lt technical manual - comer above reasons, shanghai hanbell precise machinery co., ltd. specialized...

I

Content

1. GENERAL ......................................................................................................................................................................... 1

2. SPECIFICATIONS ........................................................................................................................................................... 2

2.1 NOMENCLATURE ............................................................................................................................................................... 2

2.2 PRODUCT LINE .................................................................................................................................................................. 2

2.3 SPECIFICATIONS ................................................................................................................................................................ 3

2.4 APPLICATION LIMITS ....................................................................................................................................................... 4

3. CONSTRUCTION & FUNCTIONS ................................................................................................................................. 6

3.1 DESIGN FEATURES ............................................................................................................................................................ 6

3.2 CAPACITY MODULATION .................................................................................................................................................. 7

3.2.1 Step-type Control ............................................................................................................................................................... 8

3.2.2 Stepless Type Control ...................................................................................................................................................... 13

3.2.3 The Positions of Solenoid Valves .................................................................................................................................... 18

3.3 COMPRESSOR STARTUP LOADING & STOP UNLOADING ................................................................................................. 19

4. LUBRICANT ................................................................................................................................................................... 20

4.1 LUBRICANT TABLE ......................................................................................................................................................... 20

4.2 OIL CHARGING ............................................................................................................................................................... 20

4.3 OIL CHANGE ............................................................................................................................................................................ 21

4.3.1 Oil Change Schedule: ................................................................................................................................................ 21

4.3.2 Pre-cautions of Changing Oil .................................................................................................................................... 21

5. SYSTEM APPLICATION............................................................................................................................................... 22

5.1 PIPING DESIGN ................................................................................................................................................................ 22

5.1.1 Suction and Discharge Piping Layout....................................................................................................................... 22

5.1.2 Economizer Piping Layout ........................................................................................................................................ 24

5.1.3 Minimum Pressure Valve .......................................................................................................................................... 25

5.1.4 Liquid Line Filter Dryer ............................................................................................................................................ 26

5.1.5 Sight Glass with Moisture Indicator .......................................................................................................................... 26

5.2 OIL LINE ......................................................................................................................................................................... 27

5.2.1 Oil Supply ................................................................................................................................................................... 27

5.2.2 Lubrication and Capacity Control Modulation ......................................................................................................... 27

5.2.3 Compressor chamber injection cooling system ......................................................................................................... 28

5.2.4 Protection in Oil Line ................................................................................................................................................ 30

5.2.5 Oil Cooling System ..................................................................................................................................................... 31

5.3 MOTOR LIQUID INJECTION COOLING ........................................................................................................................... 33

5.4 ECONOMIZER SYSTEM ................................................................................................................................................................... 35

5.4.1 Sub Cooler ........................................................................................................................................................................ 35

5.4.2 Flash Tank ........................................................................................................................................................................ 36

5.5 RECOMMENDED SYSTEM LAYOUT ............................................................................................................................................ 37

II

6. MOTOR DESIGN ........................................................................................................................................................... 38

6.1 MOTOR PARAMETERS AND DESIGN ............................................................................................................................... 38

6.1.1 Y-Δ Start ..................................................................................................................................................................... 38

6.1.2 Power source requirement ......................................................................................................................................... 39

6.1.3 MCC&LRA ................................................................................................................................................................. 40

6.1.4 Terminal cover plate. ................................................................................................................................................. 42

6.1.5 Terminal box .............................................................................................................................................................. 43

7. COMPRESSOR INSTALLATION ................................................................................................................................. 44

7.1 OPEN COMPRESSOR WOODEN CRATE ............................................................................................................................. 44

7.2 COMPRESSOR LIFTING ................................................................................................................................................... 44

7.3 COMPRESSOR INSTALLATION ......................................................................................................................................... 45

8. OPERATION AND MAINTENANCE ........................................................................................................................... 47

8.1 COMPRESSOR COMMISSIONING CHECK ......................................................................................................................... 47

8.1.1 Check list before Start up ........................................................................................................................................... 47

8.1.2 Check list during operation ....................................................................................................................................... 48

8.2 TROUBLE SHOUTING TABLE ........................................................................................................................................... 49

9. DIMENSIONS ................................................................................................................................................................. 51

10. ACCESSORIES ............................................................................................................................................................... 58

10.1 ACCESSORY LIST ............................................................................................................................................................. 58

10.2 ACCESSORY FOR GAS REFRIGERANT LINE ..................................................................................................................... 59

10.2.1 Shut-off valve ........................................................................................................................................................ 59

10.2.2 Flange bushing ...................................................................................................................................................... 60

10.2.3 Check valve ............................................................................................................................................................ 63

10.2.4 Minimum pressure valve ....................................................................................................................................... 65

10.3 OIL LINE ACCESSORY ...................................................................................................................................................... 67

10.3.1 Oil flow switch ............................................................................................................................................................... 67

10.3.2 External oil filter ................................................................................................................................................... 68

10.3.3 Oil line solenoid valve ........................................................................................................................................... 70

10.3.4 Oil pressure differential switch ............................................................................................................................. 70

10.4 ELECTRICAL ACCESSORY ............................................................................................................................................... 71

10.4.1 INT-69HBY motor protector ................................................................................................................................. 71

10.4.2 Oil heater 300W ..................................................................................................................................................... 72

10.5 OTHER ACCESSORY......................................................................................................................................................... 74

10.5.1 Mounting pad ........................................................................................................................................................ 74

1

1. General

For conventional single-stage screw compressors, the minimum evaporating temperature

is -40℃to -50℃ when they are used in refrigeration field, and the minimum ambient

temperature is -15℃ when applied to heat pumps. If you want to break this application

limitation, a compound two-stage compressor or multi unit of single stage compressors are

necessary. Meanwhile, the condition of high pressure ratio brings problems to the traditional

single stage compressors during compression process, such as excessive gas leakage and

exhaust temperature overheat etc., which leads to low efficiency and poor reliability when it

is working is such harsh condition.

While the single two-stage compressor well solves above problems. Compared to the

compound two-stage compressors and multi unit of single stage compressors, the single

two-stage compressors occupy less space and the system is easy to control, so it's more

efficiency and reliable.

The LT-S single two-stage low temperature type compressor can achieve

-60~-65℃evaporating temperature; the water outlet temperature of the LT-S-H single

two-stage high temperature type compressor can reach 90℃ when it is applied on water

source and ground source heat pump, which meet the heat demand of the radiator and other

industries and -40℃ when it is applied on air source heat pump, which greatly enlarge the

application field of the traditional air source heat pump. Because its energy efficiency ratio in

the low ambient temperature is higher, it's a perfect solution for haze governance and boiler

replacement.

For above reasons, Shanghai Hanbell Precise Machinery Co., Ltd. specialized in the

development of LT series two-stage screw refrigeration compressors which is composed of

two types: the semi-hermetic type (-S) and open type (-G). They can be used in the field of

low temperature refrigeration and high temperature heat pump according to the application.

High efficiency and reliability under big pressure difference and compression ratio working

condition is the main demand in design. It is a product of elite which accumulates Shanghai

Hanbell's rich technology and extensive application experience. LT can be widely used in low

temperature frozen products, frozen tunnels, freezers, process cooling, pharmaceutical

biochemistry, high temperature hot water, central heating and many other industries.

2. Specifications

2.1 Nomenclature

Figure 2-

2.2 Product Line

Figure

﹡NOTE: LT-XXXX includes LT-S/LT-

Disp

lace

men

t

m

3

/

h

-1. Nomenclature of LT Series Compressors

LT Series Compressor Displacement

Figure 2-2. LT Series Compressor Displacement

-S-H

2

3

2.3 Specifications

Model

Compressor

Low Stage High Stage Rotation

Speed

50Hz

r/min

Capacity Control

(Step type: ST)

(Stepless type: SL)

Lubrication

Type

Nozel Level

Displacement LT-S LT-S-H

50HZ 50HZ

m3/h m3/h ST SL

LT-20/10 224 99

2950

10%/50%

100% 10%~100%

Pressure

differential

80 81

LT-30/12 316 134 81 82

LT-45/20 450 207 83 84

LT-55/25 551 257 84 85

LT-65/32 651 313 10%/50%

75%/100%

86 88

LT-83/41 840 396 87 89

Model

Quality Motor

Pressure Test

Type Starting

Voltage

(V)

50HZ

Insulation Protection LT-S LT-S-H LT-S LT-S-H

Kg Bar

LT-20/10 598 620

3

phase

2 pole

Star

Delta 380 Level F

PTC+

PT100 35 15

LT-30/12 620 650

LT-45/20 1158 1200

LT-55/25 1195 1230

LT-65/32 1395 1450

LT-83/41 1430 1490

Figure 2-3.LT Series Compressor Specification

2.4 Application Limits

Co

nd

ensin

g T

emp

erature

Co

nd

ensin

g T

emp

erature

Figure 2-1. R22 Application Range

Figure 2-2. R404A Application Range

4

Co

nd

ensin

g T

emp

erature

Figure 2-3. R134a Application Range

5

6

3. Construction & Functions

3.1 Design Features

1） Unloading-type slide valve in high stage

Patented design, high voltage, automatic unloading VI blocking structure. The pure

mechanical structure design can simply & effectively realize the light loading of the

compressor without additional configuration of solenoid valves and other external

parts.

2） Check valve, shutoff valve and built-in economizer filter

Pre-install check valve, shutoff valve and economizer filter to realize the reliable

protection of the compressor and simplify customer's configuration system.

