillary 5 No serious distortion or damaged 1 Voltage of main power 1 Hlectricity 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 1096 to the rated motor between phase to phase and voltage phase to ground 2 Standard voltage 15 220V Maximum voltage 15 4 Power terminals and wire cables 230V terminal connections 3 Insulation resistance value should be above 5 5 Grounded 4 Power terminals are firmly fixed on terminal block 2 Electrical system 6 Capacity of electrical accessories and well insulated Keep wire cables away from 7 Setting of switches sensors and heat source and sharpened metal Terminal screw controllers 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 system piping 1 Fixed firmly 3 Piping system 2 Leakage test 2 No leakage 3 Bolts to fix the compressor 3 Fix the compressor tightly 4 Safety devices 1 Motor coil sensor thermister 1 Connected in series with discharge sensor to 2 Discharge sensor thermister controller 3 Control
36. ential switch can installed The switch will trip when the oil pressure differential reaches the critical point and the compressor will automatically shut down This will protect the bearings from getting any damaged due to lack of lubricating oil 3 If the compressor discharge temperature often gets higher then the oil will spoil gradually in a short time Check the oil level or follow the recommended time period for changing the oil 4 Check the acidity of lubricating oil periodically If the acidity of the oil measured is lower than PH6 then changing of oil 1s required 5 Refer to oil replacement standard table to check the characteristic of oil 17 3 7 3 Oil level Aside from lubricating the bearings and compression chamber the lubrication oil also controls the capacity control system of the compressor It 1s necessary to monitor the oil level of the compressor periodically It has oil sight glass connected to the side of the compressor to check if the oil level is still enough above the bottom of the sight glass For bigger models RC 14 21 there are two sight glasses connected on both sides to monitor the oil level All of HANBELL screw compressor have an additional 3 liters of lubrication added to the standard amount When the compressors are running the oil level could be higher or lower in the sight glasses so the technician can check the lowest level of the oil while the chiller 15 running or check the oil level while th
37. h level lower than the floating ball pressure differential switch Cutout 2 5Kg cm g 3 5 TROUBLESHOOTING AND MAINTENANCE SCHEDULE For the replacements or status of some compressor accessories refer to the maintenance schedule table 3 Table 4 shows some problem that may encounter when the screw compressor are not running well Table 3 Maintenance schedule Lo hrs hrs hrs hrs hrs hrs hrs hrs Bewimsbin v filter cartridge Suction filter To To o ST T Tv Psong A_ Motor thermal protector Bearings LN Legend v check or clean replaced Table 4 Problems and probable causes PROBLEMS PROBABLE CAUSES 1 Low suction pressure or high suction temperature lack of refrigerant clogged suction filter or high suction superheat 2 Motor overload no liquid injection system or 1 Sudden trip of motor thermal protector liquid injection system failure thermister 3 Motor wiring protector failure 4 Electrical system failure or unstable 5 Bad motor coil winding causing temperature rise rapidly Low ambient temperature or high oil viscosity Capillary tube clogged Modulation solenoid valves clogged Internal built in oil lines clogged Piston stucked up filter cartridge clogged Modulation solenoid v
38. ig 8 3 45 5 9 SEPARATOR Refer to Fig 9 9 4 1 Lift the oil separator and put it on the adjustable push cart Fig 9 2 Clean the oil separator then wipe it with a piece of rag Fig 9 1 3 Put Teflon on the discharge side of the bearing seat and put gasket on the compressor casing Fig 9 2 5 Install the oil separator to the compressor casing and put all the hexagonal screw bolts and tighten it using an air drive spanner or hexagonal wrench Fig 9 3 9 4 Fig 9 3 Fig 9 4 TOOLS Overhead crane adjustable push cart oilstone spanner or wrench 5 10 OIL FILTER OIL SWITCH Refer to Fig 10 10 4 Fig 10 1 Put two magnet inside the compressor crankcase Fig 10 46 2 Put teflon and gasket on the oil filter cartridge Fig 10 1 3 Install the oil filter cartridge to the compressor and put all the screws and tighten it Fig 10 2 4 Put gasket on the oil switch cover Fig 10 3 5 Install the oil switch to the compressor Fig 10 4 TOOLS Spanner or hexagonal wrench 5 11 SUCTION SEALED FLANGE FILTER Refer to Fig 11 11 3 1 Put Teflon inside the suction port of the compressor and the suction filter Fig 11 47 2 Put spring and gasket on the suction sealed flange Fig 11 1 3 Install the suction sealed flange to the compressor Fig 11 2 4 Put all the hexagonal screw bolts and tighten it Fig 11 3 TOOLS Spanner or hexagonal wrench 5 12 OIL
