Hss 3200 App Iss 2.3 07 11

HallScrew HSS 3200 Series Semi-hermetic Integral Single Screw Compressors
HSS 3216, HSS 3218, HSS 3220 and HSS 3221
Application Manual
HSS 3200 Series Application Manual
J & E Hall International 2011 All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording or by any information storage or retrieval system, without permission in writing from the copyright holder. The copyright in this publication shall be and remain the sole property of J & E Hall International.
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Contents
Contents .................................................................................................................................. 3 List of Figures .......................................................................................................................... 4 List of Tables ........................................................................................................................... 4 1.
1.1. 1.2. 1.2.1. 1.3.
General Description .................................................................................................... 5

Main Features....................................................................................................................... 5 Construction ......................................................................................................................... 5 Internal Relief Valve ............................................................................................................. 7 The Compression Process ................................................................................................... 7
2.
2.1. 2.1.1. 2.2. 2.2.1. 2.2.2. 2.3. 2.3.1. 2.3.2.
Capacity Control and Volume Ratio ............................................................................ 9

Slide Valve Actuation.......................................................................................................... 10 Minimum Load Interlock ..................................................................................................... 10 Continuously Variable Capacity Control ............................................................................. 10 Controlled Stop ................................................................................................................... 11 Uncontrolled Stop ............................................................................................................... 11 Capacity Control by Inverter Drive ...................................................................................... 13 Inverter Size ....................................................................................................................... 13 Inverter Set-up .................................................................................................................... 13
3.
3.1. 3.2. 3.3.
Compressor Lubrication, Sealing and Cooling ......................................................... 14

Capacity Control Actuation ................................................................................................. 14 Bearing Lubrication............................................................................................................. 14 Oil Injection for Sealing and Cooling................................................................................... 14
4.
4.1. 4.1.1. 4.2. 4.3. 4.3.1. 4.3.2. 4.4. 4.5. 4.6.
Oil Support System ................................................................................................... 15

Internal Oil Drain................................................................................................................. 15 Oil Heater ........................................................................................................................... 15 Oil Low Level Sensor (Option) ............................................................................................ 16 Oil Differential Pressure Monitoring .................................................................................... 16 ODP1 .................................................................................................................................. 16 ODP2 .................................................................................................................................. 16 Maintaining Discharge Pressure at Start up ....................................................................... 17 External Oil Cooler/Oil Filter ............................................................................................... 17 Lubricating Oils ................................................................................................................... 17
5.
5.1. 5.2. 5.3.
Compressor Cooling ................................................................................................. 18

Deciding if Liquid Injection is Required ............................................................................... 18 Liquid Injection Control and Economiser Connections ....................................................... 18 Liquid Injection Valve Selection .......................................................................................... 18
6. 7.
7.1. 7.2. 7.3. 7.4. 7.5. 7.6.
3N1 Three Function Valve for HSS 3200 Series Compressors (R134a Only) ......... 21 Integration into the Refrigeration Circuit ................................................................... 22
Oil System .......................................................................................................................... 22 Suction Line ........................................................................................................................ 22 Liquid Separation in the Suction Line ................................................................................. 22 Discharge Superheat .......................................................................................................... 22 Liquid Injection Lines .......................................................................................................... 22 Safety Requirements for Compressor Protection ............................................................... 22
8.
8.1. 8.2. 8.3. 8.4. 8.5. 8.6.
Electrical Connections .............................................................................................. 23