3） Optimized motor cooling path

Excellent design of the motor cooling path which cools down the motor coil reliably,

that enables the compressors to be used in wider range and enhanced the adaptability

of the compressor.

4） Pressure designed can meet high temperature application

The designed pressure is 36bar which meets the requirements of high temperature

application.

7

3.2 Capacity Modulation

The capacity modulation of LT series screw compressors has step type (3-step / 4-step)

and stepless type. Both of these two different capacity modulations work with the slide valve,

piston rod, cylinder, and piston. See below Figure 3-1.

When the slide valve is at the suction side completely, the screw rotors work with full

displacement under full load, at that time the compressor work volume is the maximum.

When the slide valve moves to the discharge side, the bypass occurs between the slide valve

and the suction side. The existing of the bypass results in the compressed gas of this range

bypassing to the low pressure directly, and the actual suction volume of the screw rotor

decreases. The more the sliding valve moves to the discharge side, the smaller the actual

suction capacity of the compressor will be, thereby reducing the system cooling capacity.

The slide valve is driven by the pressure difference among the internal capacity

modulation.

The lubricant comes from the external oil separator and passes through the oil filter then

enters into the oil inlet port of the compressor, and at last divided into both sides of the piston.

As a result, the piston can be controlled by discharge one side of the high pressure lubricant

to low pressure, letting it flow to the low pressure side so that the slide valve will move with

the piston to realize the loading and unloading of the compressor.

The purpose of the piston spring is to push the piston to its initial position (min. load

position), so as to realize the automatic unloading start. It not only reduces the mechanical

impact on the compressor's moving parts, but also reduces the electrical current during

compressor start up.

Stepless capacity control, solenoid valve(SV1:unloading, SV3:50%, SV5:100% ) is

controlled by a micro controller or a thermal switch to adjust the piston smoothly with stable

control of the cold output. If the oil filter in the capacity adjusting system, capillary or

solenoid valve don't work properly, it will cause the capacity adjusting system to be abnormal

and fail.

Figure 3-1 Capacity Modulation

8

3.2.1 Step-type Control

1） Step-type table

Y: Energize the solenoid valve N: Do not energize the solenoid valve

LT-83/41 &

65/32

Capacity

regulating

system

SV1:

(NC)

SV2:10%

(NC)

SV3:50%

(NC)

SV4:75%

(NC)

SV5:100%

(NC)

100% N N N N Y

75% Y N N Y N

50% Y N Y N N

10%

（Startup/Stop） Y Y N N N

LT-20/10

LT-30/12

LT-45/20

LT-55/25

Capacity

regulating

system

SV1:

(NC)

SV2:10%

(NC)

SV3:50%

(NC) /

SV5:100%

(NC)

100% N N N / Y

50% Y N Y / N

10%

（Startup/Stop） Y Y N / N

Table 3-1. Step-type Capacity Regulating Control Logic

2） Step-type capacity modulation diagram

Figure

3） Description of Step

� 10% load

capacity modulation diagram

Figure 3-2. Step-type capacity modulation

Description of Step-type control

Figure 3-3.10% Load

9

When starting up the compressor, SV1(unloading) & SV2 (10%) need

make the piston keep at the 10% position(Left side)

Under this situation, the high pressure oil passes through SV1 then goes to the right side

of the piston. At the same time, the oil in left side of the piston passes through SV2 (10%)

then going out to the low pressure side.

position.

★ Note: 10% load is for start up only. Running the compressor

recommended.

� 50% load

Under 50% load, SV1&SV3 (50%)

oil passes to the left side of the piston continuously. At the same time, the oil passes through

SV1 goes to the right side of the piston.

If the piston position is at the left side of the 50% hole (the loading is lower than 50%),

the oil in the right side of the piston will pass through SV3 (50%) and go out to the low

pressure side then the piston will move to right side until the position

It’s called loading to the 50% position.

Vice versa, if the piston position is at the right side of the 50% hole (the loading is higher

than 50%), the oil in the left side of the piston will pass through SV3 (50%) and go out to the

When starting up the compressor, SV1(unloading) & SV2 (10%) need

make the piston keep at the 10% position(Left side)



hen going out to the low pressure side. By doing so, the piston can be held at the 10%

p only. Running the compressor at 10% load for a long time is not

Figure 3-4.50% Load

1&SV3 (50%) are energized. Under this situation, the high pressure


goes to the right side of the piston.



pressure side then the piston will move to right side until the position b

It’s called loading to the 50% position.



10

When starting up the compressor, SV1(unloading) & SV2 (10%) need to be energized to



doing so, the piston can be held at the 10%

at 10% load for a long time is not

energized. Under this situation, the high pressure




blocks the 50% hole.



low pressure side then the piston will move to left until the position

called unloading to the 50% position.

� 75% load

Under 75% load, SV1&SV4 (75%)

The logic of 75% load is similar to th

75% hole to make the compressor run under 75% position.

pressure side then the piston will move to left until the position blocks the

called unloading to the 50% position.

Figure 3-5.75% Load

Under 75% load, SV1&SV4 (75%) are energized.

The logic of 75% load is similar to that of 50%. The piston can be held at the 75% position by

75% hole to make the compressor run under 75% position.

11

blocks the 50% hole. It’s

of 50%. The piston can be held at the 75% position by

� 100% load

Under 100% load, SV5 (100%)

passes to the left side of the piston continuously. At the same time, the oil in the right side of

the piston passes through SV5 (100%) then goes to the low pressure side to make the piston

be held at 100% position.

1） The control of the water temperature with step

★ Note: T & T' should be adjusted by system designer’s experience and practical application.

50%

Start

Set point + 2T

Set point + T

Set point

Set point– T'

100%

t1 t2

75% 10%

1~3

min

Condensing water temp.

Figure 3-6.100% Load

Under 100% load, SV5 (100%) are energized. Under this situation, the high pressure oil

to the left side of the piston continuously. At the same time, the oil in the right side of


The control of the water temperature with step type

Figure3-7. Water Temperature Control with Step Type

should be adjusted by system designer’s experience and practical application.

Stop

50% 75%

60~90 sec

12

energized. Under this situation, the high pressure oil

to the left side of the piston continuously. At the same time, the oil in the right side of


Water Temperature Control with Step Type

should be adjusted by system designer’s experience and practical application.

Time

Stop

10%

60~90 sec

3.2.2 Stepless Type Control

Stepless type is suitable when the refrigeration system needs to achieve precise control of

cooling capacity.

1） Stepless-type table

N: Do not energize the solenoid valve

LT Series

Capacity

regulating system

SV1:

(NC)

Loading N

Unloading Pulse active

Holding N

10% load

（Start/Stop） Stay active

Table 3-2. Stepless Type Capacity Regulating Control 50%~100%

2） Stepless-type capacity modulation diagram

Figure 3

is suitable when the refrigeration system needs to achieve precise control of

type table

Do not energize the solenoid valve

SV2:10%

(NC)

SV3:50%

(NC)

N N

Pulse active N Stay active

N N

Stay active Stay active N

2. Stepless Type Capacity Regulating Control 50%~100%

type capacity modulation diagram

Figure 3-8. Stepless-type capacity modulation

13

is suitable when the refrigeration system needs to achieve precise control of

SV5:100%

(NC)

Pulse active

N

N

N

2. Stepless Type Capacity Regulating Control 50%~100%

3） Description of Stepless

In stepless type control, the oil keeps going to the left side of the piston. The oil bypass

in the left side of the piston is controlled by SV

the piston is controlled by SV1 and oil bypass in the right side of the pisto

SV5 (100%). These three solenoid valves are controlled by temperature controller or PLC.

Through the three solenoid valve, the cooling capacity can be controlled at any position

from 50%~100%, so periodical adjustment of

stably.

★ Note: SV2(10%) can only be used for machine start and stop. Don't run the machine

at 10% loading for long time once the machine is started. It shall be switched to loading

model directly.

The stepless type capacity regula

controller(optional), eg. PLC etc. in order to control the system at the

� Loading

During loading process, the SV5 (100%)

valve are not activated. In this kind of situation, the

the piston continuously and the oil in the right side of the piston bypasses through SV5 (100%)

to the low pressure side. The piston

compressor will load.

Description of Stepless-type control

type control, the oil keeps going to the left side of the piston. The oil bypass

s controlled by SV3 (50%). The oil charging in the right side of

the piston is controlled by SV1 and oil bypass in the right side of the pisto



from 50%~100%, so periodical adjustment of SV1、SV3、SV5 can control the energy output

SV2(10%) can only be used for machine start and stop. Don't run the machine


The stepless type capacity regulating system shall be connected to the micro

etc. in order to control the system at the 6

Figure 3-9. Loading

he SV5 (100%) adopts pulse activation, and the

valve are not activated. In this kind of situation, the high pressure oil goes into the left side of


to the low pressure side. The piston will continue to move to the right side and the

14

type control, the oil keeps going to the left side of the piston. The oil bypass

0%). The oil charging in the right side of

the piston is controlled by SV1 and oil bypass in the right side of the piston is controlled by



control the energy output

SV2(10%) can only be used for machine start and stop. Don't run the machine


ting system shall be connected to the micro

6

and the rest solenoid

high pressure oil goes into the left side of


to the right side and the

� Unloading

During unloading process, t

and the rest solenoid valve are not activated. T

continues to inject into the left side of the piston &

right side of the piston. Through SV3(50%), it bypasses to the low pressure side, so that the

piston continues to move to the lift side, an

Figure 3-10. Unloading

During unloading process, the SV2(50%) stays active, and SV1 adopts pulse activation

rest solenoid valve are not activated. The high pressure oil coming from the oil tank

into the left side of the piston & passes through SV1 and goes into the

Through SV3(50%), it bypasses to the low pressure side, so that the

piston continues to move to the lift side, and the compressor will load to 50% piston.