39. iw s a DIMENSION UNIT mm RC20 21 822 5 N o Ki 60 5 v w RC 22 Outline Drawing 2 a _ B m _ lo A 6 1 PQ N T CE N NS 1970 2 E N N ee TC s H d N PTN 5 25 es 16 1 Suction Flange 9 Modulation S V 5090 2 Discharge Flange 10 Modulation S V 7590 3 Oil Inlet Connector 11 Liquid Injection Connector 4 Oil Inlet Connector 12 Stop Valve Middle pressure side 5 Economizer Connector 13 Stop Valve High pressure side 6 Liquid Injection Connector 14 Stop Valve Low pressure side 7 Modulation S V Continuous Control 15 Refrigerant Charge Connector 9 Modulation S V 2596 16 Cable Box 61 7 2 OUTLINE DIMENSION OF DISCHARGE AND SUCTION FLANGE COUPLING Specification and dimension of standard flanges coupling Com ise sv 4W aw 28 4M _ x a ed Or 4w swe s SW _ s sw
40. l bearing outer ring on the casing male Fig 20 4 5 Put loctite sealant on the screw hole 12 20 5 6 Install the suction bearing fix ring and fix bolt Fig 20 6 20 7 Fig 20 6 TOOLS Hammer trumpet shape tool loctite sealant 5 3 SLIDE VALVE SOLENOID VALVE Refer to Fig 21 21 3 1 Clean oil hole of the compressor casing using air Fig 21 38 2 Screw the modulation solenoid valve using air drive spanner or hexagonal wrench Fig 21 1 3 Use a pile or oilstone to eliminate any burrs on the surface of the slide valve Fig 21 2 4 Install the slide valve in the compressor casing Check the clearance refer to Table 9 for the clearance Fig 21 3 TOOLS Pile oilstone hexagonal wrench spanner 5 4 COMPRESSOR CASING Refer to Fig 22 22 4 1 Clean the compressor casing using spatula and wipe it with clean paper Fig 22 2 Rotate the table with the discharge side on top and put loctite sealant on the surface of the compression chamber Fig 22 1 39 3 Lift the bearing assembly and put it slowly in the compressor casing Fig 22 2 4 Put two guide pin on the bearing seat and hammer it Fig 22 3 5 Put all the hexagonal screw bolts and tighten it Fig 22 4 TOOLS Spatula clean paper loctite sealant overhead crane spanner or hexagonal wrench hammer 5 5 PISTON PISTON ROD SPRING COVER PLATE Refer to Fig 23 23 8 1 Rotate the table with the discharge si
41. ler 2 Connected in series with motor sensor to controller 3 Closed circuit with N C amp N O NOTE A In addition to the checklist mentioned in table 1 it is necessary to pay more attention to the auxiliary facilities while the chiller commissioned at the job site and the periodic maintenance after the initial start up B In order to keep the capacity control smoothly under the low ambient temperature with normal oil viscosity it 1s required to heat first the oil for at least 8 hours before the next starting The lower the ambient temperature 15 the longer the heating time of oil The oil temperature should be over 23 C before starting the compressor Keep the oil heater energizing after the compressor shut down for preparation for the next start up C Check all the settings on each pressure switch timer relay D Check if all the stop valves have been opened E The running conditions of compressor after commissioning at the factory or job site should be adjusted The discharge temperature should be 20K above the saturated condensing temperature the superheat of suction vapor should be within 10K to the saturated evaporating temperature 3 3 COMPRESSOR START UP Compressor motor designed for Y A connection refer to figure 2 shown below for the wiring connections MOTOR TERMINAL U X R 0 4 UO 4 0 V 5 MOTOR O O Jem