15

and SV1 adopts pulse activation ,

coming from the oil tank

passes through SV1 and goes into the

Through SV3(50%), it bypasses to the low pressure side, so that the

d the compressor will load to 50% piston.

� Holding

During this process, all S/V are not energized.

tank continues to inject into the left side of the piston. The left side oil inlet of the piston

SV1and SV5(100%) are closed to keep the oil amount in the piston right side. The piston will

not be able to move and stay at its original position, so that the compressor capacity wil

change as well.

� The control of the water temperature with stepless type

Below picture shows load control model of single compressor using stepless type capacity

regulation.

Chilled water temp.

Figure 3-11. Holding

, all S/V are not energized. The high pressure oil coming from the oil

into the left side of the piston. The left side oil inlet of the piston

to keep the oil amount in the piston right side. The piston will

not be able to move and stay at its original position, so that the compressor capacity wil

The control of the water temperature with stepless type

load control model of single compressor using stepless type capacity

Figure 3-12 Stepless Capacity Regulation

16

The high pressure oil coming from the oil

into the left side of the piston. The left side oil inlet of the piston

to keep the oil amount in the piston right side. The piston will

not be able to move and stay at its original position, so that the compressor capacity will not

load control model of single compressor using stepless type capacity

12 Stepless Capacity Regulation Time

★ Note：X′ : Upper Limit；X〞:Lower Limit

� Description

� The real value is larger than the top line between A & B. It means the required cooling

capacity is increasing and the compressor needs to be loaded until the

the control range.

� The real value is smaller than the bottom line between C & D. It means the required

cooling capacity is decreasing and the compressor needs to be unloaded until the real

value returns to the control range.

Figure 3-13 Solenoid Valve Action Intervals

★ Note：For detail stepless type capacity regulation control logic, please refer to Table 3

Load/Unload functions between A and B & C and D.

� Open means S/V is energized

� Close means S.V is not energized

� T1，T3：Pulse time 0.5~1.5seconds

� T2，T4：Pause time 10~20seconds

:Lower Limit；X:Set Point；H: Control Range；

The real value is larger than the top line between A & B. It means the required cooling

capacity is increasing and the compressor needs to be loaded until the

The real value is smaller than the bottom line between C & D. It means the required


value returns to the control range.

13 Solenoid Valve Action Intervals-Stepless type

For detail stepless type capacity regulation control logic, please refer to Table 3

Load/Unload functions between A and B & C and D.

Open means S/V is energized

Close means S.V is not energized

Pulse time 0.5~1.5seconds

Pause time 10~20seconds

17

；Y:Actual value

The real value is larger than the top line between A & B. It means the required cooling

capacity is increasing and the compressor needs to be loaded until the real value returns to

The real value is smaller than the bottom line between C & D. It means the required


Stepless type

For detail stepless type capacity regulation control logic, please refer to Table 3-2

3.2.3 The Positions of Solenoid Valves

1. LT-65/32, LT-83/41

Figure

2. LT-20/10, LT-30/12, LT

Figure 3-15 LT

3.2.3 The Positions of Solenoid Valves

Figure 3-14 LT-83/41&LT-65/32 S/V position

LT-45/20, LT-55/25

LT-20/10&LT-30/12&LT-45/20&LT-55/25 S/V position

18

S/V position

3.3 Compressor startup loading

To decrease the mechanical loading to compressor’s parts and

during start up. Hanbell designs for LT compressor the function of unloading startup. To

ensure compressor loads steadily, please follow Figure 3

whole loading process.

When compressor is about to shut down, it is also required to unload. Theref

the slide valve is at lowest loading position during next startup and compressor could have an

unloading startup. Thus Hanbell requires n

is, it should be unloaded step by step to minimum loading

Figure 3

Caution：

1） After startup, keep the minimum load for

minimum load for 30 seconds

2） After startup, when the pressure difference between high pressure and middle pressure

is less than 3.5bar, the compressor shall be run at 10% load at low pressure stage. Don't

load and open ECO.

3） t＞30 seconds(Time can be set to 30~60seconds)

4） After the compressor shut down, the SV1 & SV2(10%) need to be still energized

minutes, so as to ensure the compressor can still at min loading position at next startup

5） Hanbell strongly recommends that the compressor start

shall refer to above diagram.

written in LT-S Control Requirements.

loading & stop unloading

the mechanical loading to compressor’s parts and reduce

designs for LT compressor the function of unloading startup. To

ensure compressor loads steadily, please follow Figure 3-16 to load step by step during the

When compressor is about to shut down, it is also required to unload. Theref


Thus Hanbell requires no matter what loading condition o f the compressor

step by step to minimum loading before stop.

Figure 3-16. Compressor Sartup & Stop Process

After startup, keep the minimum load for 10 seconds. Before shut down, keep the

econds(Time can be set to 10~60seconds)

when the pressure difference between high pressure and middle pressure

3.5bar, the compressor shall be run at 10% load at low pressure stage. Don't

(Time can be set to 30~60seconds).

After the compressor shut down, the SV1 & SV2(10%) need to be still energized

the compressor can still at min loading position at next startup

Hanbell strongly recommends that the compressor start-up and shutdown control log

shall refer to above diagram. For detail information, please refer to the regulations

S Control Requirements.

19

reduce the starting current

designs for LT compressor the function of unloading startup. To

to load step by step during the

When compressor is about to shut down, it is also required to unload. Therefore ensure


what loading condition o f the compressor

. Before shut down, keep the

(Time can be set to 10~60seconds).

when the pressure difference between high pressure and middle pressure

3.5bar, the compressor shall be run at 10% load at low pressure stage. Don't

After the compressor shut down, the SV1 & SV2(10%) need to be still energized for 3

the compressor can still at min loading position at next startup.

up and shutdown control logic

For detail information, please refer to the regulations

4. Lubricant

4.1 Lubricant Table

Note:

1) Please refer to the table above to select the suitable

operation range need to be taken into consideration as well.

2) Hanbell strongly recommends do not use the lubricant which isn’t certified by Hanbell

since it may damage the compressor seriously.

3) This table is for LT series compressors only

4) The oil temperature at the point when the compressor starts is suggested to be 5K higher

than the corresponding saturation temperature of the oil separator in order to avoid too

much oil containing in the refrigerant which may affect th

5) After compressor stops, please turn on the oil heater. If the compressor shuts down for a

long time, the oil heater doesn’t need to be turned on. Please turn on the oil heater for

more than 2 hours before next start up.

4.2 Oil Charging

1) Make sure the system is clean and free of

2) In order to ensure no moisture in the system, Hanbell suggests cleaning the system by

charging dry Nitrogen and vacuuming for several times. Try to make vacuuming time as

longer as possible to eliminate moisture in the system.

Note:

a. Hanbell strongly recommends do not use the lubricant which isn’t certified by Hanbell


b. Hanbell strongly recommends do not mix up different lubr

compressor seriously. Please pay attention to this issue in all future maintenance.

Table 4-1 Lubricant Specification

Please refer to the table above to select the suitable lubricant and the refrigerant and its

operation range need to be taken into consideration as well.

Hanbell strongly recommends do not use the lubricant which isn’t certified by Hanbell


es compressors only

The oil temperature at the point when the compressor starts is suggested to be 5K higher


much oil containing in the refrigerant which may affect the lubricant.

After compressor stops, please turn on the oil heater. If the compressor shuts down for a


more than 2 hours before next start up.

Make sure the system is clean and free of welding debris before charging



longer as possible to eliminate moisture in the system.



b. Hanbell strongly recommends do not mix up different lubricant since it may damage the


20

lubricant and the refrigerant and its

Hanbell strongly recommends do not use the lubricant which isn’t certified by Hanbell

The oil temperature at the point when the compressor starts is suggested to be 5K higher


e lubricant.

After compressor stops, please turn on the oil heater. If the compressor shuts down for a


welding debris before charging the oil.




icant since it may damage the


21

4.3 Oil Change

4.3.1 Oil Change Schedule:

1）Check lubricant every 10,000 hours of continuous running. For the first operation of

the compressor, it is recommended to change the oil and clean the external oil filter

after running 2,000 hours. Check the system whether clean or not and then change oil

every 20,000 hours or after 4 years continuous running while the system operates in

good condition.

2）The oil will deteriorate if the compressor runs at high discharging temperature (Above

95℃) in the long term. Please avoid this situation, but if it’s necessary to run in this

condition, please shorten the intervals of oil changing.

4.3.2 Pre-cautions of Changing Oil

1） It is recommended to double check the quality of oil periodically in order to

maintain the lubrication performance.

2） The lubricant absorbs moisture in the air. Avoid the situation that oil expose to

air for a long time

3） It is a must to change the oil in motor burned out case, because acid material and

debris may still remain inside the system. Please follow the procedures mentioned

above to change the oil in the system. Check acidity of oil after 72 hours of

operation and then change it again until acidity of oil returns to normal value.

4） The foreign body of the oil will block up the oil line, so it is necessary to install

the oil filter in oil line. It is necessary to install the pressure sensor before and after

the oil filter. If the pressure difference between these two sensors reaches 1.5 bar,

the oil filter need to be changed.

5） The acidity of oil will affect directly the life of the motor, and it is recommended

to change the oil when PH≤6. (Please also change the filter drier at the same time

to make sure the system is in dry condition.）

6） It is important to change the oil, especially when the motor burnt because the

acidity remains in the system. By changing the oil can help check the status of the

system. Check the acidity of the lubricant, re-change the after the system runs for

72 hours until the acidity of the lubricant reaches the standard valve.

7） In case of motor burned out, please not only change the compressor, but also

change the oil and check the condition of the oil periodically. If the acidity

excesses the standard, please change it immediately and always be aware of the

cleanliness and moisture content in the system.

22

5. System Application

★ Note：Please consult Hanbell for parallel application and heat pump application.

5.1 Piping Design

5.1.1 Suction and Discharge Piping Layout

1） Material and structure of suction and discharge pipe

The vibration is low when the compressor is in operation so it is not

necessary to use flexible joint materials for suction and discharge tubes. However,

piping in other places must be flexible enough without causing any inner stress

for the compressor. It is recommended to use copper tube for the suction and

discharge piping in order to lower the piping vibration when the compressor is in

operation.

2） The dimensions of suction and discharge piping:

It is recommended to design the dimension of suction and discharge piping

according to Hanbell’s suggestion.（refer to 10.2.2）

3） Piping for the parallel system

To improve the system operation efficiency, it’s necessary to reduce the

gas-flow resistance and consider the oil return of suction piping.

The recommended piping of suction and discharge side for parallel system is shown

below:

Be aware of the dimension of the main pipe should not be less than the dimensions of the

other pipes to make sure the pressure drops could be controlled in reasonable ranges.

23

� Recommended discharge piping

Figure 5-1: Discharging piping for parallel system

Detail drawing 1

� Recommended suction piping

Figure 5-2: Suction piping for parallel system

x x x

x x x

Refrigerant drained to the

condenser

Detail drawing 2

Refrigerant from

evaporator

4） Suction Filter

There is a built in suction filter in compressor, but it only functions as a final

protection, so it cannot be used as a normal suction filter which requires

periodically clean.

Please install anot

periodically clean.

It might require frequent cleaning of

commissioning. If the pressure drop is higher than

change the filter or clean it until the system is clean.

if the filter is damaged,

the piping. When installation, please confirm the direction of suction

correct, and it is highly recommended to install service valves before and after

the filter chamber for easy maintenance. Hanbell recommended suction filter

layout as shown below

★ Note：The external suction filter is for low temperature refrigeration system; it's not necessary for high

temperature heat pump.

5.1.2 Economizer Piping Layout

1） Dimension of Economizer

A stop valve of the economizer is the standard accessory. It’s recommended

to design the dimens

（Refer to 10.2.2）

2） Check valve for the economizer

Parts of oil and refrigerant will flow back when the working condition is not


, so it cannot be used as a normal suction filter which requires

Please install another suction filter（25μm）at the suction area

require frequent cleaning of the suction filter

commissioning. If the pressure drop is higher than 0.5bar

change the filter or clean it until the system is clean. When dismantling the filter,

damaged, please change it immediately and clean the

the piping. When installation, please confirm the direction of suction



layout as shown below Figure 5-3.

Figure 5-3 Suction filter

suction filter is for low temperature refrigeration system; it's not necessary for high

Economizer Piping Layout

Dimension of Economizer


to design the dimension of the piping according to Hanbell’s suggested value.

Check valve for the economizer


24


, so it cannot be used as a normal suction filter which requires

at the suction area & do

the suction filter in the initial

0.5bar，it’s necessary to

When dismantling the filter,

please change it immediately and clean the debris left in

the piping. When installation, please confirm the direction of suction filter is



suction filter is for low temperature refrigeration system; it's not necessary for high


ion of the piping according to Hanbell’s suggested value.


25

stable or when economizer route is closed. In order to avoid this situation, the

check valve should be installed in the economizer piping.

3） Filter for economizer

There is a built in economizer filter for protecting the compressor from

debris penetration in initial commissioning. It is not suitable to change the core of

this filter and do periodically cleaning. If the system do need this function, please

add another external filter on the economizer piping.

5.1.3 Minimum Pressure Valve

The oil pressure difference between oil inlet on middle pressure chamber and

discharge pressure must reach 2.5 bar in 30 seconds after start up.

If the oil pressure difference is too low, the oil supply is not sufficient and may

cause damage to compressor.

So, we provide a minimum pressure valve for LT series compressor, as to

achieve the pressure difference between high pressure and middle pressure quickly.

The minimum pressure valve should be mounted after the external oil filter, and

connected to the compressor medium pressure test point.

The place of the minimum pressure valve and its assembly method are shown as

below picture.

Figure 5-4. Pressure Maintenance Valve Assembly Diagram

26

Model Single

Parallel configuration

Two in parallel Three in

parallel

Four in

parallel

LT-20/10 2” 3” 4” 5”

LT-30/12 2” 3” 4” 5”

LT-45/20 2.5” 4” 5” 6”

LT-55/25 2.5” 4” 5” 6”

LT-65/32 2.5” 4” 5” 6”

LT-83/41 2.5” 4” 5” 6”

Table 5-1. Pressure Maintenance Valve configuration Single & in Parallel

★Note：For LT series compressors, the standard minimum pressure valve size we provide to you is

the same as that of the discharge valve.

★Note：Besides the standard size, other sizes are optional (refer to 10.2.4)

★Note：LT series compressor must be equipped with minimum pressure valve.

5.1.4 Liquid Line Filter Dryer

It will cause damage to the compressor and system even a low moisture content

left in the system, so it’s a must to install a filter drier on liquid line to keep the

system dry.

5.1.5 Sight Glass with Moisture Indicator

It is strongly recommended to install the sight glass with moisture indicator in

order to observe the moisture content in the system. When the moisture content is

high, it is necessary to change the filter dryer.

★Note：Hanbell can provide the sight glass with moisture indicator ad an option.

27

5.2 Oil Line

5.2.1 Oil Supply

The oil is supplied by the pressure difference which equals to the pressure

difference between oil separator and oil injection point. The oil is injected into the

bearings and compression casing, and then carried out of the compressor with

discharging gas. The oil will enter the oil separator again and complete the oil

circulation.

5.2.2 Lubrication and Capacity Control Modulation

The oil will be injected from two oil injection connectors which supply the oil

to suction and discharge bearings respectively as shown below. Besides, the

connector for the lubrication of suction side bearings is also used for oil supply to

capacity control system.

Figure 5-5 Oil supply connector of discharge bearing & suction bearing

low pressure bearing oil

supply connector

high pressure bearing oil supply connector

5.2.3 Compressor chamber injection cooling system

In certain working condition, the compressor might need liquid inject

chamber to lower the discharge temperature and make sure the

operated properly. There

Figure 5-6 below)

Figure

1） High stage chamber cooling

After low pressure compression, the

Although the economizer provides medium pressure air to mix with the low stage

discharged gas, which realizes

is also responsible for the cooling of the motor,

temperature. Thus, when the re

high stage, the liquid injection cooling function become a must. That's why Hanbell

requires that the high stage chamber liquid injection cooling must be applied.

★ Remark： Hanbell recommends to use oil for liquid injection to chamber.

Compressor chamber injection cooling system

In certain working condition, the compressor might need liquid inject

chamber to lower the discharge temperature and make sure the

operated properly. There is one port for liquid injection to chamber. (As shown in the

Figure 5-6 Connector for Liquid injection to chamber

age chamber cooling

After low pressure compression, the temperature of the gas has been higher.


discharged gas, which realizes a certain intermediate cooling. However, the refrigerant

is also responsible for the cooling of the motor, so it remains with over high

temperature. Thus, when the refrigerant with over high temperature is compressed in



Hanbell recommends to use oil for liquid injection to chamber.

28

In certain working condition, the compressor might need liquid injected to the

chamber to lower the discharge temperature and make sure the compressor will be

for liquid injection to chamber. (As shown in the

temperature of the gas has been higher.


a certain intermediate cooling. However, the refrigerant

so it remains with over high

frigerant with over high temperature is compressed in



29

Suggestions for oil line layout

Figure 5-7 Basic oil line

30

5.2.4 Protection in Oil Line

The normal operation of line system is critical to the reliability of compressor.

To ensure the normal operation of the capacity modulation, reliability of the bearing

and cooling effect, please pay attention to the below points:

1) Oil temperature

The oil inlet temperature of lubricant needs to be strictly maintained.

When temperature of oil is too low：

� It may lead to the viscosity of the lubricant over high and insufficient oil supply and

abnormal capacity control.

� It may cause excessive liquid refrigerant dissolving in the lubricant, which leads to

severe oil being carried over, resulting in oil lacking in the system. The lubrication

effect will be influenced as well, and it will lead to the bearing to be damaged.

When temperature of oil is too high：

� The viscosity will reduce, so the lubricant effect will be poor, which leads to

premature of bearing.

� Cooling effect is bad and results in high discharge temperature. In strict condition,

the compressor may be stuck.

� High temperature will accelerate the deterioration of the lubricant and shorten the

service life of the bearing. If the lubricant isn't replaced on time, it may cause serve

damage to the compressor.