42. n the base surface of the hydraulic press machine put some rags inside the cylinder 2 Lift the bearing seat and put it in the cylindrical drum Get a piece of steel bar and put it inside the bearing seat so that it will push the rotor when the press machine moves downward Fig 16 3 Press the downward button of the press machine and if the rotors have already been taken out press the upward button Fig 16 1 4 Lift the bearing seat and put it on the pallet also put the rotors on the pallet 1 16 2 16 3 7 1 5 Remove all the bearings spacer ring and balance piston Fig 16 2 of the bearing seat by hammering it Fig 16 4 16 5 29 6 Remove the inner ring spacer ring the male and female suction bearings by 1 cutting first the inner ring with grinder and used a chisel and hammer it or 2 heating it to expand and can take out easily Fig 16 6 16 7 4 13 MOTOR STATOR Refer to Fig 17 17 2 1 Remove first the motor stator guide vane by loosening all the screws Fig 17 2 Install the motor stator puller Fig 17 1 3 Install the hydraulic hose for the puller machine Fig 17 2 4 Operate it until the stator 15 being remove from the motor casing Fig 17 2 30 TOOLS Hexagonal wrench hydraulic puller 4 14 CLEANING OF COMPONENTS Refer to 12 18 18 2 1 Lift the compressor casing and clean it by washing it with oil and use air to dry it Fig 1
43. ng and check the clearance Fig 19 6 7 Heat the discharge radial bearing inner ring up to 80 C Fig 19 7 8 Insert the radial bearing inner ring and inner spacer ring on female rotor shaft Fig 19 8 9 Lift the bearing seat and put it on the table then clean it using oilstone and clean paper Also check and clean the oilhole using air Fig 19 9 33 10 Insert the radial bearing outer ring on the bearing seat Fig 19 10 11 Insert the outer spacer ring on the bearing seat Fig 19 11 12 Lift the bearing seat and slowly put it in the compressor casing Fig 19 12 13 Used two guide pin and hammer it Fig 19 13 14 Put the balance piston on the male rotor and hammer it up to the bottom flat surface is at the bottom Fig 19 14 34 Fig 19 14 15 Put the radial bearing outer ring the male rotor and hammer it Fig 19 15 19 16 Fig 19 15 16 Insert the radial bearing inner ring on the male rotor and hammer it Fig 19 17 19 18 Fig 19 17 17 Heat the male and female axial bearing up to 80 Fig 19 19 18 Insert the axial bearing on the male rotor shaft first then the female rotor Wait a few seconds to cool Fig 19 20 NOTE The bearing position should be the two bearing face with the series number at the bottom side and the third bearing with series number on top Do it on both the male and female 19 Use rotor assem
44. on the floor Fig 6 1 Fig 6 Fig 6 1 4 3 SUCTION SEALED FLANGE FILTER Refer to Fig 7 7 2 1 the screw bolts of the suction flange using air drive spanner or hexagonal wrench Fig 7 2 Pull out the suction flange and gas filter Fig 7 1 7 2 Fig 7 1 TOOLS Air drive spanner hexagonal wrench 21 4 4 ELECTRICAL COVER PLATE Fig 8 8 2 1 Loosen the screw bolts of electrical cover plate and remove all the screws Fig 8 2 Use screw gauge to hold the cover plate Fig 8 1 3 Loosen all the screw nuts of each electrical cover terminal and removed the cover plate Fig 8 2 TOOLS Air drive spanner hexagonal wrench cover plate holder 4 5 MOTOR CASING MOTOR Refer to Fig 9 9 5 1 Usea rope to support the motor casing before loosening all the screw bolts Fig 9 9 1 22 2 Pull out the motor casing slowly and carefully Fig 9 2 3 Loosen the bolt of motor rotor Fig 9 3 4 Remove the screw bolt washer and spacer Fig 9 3 5 Pull out the motor rotor and the rotor shaft key 9 4 9 5 Fig 9 5 NOTE For bigger model use a rope and pull out motor rotor using overhead crane TOOLS Rope overhead crane air drive spanner or hexagonal wrench 4 6 OIL FILTER OIL LEVEL SWITCH COVER Refer to Fig 10 10 2 1 the screw bolts of oil filter cartridge and oil switch cover Fig 10 23 2 Remove all the screws
45. or have been vacuum Inlet Outlet stop valve had been open 5 Check if there is refrigerant in the system Check if the motor rotation is correct The discharge pressure is higher than suction Iz Be sure the compressor is in 50 capacity position after compressor stop 8 Be sure to turn OFF the main breaker when compressor stop NFB Check if there is anything wrong then fill up the production check table ho Check the voltage current phase while running OK OK specified fibration frequency analysis to measure the vibration OK OK specified h2 Noise level dBA Background noise dBA If there some noise what kind of noise Which of the modulation have problem hHalcheck the modulation loading 2596 5096 5096 757 75 100 LN unloading 2590 5040 50 75 75976 10076 __ 1 Check if the compressor are clean inside metallic particles U 0 2BesurethatPiholehadbeencian j LEAK TEST 3 Check all the packing gasket of compressor If damage change with new U 2ndTEST 4 Check if there is two magnet in the crankcase and clean it first SjCheckifthe copper flare had been damage and change with new ________ change the suction and oil filter with new one after each performance test 7 Check if there is any leak implating with dry air with pressure of 28 kg cm2 for 1 theckthespecificationofoi Stan