Note

1） When the compressor is running, the temperature of oil should be kept

between20℃~60℃

2） When compressor stops, the oil heater needs to be switched on to make the oil

temperature above 20℃

3） When compressor is stopped for a long time, the oil heater can be switched off.

However, a great number of refrigerant may be dissolved in lubricant due to long term

stop, so the lubricant may be diluted in the lubricant and its viscosity is too low. That's

why the oil requires to be heated to 20℃ before machine start.

★ Note：Hanbell can provide the oil heater（Refer to 10.4.4）.

2) Oil filter

The cleanliness of the lubricant is very important to compressors. If the welding

debris or other debris enters the compressor along with the lubricant, it would cause

damage to the bearings or the screw rotors. Thus, Hanbell requires to install an oil

filter and it must be after the cooler to ensure no new debris will enter into the

lubricant once it is filtered.

It is suggested to install a pressure difference switch to detect the pressure

drop before & after the oil filter. If the pressure drop bigger than 1.5 bar, the

compressor must be stopped for cleaning or replacing the oil filter to ensure enough

31

lubricant supply pressure and cleanliness.

★ Note：Refer to Figure 5-7 for the layout of oil filter and pressure difference switch.

3) Oil pressure difference

The oil supply to compressor is depending on the oil pressure difference. To ensure

the oil supply, it is necessary to keep the pressure difference between oil inlet and

middle pressure chamber/suction pressure above 2.5 bar.

4) Oil level protection

It is suggested to install an oil level switch in oil tank or oil sump to ensure the oil

supply.

5) Oil flow protection

To ensure the oil supply and increase the reliability, an oil flow switch is also

suggested.

★ Note：1）Refer to Figure 5-7for oil flow switch installation

2）Hanbell provides oil flow switch（refer to 10.3.1）

5.2.5 Oil Cooling System

It is normally used in high pressure ratio working condition. Under such working

condition, a lot of heat will be generated, and part of the heat will be taken away by the

lubricant, so if additional measures are not taken to cool down the lubricant, the

temperature will be over high, which cannot be able to meet the conditions of

compressor's normal operation.

Installing an external cooler is a normal way to solve the problem, which can make

the temperature of the lubricant remain at a certain reasonable range. Thus the

compressor can work properly even in strict working condition.

★ Note：

1) It is suggested to install the oil cooler near the compressor.

2)When the piping of the cooler is designed, please make sure to avoid the gas chamber formed inside

the cooler or the lubricant inside the cooler go into the oil separator or the compressor after

compressor is stopped. That's why the position of the oil cooler is normally lower than that of the

compressor and the oil separator.

3) Be sure to equip a temperature control device for the oil cooler to ensure that the oil temperature is

between 40℃~60℃.

4) A bypass way is suggested to be designed for ease the control of oil temperature. Refer to Figure

5-8&5-9&5-10.

Below are the three oil cooler layout suggested by Hanbell.

1） Air cooling type

★ Note：During heating operation, it is

avoid heat loss.

2） Water cooling type

★ Note：If the water temperature appropriate, the water is suggested to be taken from the water

inlet of the condenser to recover the oil cooler load to the hot water side.

During heating operation, it is recommended not to use the air cooling type oil cooler to

Figure 5-8. air cooling oil cooler

If the water temperature appropriate, the water is suggested to be taken from the water

recover the oil cooler load to the hot water side.

Figure 5-9. water cooling oil cooler

32

recommended not to use the air cooling type oil cooler to

If the water temperature appropriate, the water is suggested to be taken from the water

3） Refrigerant oil cooling

★ Note：Oil cooler takes liquid from the liquid pipe and returns back to compressor medium pressure

gas inlet

5.3 Motor Liquid Injection Cooling

The motor is mainly cooled down by the gas refrigerant.

from the low stage together with the gas from the economizer flows through the motor to

achieve the cooling of the motor.

However, in strict working condition, the cooling effect of gas refrigerant is not sufficient.

As a result, Hanbell designed port on the mot

the liquid refrigerant can be injected to the medium pressure cham

refrigerant enters the medium pressure chamber, it will diffuse with the air flow to realize the

cooling of the motor. Meanwhile, it guarantees the minim

working condition of the compressor.

Refrigerant oil cooling

Oil cooler takes liquid from the liquid pipe and returns back to compressor medium pressure

Figure 5-9. refrigerant oil cooling

Liquid Injection Cooling

cooled down by the gas refrigerant. The gas refrigerant discharged

together with the gas from the economizer flows through the motor to

achieve the cooling of the motor.


port on the motor to assist the cooling of the

the liquid refrigerant can be injected to the medium pressure cham


Meanwhile, it guarantees the minimum energy loss and expand the

working condition of the compressor.

33

Oil cooler takes liquid from the liquid pipe and returns back to compressor medium pressure

The gas refrigerant discharged

together with the gas from the economizer flows through the motor to


to assist the cooling of the motor, from which

the liquid refrigerant can be injected to the medium pressure chamber. Once the liquid


energy loss and expand the

34

Figure 5-11 Port for liquid injected in to cool the motor

★ Note：

1）Refer to 2.4 for the working condition that liquid injection to motor is necessary.

2）PT 100 motor temperature sensor is a standard accessory for controlling the liquid injection solenoid valve.

liquid injection to motor port

35

5.4 Economizer System

Cooling capacity and efficiency will increase by applying an economizer in front of

expansion valve to get sub cool effect. Economizer has significant effect especially in high

pressure ratio working condition.

For a two stage compressor, the economizer is even more required. Due to its two stage

design, the economizer effect is magnified. Both cooling capacity and COP increase are more

significant in two stage than those of single stage compressor. The gas supplied by the

economizer could reduce the discharge temperature of low stage therefore the discharge

temperature at high stage can be maintained. This increases the compressor performance,

reliability and widens the application limit.

Here are two typical application systems for the economizer:

5.4.1 Sub Cooler

With this form of operation, a heat exchanger (refrigerant sub-cooler) is used to

sub-cooled liquid refrigerant. The sub-cooling is achieved by injecting a part of the

refrigerant from the condenser through an expansion device in counter flow into the

sub-cooler, which then evaporates due to the absorption of heat. The superheated vapor is

pulled into the compressor at the economizer connection and mixed with the vapor, which

is already compressed in low stage.

The sub-cooled liquid is at condensing pressure with this form of operation, the pipeline

to the evaporator does not therefore require any special features, aside from insulation.

The system can be generally applied.

Figure 5-12 shows the system with economizer, sub-cooler.

Figure 5-12 Sub cooling economizer system

36

5.4.2 Flash Tank

The liquid sub-cooling is achieved with this form of operation by reducing the boiling

point pressure in an intermediate pressure vessel (flash type sub-cooler) arranged between

condenser and evaporator. This physical effect leads to the cooling of the liquid down to

the boiling point, due to evaporation of part of the liquid. To stabilize the pressure of the

vessel, a regulator is used which at the same time controls the quantity of vapor flowing to

economizer connection of the compressor.

This form of operation gives the most economical thermodynamic performance due to

direct heat exchanging. As the intermediate pressure is reduced to the boiling point

temperature this system should only be used with flooded evaporators. Figure 5-13 shows

the system with economizer, flash type sub-cooler.

Figure 5-13. Flash tank economizer system

5.5 Recommended System Layout

Figure 5-14 Recommended

Figure 5-15 Recommended system layout

System Layout

Recommended system layout- Cryopreservation

15 Recommended system layout-air source heat pump

37

Cryopreservation

air source heat pump

6. Motor Design

6.1 Motor Parameters and Design

� Motor design

Standard starting method of

6.1.1 Y-Δ Start

Y-Δ motor connects motor coil by Y connection during starting therefore reducing

voltage on coils to 1/3 of input voltage and reconnects motor coil by

starting. By doing so, we can decrease starting current thorough voltage drop, i.e.,

so-called voltage-drop starting.

Y-Δ motor connection method is shown in the following motor wiring diagram:

In Y connection, MCM, MCS are inductive while motor leads Z,X,Y

neutral connecting as Y fashion. A few seconds later (3~5 sec is recommended), MCM,

MCS become deductive. Around 0.25 sec later, MCM, MCD are inductive, it turns out

run connection.

Caution：

After Y start, MCM & MCS are deducti

inductive for Δ run. Within as transient

inappropriate action of contactors, causing trip of compressors. When it occurs, we

recommend usage of adjustable Y

MCM, MCS deduction - MCM, MCD re

micro controller or PLC program. Please refer to Y

motor is not powered during Y-

Motor Parameters and Design

Standard starting method of Hanbell LT series screw compressor is

Δ motor connects motor coil by Y connection during starting therefore reducing

voltage on coils to 1/3 of input voltage and reconnects motor coil by


drop starting.

Δ motor connection method is shown in the following motor wiring diagram:

In Y connection, MCM, MCS are inductive while motor leads Z,X,Y


MCS become deductive. Around 0.25 sec later, MCM, MCD are inductive, it turns out

After Y start, MCM & MCS are deductive for 0.25 sec and then MCM & MCD are

Δ run. Within as transient as 0.25 sec, pseudo short circuit might occur due to


recommend usage of adjustable Y-Δ dedicated timer or slightly lengthen span of time for

MCM, MCD re-induction from 0.25 sec to 0.5 sec max directly in

micro controller or PLC program. Please refer to Y-Δ shift time diagram for details. Because

-Δ shift, shorter Y-Δ shift span is suggested to prevent second

38

series screw compressor is Y-Δ start.

Δ motor connects motor coil by Y connection during starting therefore reducing

voltage on coils to 1/3 of input voltage and reconnects motor coil by △ connection after


Δ motor connection method is shown in the following motor wiring diagram:

In Y connection, MCM, MCS are inductive while motor leads Z,X,Y are tied together as a


MCS become deductive. Around 0.25 sec later, MCM, MCD are inductive, it turns out △

ve for 0.25 sec and then MCM & MCD are

as 0.25 sec, pseudo short circuit might occur due to


ated timer or slightly lengthen span of time for

to 0.5 sec max directly in

Δ shift time diagram for details. Because

Δ shift span is suggested to prevent second

39

start due to decreased rotation speed. However, if Y-Δ shift span is too short,

aforementioned pseudo short circuit might occur.

Full load Amper

Starting

Current

Time

I (AMP)

Y- shift time 0.25~0.5sec

Figure 6-2. Y-△ transaction time diagram

� Y-Δ start features

1. Starting current in Y connection is 1/3 of lock rotor ampere.

2. Starting torque in Y connection is 1/3 of lock rotor torque.

3. Acceleration of motor rotor becomes smaller at full-load starting, therefore compressors

require starting at partial load.

� Except for Y-Δ start, concerning soft start or reactance start, please kindly contact

Hanbell for further information.

6.1.2 Power source requirement

� Power limitation

� Voltage limitation

Long term operation：within ±5% of rated voltage

Instant operation：within ±10% of rated voltage

� Frequency：within ±2% of rated frequency

Caution：

Note: In the region where the electricity power is unstable, install an additional hi-low

voltage protector with ± 5% tolerance of normal voltage to ensure safe operating of the

compressor.

� Unbalanced voltage

Unbalanced voltages usually occur because of variations in the load. When the load

on one or more of the phases are different from the other(s), unbalanced voltages will

40

appear. This can be due to different impedances, or type and value of loading in each

phase. Unbalanced voltages can cause serious problems, particularly to the motor.

� NEMA defines voltage unbalance as follows :

Percent voltage unbalance = 100% x

� NEMA states that poly-phase motors shall operate successfully under running conditions

at rated load when voltage unbalance at the motor terminals does not exceed 1%. Furthermore,

operation of a motor with over 5% unbalance is not recommended for it probably results in

motor damage.

Unbalanced voltages at motor terminals cause phase current unbalance ranging from 6 to 10

times the percent of voltage unbalance for a fully loaded motor. This causes motor over

current resulting in excessive heat that shortens motor life, and hence, eventual motor burnout.

If the voltage unbalance is great enough, the reduced torque capability might not be adequate

for the application and the motor will not attain rated speed.

6.1.3 MCC&LRA

Model Start current LRA（A）Y-△

Maximum continues current

MCC（A）

LT-S-20/10 420/140 115

LT-S-30/12 620/206 170

LT-S-45/20 810/270 241

LT-S-55/25 875/292 268

LT-S-65/32 1430/477 305

LT-S-83/41 1430/477 404

Model Start current LRA（A）Y-△

Maximum continues current

MCC（A）

LT-S-20/10-H 880/294 160

LT-S-30/12-H 950/316 235

LT-S-45/20-H 1675/558 310

LT-S-55/25-H 1675/558 380

LT-S-65/32-H 2625/875 450

LT-S-83/41-H 2625/875 580

Table 6-1. MCC&LRA

1） Above data based on 380V, 50Hz power supply.

2） The LRA&MCC data above has nothing to do with the refrigerant or working

(maximum voltage deviation from average voltage)

(average voltage)

41

condition.

42

Temperature

display module

Warning Light

Power Light

Control relay connection

Connection to discharge PTC

Connection to 3 phase main

power supply

Motor protector power

Motor embedded PTC temperature

sensor terminal

Motor embedded Pt100

temperature sensor terminal

Control output to liquid

injection solenoid valve

6.1.4 Terminal cover plate.

Figure 6-3.Terminal cover plate connection diagram

Table 6-2. Nuts specifications for bolt on terminal cover plate

Model Specification

Torque

(N.m)

Model Specification

Torque

(N.m)

LT-S-20/10 M12 nut 35

LT-S-20/10-H M12 nut 35

LT-S-30/12 M12 nut 35

LT-S-30/12-H M12 nut 35

LT-S-45/20 M12 nut 35

LT-S-45/20-H M12 nut 35

LT-S-55/25 M12 nut 35

LT-S-55/25-H M12 nut 35

LT-S-65/32 M12 nut 35

LT-S-65/32-H M12 nut 50

LT-S-83/41 M12 nut 35

LT-S-83/41-H M12 nut 50

43

6.1.5 Terminal box

An IP54 terminal box is provided as standard accessory. Please refer to below diagrams for

dimensions.

LT-45/20,LT-55/25, LT-65/32, LT-83/41

LT-20/10, LT-30/12

Figure 6-4 Terminal Box Dimension

44

7. Compressor installation

7.1 Open compressor wooden crate

Upon receiving the compressor, please check if the crate is intact, and compressor is in

good condition. Please also check accessories and documents to be consistent with order.

Caution：compressor is charged with 0.5~1bar of nitrogen before delivery. Please release

the interior pressure before dismantling any parts on compressor.

7.2 Compressor Lifting

When lifting the compressor, it is recommended to use a steel chain or steel cable.

Make sure that chains, cables or other lifting equipments are properly positioned as shown

below to protect the compressor and its accessories from damaging. Keep the compressor

in horizontal position when lifting, and prevent it from crashing or falling on the ground,

hitting the wall or any other accident that may damage it or its accessories.

Caution：

1） Please ensure the steel cable weight load is sufficient.

2） Check the steel cable and hook before lifting, making sure there is no deform or crack

to avoid accident.

3） Ensure sufficient space for lifting.

Figure 7-1 compressor lifting

45

7.3 Compressor installation

The installation of the compressor in the refrigeration system should be accessible and

make sure that the compressor is away from the heat source to prevent heat radiation. The

compressor should also be installed as close as possible to the electrical power supply for

easier connection. It is necessary to keep good ventilation and low humidity condition in

the site. Make sure that the frame or supporter is strong enough to prevent excessive

vibration and noise while the compressor is running and must reserve enough space for

compressors’ future maintenance work.

Compressor should be installed horizontally. Meanwhile, it is recommended to install

mounting pad to avoid the compressor from delivering vibrations to the piping.

The compressor anchor holes (NO.1~4) are chosen as in figure 7-2&7-3.

1. LT-83/41 , LT-65/32

1

Figure 7-2 LT-83/41 & LT-65/32 anchor holes

2. LT-45/20, LT-55/25

Figure 7-3 LT-45/20&LT-55/25 anchor holes

46

3. LT-20/10, LT-30/12

Figure 7-4 LT-20/10&LT-30/12 anchor holes

47

8. Operation and maintenance

8.1 Compressor commissioning check

8.1.1 Check list before Start up

Items Check point States or standard values

1.Compressor

and

accessories

1. Oil level of external oil

separator

2.Oil temperature

3.Open stop valves

4.Open motor liquid

injection port(angle valve)

1. High oil level window filled.

2. Before start up, heat up the oil to 40℃/

heating time is around 8Hrs.

3. Open caps of stop valves to check.

4. Open cap of angle valve cap to check.

2.Power

system

1. Voltage of main power

2. Voltage of control circuit

3. Insulation resistance

value of the motor

between phase to phase

and phase to ground.

4. Power terminals and

wire cables’ terminals

connection.

5. Grounded

6. Settings of switches,

sensors and controllers.

1. Main power voltage fluctuation range

within ±5%. Instant voltage drop during

start up is less than 10%；

2. Voltage of auxiliary power is 220V±10%.

3. Resistance value should exceed 50MΩ.

4. Power terminals are firmly fixed on

terminal block and well insulated. Keep

wire cables away from heat source and

sharpened metal. Power terminals are fixed

firmly and well insulated. Terminal screw

and block are both required.

5. Installation confirmation.

6. Check original value of design.

3.Piping

system

1. Check the piping is

firmed.

2. Check if there is any

leakage.

1. Observation or manual check.

2. Apply leakage test liquid to check

especially on connections and welding

junctions.

4.Protection

devices

1. Winding temperature

2. Discharge temperature

3. Oil level switch

4. PT100 motor

temperature sensor

1. Not active（close circuit）

2. Not active（close circuit）

3. Oil is full（close circuit）

4. Same or close to environment

temperature.

Table 8-1 Start up check list

48

8.1.2 Check list during operation

1）Start up compressor for 0.5~1 second. Confirm the rotation direction through

monitoring suction and discharge pressure.(correct rotation direction: suction pressure

goes down and discharge pressure goes up at the same time)

2）Check if the oil sight glass on external oil line is full of lubricant after start up. In case

of abnormal, please check pressure difference (oil pressure differential supply), oil

filter and oil line solenoid valve.

3）There will be some oil foams in the oil separator during start up but only in a short

time. When working under rated working condition, the foam will disappear.

Otherwise it means the system is without sufficient oil or there is oil carryover

problem.

4）Compressor’s operating working condition adjustment as follows: suction superheat

shall be within 15K; for low temperature use (R22/R404A), discharge superheat shall

be 25K above condensing temperature. For high temperature use (R134a), discharge

superheat shall be 15K higher than the condensing temperature.