46. or stator and put it on the base surface of the hydraulic press machine Fig 7 1 3 Insert the motor stator key and hammer it Fig 7 2 4 Lift the motor casing and put it on top of the motor stator with the key on the stator In the same position as the keyway on the motor casing Fig 7 3 43 5 Press the advance button of the machine and then the downward button to press the motor casing to the motor stator Fig 7 4 6 Press the upward button of the machine and remove the motor assembly by lifting it and put it on the pallet Fig 7 5 7 6 Fig 7 5 TOOLS Stator fix jig overhead crane press machine hammer 7 Install the motor stator guide vane and use hexagonal screw bolts and tighten it Fig 7 7 8 Lift the motor assembly and put gasket on it and install it to the compressor Fig 7 8 9 Pull out the wiring terminal Fig 7 9 44 10 Put all the screws on the motor and tighten it Fig 7 10 TOOLS Spanner or wrench overhead crane motor cable cover plate lifter press machine 5 8 TERMINAL COVER Refer to Fig 8 8 3 1 Pull out the motor wiring terminal and install it to the cover plate Fig 8 2 Put all the screw nuts and tighten it install the motor thermostat wiring terminal Fig 8 1 Fig 8 1 4 Check each terminal using a tester Refer to Table 10 for the test standard Fig 8 3 TOOLS Motor cover plate lifter tester spanner hexagonal wrench F
47. ss s Ls Re SE AKIESEAES E Suction filter Em F Oil filter mm filter mm 4 DISASSEMBLY PROCEDURES This service manual is described regarding the maintenance work HANBELL semi hermetic twin screw compressor The compressor has been brought into the workshop under the following conditions The compressor s discharge and suction side are still closed with sealed flanges and the compressor are free of refrigerant gas 2 Refrigerant oil still remain inside the compressor 3 The modulation solenoid valves and some of the accessories are still connected to the compressor 4 1 WORK PREPARATION Before performing the disassembly work of the compressor be sure to prepare first the washing area the rotation table and the facility should be kept clean and in order so that any parts of the compressor can be put in proper place Refer to fig 5 and fig 5 1 Fig 5 20 4 2 REFRIGERANT OIL PURGES Refer to Fig 6 6 1 1146 the compressor using an overhead crane and put it on the adjustable table and use two hexagonal screw bolts to fix it Fig 6 2 Put an oil pan or basin under the adjustable table to drain the oil Fig 6 1 3 Loosen the M12 screw bolts of the oil filter cartridge using an air drive spanner hexagonal wrench so that the oil can flows out Do not totally remove the oil filter cartridge until all the oil has flowed out in order to prevent excessive flowing and spillage
48. wable shift time from Y to A be 40 milliseconds It 15 advisable to change the Y starting time prior to different working condition in the job site in accordance with the current variation of Y starting It is recommended that the duration of Y starting 1s not over 15 seconds at the step of 25 capacity Starting current Secondary current AMP Rated running current Running Starting time Y Starting Shifted 4 sec Fig 3 B Power supply 1 Voltage Long term running Rated voltage 5 2 Instant running Rated voltage 10 3 Frequency Rated frequency 2 4 Phase current unbalance The difference between biggest phase current differential and smallest phase current differential 15 advised to be less than 3 If the phase current unbalance happens change the supply power of any of the two phases to avoid the trouble caused by motor or primary power supply If the problem occurs then shut down the chiller immediately and do the troubleshooting and then restart the chiller C Phase voltage unbalance 2 25 D Control voltage Standard sub control voltage 15 220V on HANBELL screw compressor 3 4 PROTECTIVE DEVICES Table 2 shows some of the protective devices which are very essential to protect the compressor and operate safely and smoothly Table 2 Compressor protective devices for different application Protection switch set point setting should be tripped in 15 sec Oil level switc
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