5）The whole system should pass vibration test, especially the piping. If there is

abnormal vibration and noise from compressor, please contact HANBELL.

6）Below items need to be checked every day, when compressor is operating in a long

time: Compressor running data such as 3 phase voltage, current, etc. Oil temperature,

oil level, all the sensors, wiring junctions, and oil line window.

7）When condensing unit operates in job site, we should beware of its complementary

devices and the maintenance schedule after first commissioning.

8）To keep the lubricant viscosity normal at low ambient temperature and to ensure the

function of bearing lubrication, it is suggested to keep the oil heater in the external oil

separator “on” after compressor is turned off. This is to prepare for the next start up.

9）In the running state of the compressor, the liquid supply valve shall not be closed for

evacuation.

49

8.2 Trouble shouting table

Issue Possible Reason

Motor temperature

sensor trip

1. Motor over load, liquid injection solenoid valve malfunctions.

2. Motor temperature sensor switch malfunction.

3. Power system malfunction

4. Defective motor coil.

5. Liquid injection expansion valve malfunctions.

Poor Motor

Insulation

1. Motor line connector wet dew.

2. Defective Motor.

3. Defective power bolts.

4. Defective magnet contactor.

5. Acid in the system deteriorates the insulation

6. Long term running at high temperature cause motor insulation

deterioration.

7. Frequent start up.

8. Too much water content in the refrigerant.

Motor unable to

start up or

switch

1. Inlet solenoid valve failure, which leads to compressor start up at full

load

2. Voltage is too low or wrong.

3. Too much voltage drop, and the magnet contactor s can’t induct.

4. Motor malfunction

5. Phase loss or phase reverse

6. Motor protection switch is active.

7. Wrong connection of motor terminals.

8. Timer of Y−△ starting malfunctions.

9. Capacity of over load relay is too small.

10. Magnet contactors malfunction.

Abnormal

vibration or noise

1. Bearings are damaged.

2. Liquid compression.

3. Overheated rotors touch each other or touched the chamber

4. Oil loss causes bad lubrication effect.

5. Inner parts are loose.

6. Defective piping causes resonance.

7. Objects enter the compression chamber

Reverse time of the

rotor is too long

1. Stop action is not set in control logic.

2. The suction check valve stuck, cannot be closed

Discharge

temperature is too

high

1. Suction superheat is too high. (less refrigerant volume or expansion

valve malfunctions)

2. High pressure side is abnormal. (bad cooling effect, air penetrates in

the system, temp. of cooling water is too high, cooling water flow is

50

Table 8-2. Trouble shooting

too less, heat exchange capability of condenser is bad.)

3. Compression ratio is high without liquid injection.

4. Bearings are damaged. Rotors friction.

5. Oil loss or oil level is too low.

6. Suction check valve malfunctions.

System low

pressure alarm

1. Lack of refrigerant

2. Evaporator frosts seriously, and affects the heat exchange.

3. Opening of expansion valve is too small.

4. Suction filter is blocked by ice or debris.

5. Capacity of evaporator is too small.

6. Wrong setting of the low pressure protection.

System high

pressure alarm

1. Too much refrigerant.

2. Condenser is blocked by debris, dust or penetrated by air.

3. Discharge temperature is too high.

4. Expansion valve is blocked by ice or debris.

5. The capacity of condenser is too small.

6. Wrong setting of high pressure protection.

Oil flow alarm

1. Oil flow switch malfunctions.

2. The condensing pressure is not built up.

3. Oil line blocked.

4. Oil line solenoid valve malfunctions.

Discharge

temperature is too

low


2. Temperature of returned oil is too low.

3. Opening of liquid line expansion valve is too large.

4. Opening of economizer expansion valve is too large.

Oil carry over

1. Discharge temperature is too low.

2. Demister of oil separator malfunctions.

3. Oil temperature is too low（oil heater is not switched on）


5. Opening of economizer expansion valve is too large.

9. Dimensions

9.1 LT-S-20/10

51

9.2 LT-S-30/12

52

9.3 LT-S-45/20&LT-S-55/25

53

9.4 LT-S-65/32& LT-S-83/41

54

9.5 LT-S-20/10-H& LT-S-30/12-H

55

9.6 LT-S-45/20-H& LT-S-55/25-H

56

9.7 LT-S-65/32-H& LT-S-83/41-H

57

58

10. Accessories

In order to provide customers with an overall solution, HANBELL

design standard accessories and optional accessories according to

different application requirements to ensure that the compressor can

be safe, stable operation, and achieve the highest efficiency.

10.1 Accessory list

Accessory list-LT series ● Standard

△ Optional

Item Description Qty Single In parallel

1 Protection module 1 ● ●

2 Suction shut-off valve 1 ● ●

3 Discharge shut-off valve 1 ● ●

4 Economizer shut-off valve 1 ● ●

5 Suction flange bushing 1 ● ●

6 Discharge flange bushing 1 ● ●

7 Economizer flange bushing 1 ● ●

8 Suction check valve 1 ● ●

9 Economizer check valve 1 ● ●

10 Suction filter（suction side） 1 ● ●

11 Suction filter（middle pressure side） 1 ● ●

12 Pressure difference switch(manual reset) 1 ● ●

13 Mounting pad 8 ● ●

14 Minimum pressure valve 1 ● ●

15 Flow switch 1 ● ●

16 Hanbell special oil 1 △ △

17 Solenoid valve oil circuit 1 △ △

18 Oil heater 300W 1 △ △

★ Note：

The standard quantity of minimum pressure valve for single and compressor in

parallel is one. Please refer to Table 5-1. Pressure Maintenance Valve configuration

Single & in Parallel

10.2 Accessory for gas refrigerant line

10.2.1 Shut-off valve

For easy maintenance

discharge, and economizer s

specification are shown below:

Accessory for gas refrigerant line

valve

maintenance & repair, it is suggested to install suction,

discharge, and economizer shut-off valve. Dimension and

are shown below:

10-1. Shut-off valve diagram

59

, it is suggested to install suction,

valve. Dimension and

Figure 10

*Specification of shut-

Model

LT-20/10

LT-30/12

LT-45/20

LT-55/25

LT-65/32

LT-83/41

10.2.2 Flange bushing

Standard flange bushing

Model Discharge

Steel

LT-20/10 2

LT-30/12 2

LT-45/20 2 1/2

LT-55/25 2 1/2

LT-65/32 2 1/2

LT-83/41 2 1/2

Figure 10-2. 5" Suction shut-off valve

-off valve

Size

Suction Discharge Economizer

3" 2"

3" 2"

4" 2 1/2"

4" 2 1/2"

5" 2 1/2"

5" 2 1/2"

Flange bushing

Standard flange bushing-LT series

Discharge Suction Economizer

Copper Steel Copper Steel

2 1/8” 3 3 1/8” 1 1/2

2 1/8” 3 3 1/8” 1 1/2

2 5/8” 4 3 5/8” 2

2 5/8” 4 3 5/8” 2

2 5/8” 5 4 1/8” 2

2 5/8” 5 4 1/8” 2

60

Economizer

1 1/2"

1 1/2"

2"

2"

2"

2"

Economizer

Copper

1 5/8”

1 5/8”

2 1/8”

2 1/8”

2 1/8”

2 1/8”

61

★Note ：Above table lists the standard flange bushing sizes the LT series of Hanbell.

Their size specifications are shown in the table below. If the specification of the

flange bushings are not specified in order, Hanbell will provide standard flange

bushing as written in above table..

If non-standard flange bushing is required, please contacts Hanbell sales

representative when purchasing the compressor.

LT flange bushing size and specification

Figure 10-3 flange bushing

Model Locaiton Diameter &

material

Dimension

A B C D E

LT-20/10

LT-30/12

Discharge Copper 2 1/8"

50 90 30 55 65

Steel 2" 61.3 74

Suction Copper 3 1/8"

66 120 45 80.5 90

Steel 3" 90.2 103

Economizer Copper 1 5/8"

52 75 35 42 52

Steel 1 1/2" 49.3 64

LT-45/20

LT-55/25

Discharge Copper 2 5/8"

60 110 35 68 77

Steel 2 1/2" 77 90

Suction Copper 3 5/8"

76 145 50 93 103

Steel 4" 110 128


50 90 30 55 65

Steel 2" 61.3 74

LT-83/41 Discharge Copper 2 5/8" 60 110 35 68 77

62

LT-65/32 Steel 2 1/2" 77 90

Suction Copper 4 1/8" 80

174 35 106 121

Steel 5" 75 135 154


50 90 30 55 65

Steel 2" 61.3 74

63

10.2.3 Check valve

The discharge check valve on Hanbell LT series compressor

belongs to horizontal type. When the compressor is stopped, the teflon

valve plate will be pushed by spring force to close the opening. This

reduces the time of reverse rotation to protect the compressor.

1）Economizer check valve(Horizontal type)

Figure 10-4. Economizer check valve

Size

Dimension: mm

A B C D E F G H I

2” 102 6 53 69 91 65 90 85 5

2 1/2″ 122 6 69 89 111 85 110 97 5

3″ 138 6 80 99 121 95 120 108 5

4″ 163 6 96 124 146 120 145 123 5

2）Discharge check valve(Horizontal type)

64

Figure 10-5 Discharge check valve

Size Dimension: mm

A B C D E F G H I J

1 1/2″ 86 4 55 59 76 42 60 75 80.5 6

2” 102 4 65 69 91 53 70 90 85 6

2 1/2″ 122 4 85 89 111 67 90 110 97 6

3″ 138 4 95 99 121 80 100 120 108 6

4″ 163 4 120 124 146 96 125 145 123 6

6” 238 5 190 195 216 146 190 215 160 6

★Note: the size of the check valve is same to that of the shut-off valve. Refer to

10.2.1

10.2.4 Minimum pressure valve

The minimum pressure valve

establish enough high and low pressure difference in a short time

the compressor is started.

minimum pressure valve

compressor. Thus, the compressor capacity adjustment and loading is

smooth, so it's especially suitable for the air

the compressor which has

which is caused by the

also has the function of

minimum pressure valve will

connection to the exhaust pipe to p

backflow into the compressor, so as to avoid the long

the compressor effectively.

Figure 10

Specification Pressure difference open

1.5" 3.6±0.3Bar

Minimum pressure valve

minimum pressure valve can make the compressor quickly

establish enough high and low pressure difference in a short time

the compressor is started. When the compressor starts running,

minimum pressure valve ensures the internal oil supply pressure of the


especially suitable for the air-cooled heat pump and

or which has insufficient supply pressure differential

which is caused by the seasonal reasons. The minimum pressure valve

has the function of check valve. When the compressor stops,

minimum pressure valve will quickly cut off the compressor's

nection to the exhaust pipe to prevent the high-pressure gas

into the compressor, so as to avoid the long-term reversal of

the compressor effectively.

Figure 10-6. Minimum pressure valve

Pressure difference open Temperature range

3.6±0.3Bar <120℃

65

can make the compressor quickly

establish enough high and low pressure difference in a short time once

the compressor starts running, the

supply pressure of the


cooled heat pump and

insufficient supply pressure differential

minimum pressure valve

check valve. When the compressor stops, the

the compressor's

pressure gas

term reversal of

Pressure loss

<0.1Bar

2"

2.5"

3"

4"

5"

6"

Size

1.5inch

2 inch

2.5 inch

3 inch

4 inch

A B C D E F

235 93 119 76 109 M16

247 105 126 91 122 M16

300 110 136 111 134 M16

364 122 156 121 153 M20

413 165 166 146 171 M20

66

G H

75 18

90 18

110 18

120 22

145 22

10.3 Oil line accessory

10.3.1 Oil flow switch

An oil flow switch should be installed in the oil returned line

external oil separator

drawing and specification of the oil switch is shown below.

Specification:

Type

3/8” flow switch

5/8” flow switch

1” flow switch

Oil line accessory

10.3.1 Oil flow switch

An oil flow switch should be installed in the oil returned line

external oil separator is installed to protect the compressor.


Dimension Connector

3/8” flow switch DN10 3/8〃

5/8” flow switch DN16 5/8〃

1” flow switch DN25 1〃

67

An oil flow switch should be installed in the oil returned line if the

compressor. The


Connector

68

Figure 10-7. Oil flow switch drawing

Parameters:

� Maximum working

temperature:100℃

� Minimum flow protection: 0.7L/min

� Protection class: IP65 � Maximum working pressure

difference at max. flow:0.01bar

� Maximum current: 5A � Maximum voltage:250VAC

� Maximum voltage:250VAC � Minimum flow protection: 0.7L/min

� Maximum working pressure

difference at max. flow:0.01bar

10.3.2 External oil filter

The oil filter is 300 mesh and can be reused by cleaning.

Figure 10

Specification

3/8”（Φ10）

5/8”（Φ16）

1”（Φ25.5）

� Structure

1.Bolts

6.O-ring

Figure 10-8. External oil filter drawing

A（mm） B（

89 340

89 345

140 370

Specification of external oil filter

2.Cover 3.Gasket 4.Spring

ring 7.Oil inlet 8.Body 9.Oil

69

（mm）

340

345

370

5.Filter core

10.Angel

� Maximum working temperature:105℃

� Power source:220V/ 50Hz

10.3.3 Oil line solenoid valve

10.3.4 Oil pressure differential switch

� Function：Detect the pressure drop before and after the oil filter. If

the pressure drop reaches

to prevent the excessive

which will damage the

� Specification：Hanbell s

can be reset manually

� Instructions：For single

high pressure connector (HP) of the pressure differential switch is

connected to the high pressure connector of the compressor (high

pressure angle valve or discharge oil separator side angel valve) ; the

low pressure connec

the compressor. When the oil resistance exceeds the set valve (1.5

bar), the pressure differential switch (OFF) cut off the compressor

control circuit to remind the user to clean the filter

connected in parallel or single compressor with external oil line, the

oil pressure differential switch shall be installed the inlet and outlet

of the external oil filter. When the circuit is cut off, please clean or

change the oil filter.

Maximum working temperature:105℃

Power source:220V/ 50Hz

Oil line solenoid valve

Oil pressure differential switch

Detect the pressure drop before and after the oil filter. If

reaches the trip point, the switch will be activ

excessive debris to be absorbed at the filter film,

will damage the oil supply problem.

Hanbell standard trip value is 1.5 bar and

nually.

For single compressor without external oil line, the




low pressure connector (LP) is connected to the oil filter flange of



control circuit to remind the user to clean the filter. For compressors




change the oil filter.

Directional arrow at the

bottom“ ”

70

Detect the pressure drop before and after the oil filter. If

the switch will be activated

to be absorbed at the filter film,

tandard trip value is 1.5 bar and the valve

without external oil line, the




tor (LP) is connected to the oil filter flange of



compressors




Directional arrow at the

Figure 10

10.4 Electrical accessory

10.4.1 INT-69HBY motor protector

The INT69 HBY motor protection module is developed for

monitoring the motor

phase lack of the compressor.

The major functional descriptions are as follow:

1. When the supply voltage has been connected,

closes after three second

are below their critical temperature

2. If any one of the internal series thermistor

critical value, the motor protector will be disconnected

3. Press the reset button for 5 seconds to cancel lock protection.

4. In order to avoid tripping caused by reversal of the compressor

because of machine

keep for 20 seconds when the compressor

5. An LED (light emitting diode) (red / green) display

information.

6. Use N/O dry contact relays,

good.

7. The sensor and the supply circuit should be well insulated.

8. The motor prot

frequency drive device.

Technical Data

Figure 10-10. Pressure differential switch

Electrical accessory

69HBY motor protector


monitoring the motor winding temperature, phase sequence and

e compressor.

he major functional descriptions are as follow:

the supply voltage has been connected, the output relay

seconds initialization. At that time all thermistors

are below their critical temperature.

If any one of the internal series thermistor resistance exceeds the

motor protector will be disconnected and locked.

Press the reset button for 5 seconds to cancel lock protection.

In order to avoid tripping caused by reversal of the compressor

because of machine stop, the phase monitoring function can only

keep for 20 seconds when the compressor stops and starts reverse.

An LED (light emitting diode) (red / green) display

se N/O dry contact relays, and its external conditions should

The sensor and the supply circuit should be well insulated.

he motor protection module cannot be used for variable

frequency drive device.

Technical Data

� In normal c

� When pressure difference reach

point,

� When pressure difference is under

set point, push the manual reset

button and 1

71


winding temperature, phase sequence and

the output relay

ll thermistors

resistance exceeds the

and locked.

Press the reset button for 5 seconds to cancel lock protection.

In order to avoid tripping caused by reversal of the compressor

stop, the phase monitoring function can only

stops and starts reverse.

An LED (light emitting diode) (red / green) displays the

external conditions should be

The sensor and the supply circuit should be well insulated.

not be used for variable

In normal case 1-2 is connected.

When pressure difference reaches set

, 3-4 are connected.

When pressure difference is under

set point, push the manual reset

button and 1-2 will be connected.

72

Supply voltage /

double voltage

AC 50/60Hz 115/120V -15…+10% 3VA

AC 50/60Hz 230/240V -15…+10% 3VA

Temperature

monitoring PTC，to DIN 44081/082

Phase monitoring 3AC 50/60Hz 200...575V+10%

Reverse phase Lock

Phase loss Lock

Relay Max.AC 240V, max.2.5A, C300

Min. >24V AC/DC, >20mA

Figure 10-11. INT69 HBY&PTC Wiring

Note: Above drawing is only the wiring for protection module not

the compressor method.

10.4.2 Oil heater 300W

Each Hanbell compressor is equipped with UL certified 300W

oil heater as standard accessory. Restart the compressor after the

long time shut down, please keep the oil heater open for more than 8

hours to ensure the internal temperature of the compressor is higher

than the system temperature and the ambient temperature, avoiding

the poor lubrication effect caused by lubricating oil viscosity too

low.

73

Specification：300W；220V；IP54；UL certificate.

74

10.5 Other accessory

10.5.1 Mounting pad

To reduce the vibration level, mounting pads are suggested

for installation. The torque value to tighten the mounting pad:20～

30N·m.

Note: The anchor of the compressor is shown in Figure 7.3.

� Specification of the mounting pad:

压缩机减振垫

Figure 10-12. Compressor mounting pad

� Mounting pad specification table:

Item A(mm) B(mm) C(mm) D(mm) E(mm) Model

1 50 55 20 20 20 LT-20/10&LT-30/12

2 80 100 20 25 25 LT-65/32&LT-83/41

LT-45/20&LT-55/25

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