Compressor Starting........................................................................................................... 23 Motor Wiring Connections .................................................................................................. 23 Thermistors......................................................................................................................... 23 Capacity Control Solenoids ................................................................................................ 23 Linear Variable Displacement Transducer (LVDT) ............................................................. 23 Oil Low Level Sensor (Option) ............................................................................................ 23
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HSS 3200 Series Application Manual Appendix 1 Compressor Data ............................................................................................... 25 Appendix 2 Oil Support System Schematic Flow Diagrams ................................................. 38 Appendix 3 Limits of Operation Envelopes ........................................................................... 40 Appendix 4 No Cooling Load Limits ...................................................................................... 46 Appendix 5 Compressor Performance Data ......................................................................... 52 Appendix 6 Pepperl & Fuchs Signal Conditioning Module KFU8-USC-1.D Set up .............. 53
List of Figures
Fig 1 Compression Process.................................................................................................................... 8 Fig 2 Capacity Control Mechanism ......................................................................................................... 9 Fig 3 Continuously Variable Capacity Control ...................................................................................... 11 Fig 4 Oil Differential Pressure Monitoring ............................................................................................. 15 Fig 5 Deciding if Liquid Injection is Required ........................................................................................ 19 Fig 6 Liquid Injection and Economiser Arrangements .......................................................................... 20 Fig 7 3N1 Three Function Valve for HSS 3200 Series Compressors (R134a Only) ............................. 21 Fig 8 Motor Terminal Box Wiring: Star/Delta ........................................................................................ 24 Fig 9 Motor Terminal Box Wiring: Soft-start and Inverter Drive ............................................................ 25 Fig 10 LVDT External Wiring Connections ........................................................................................... 25 Fig 11 Oil Low Level Switch External Wiring Connections ................................................................... 26 Fig 12 Oil Support System .................................................................................................................... 38 Fig 13 Oil Support System With External Oil Cooler/Oil Filter .............................................................. 39
List of Tables
Table 1 External Oil Filter Minimum Specification ................................................................................ 17 Table 2 Basic Set up for 4 mA and 20 mA Output Values at Minimum and Maximum Slide Valve Positions............................................................................................................... 54 Table 3 Setting the Display to Read 0 at Minimum Load and 100 at Maximum Load........................... 56 Table 4 Setting the Relay Switch Value................................................................................................ 57
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1.
General Description
The J & E Hall International HSS 3200 series of semi-hermetic integral compressors are the latest addition to the HallScrew family of oil injected, positive displacement, single screw compressors. Reflecting the very latest innovations in screw compressor technology, they are designed for incorporation into factory built DX chillers using R407c, R134a or R22 with independent refrigerant circuits for each compressor. HSS 3200 series compressors are capable of operating without cooling over a limited range, but when indicated, cooling by liquid injection can be employed. 1.1. Main Features For use with R407c, R134a and R22. Integral oil separator. Designed and tested to international standards. Robust construction. Improved machine clearance control for maximum efficiency. Oil injected for maximum reliability. Balanced loading on main bearings for maximum bearing life. Enhanced slide valve geometry for capacity modulation with minimum loss of efficiency. Infinite adjustment between maximum (100 %) and minimum load (nominal 25 %). Simple, built-in capacity control using two solenoid valves. Economiser facility provided to improve operating efficiency, especially at high compression ratios. For further information refer to publication 2-129 Economiser Facility For HallScrew Compressors. Internal suction/discharge safety relief valve (not UL approved). Integral discharge check valve. Combined discharge stop valve, check valve and head pressure control valve available as optional extra (R134a applications only). High efficiency built in 3 phase, 2 pole motor unit for reliable operation. Two different motor power options. Available for 50 Hz or 60 Hz operation. Motor designed for star/delta or soft-start. Thermistor high temperature protection to motor. Thermistor discharge gas high temperature protection. Built-in oil filter. 1.2. Construction The compressor is driven by a specially designed motor mounted on one end of the compressor main shaft.
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HSS 3200 Series Application Manual The compressor consists of three cast-iron castings which are bolted together. The first casting, the main casing, encloses the motion work comprising the main rotor and star rotors. The second casting, the motor housing, encloses the 3 phase, 2 pole motor. Returning suction vapour flows around the stator/rotor unit, cooling the windings in the process, before entering the main rotor flutes. The third casing provides three functions: a delivery end cover, a separator and an oil filter housing. Thermistor probes, buried deep in each phase of the stator windings, provide protection against high temperatures. Phase wiring and thermistor terminations are made to a terminal plate inside an enclosure mounted on the top of the motor housing. The motion work, i.e. that part of the machine which performs the compression function, consists of three rotating parts; there are no eccentric or reciprocating motions. These fundamental components comprise the cylindrical main rotor in which are formed six-start, helically grooved screw threads with a spherical (hourglass) root form. The main rotor meshes with two identical toothed wheels each having eleven teeth. These wheels (or 'star rotors' as they are called owing to their shape), are made from a special synthetic material. They are located in a single plane diametrically opposite each other on either side of the main rotor, with their axes at right angles to the main rotor axis. As the main rotor turns, it imparts a freely rotating motion to the star rotors. The star rotors are supported by metal backings which are cast in onepiece with the star rotor shafts. Although they are located in place on their backings, the stars are allowed to 'float' a small amount in a rotational sense. This floating action, combined with the low inertia and negligible power transmission between the main rotor and star rotors, ensures compliance of the star/main rotor combination. The star rotor shafts are supported at each end by taper roller bearings. The main rotor is supported on a shaft the other end of which carries the motor rotor. The shaft is supported by an arrangement of rolling element bearings at three positions. This entire assembly is dynamically balanced. The main rotor and star rotors are housed inside the main casing. The inside of this main casing has a somewhat complex shape, but essentially consists of a specially shaped cylindrical annulus, which encloses the main rotor leaving a small clearance. Part of the annulus is cutaway at the suction end to allow the suction gas to enter the rotor. In addition there are two slots, one each side, to allow the star teeth to mesh with the main rotor flutes. The discharge ports (one for each star), are positioned at the other end of the annulus. These ports convey the compressed gas out of the compressor via the discharge outlet. Except for the discharge ports and oil management system, suction pressure prevails throughout the main casing. Side covers are provided to allow easy access to the star rotors, star rotor shafts and bearings, without disturbing working tolerances. The discharge end cover can also be removed to inspect the capacity control mechanism. The compressor is fitted with an integral suction strainer, built into the suction end cover, designed to trap any dirt circulating with the refrigerant which might otherwise enter and damage the compressor.
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HSS 3200 Series Application Manual The integral oil separator is bolted to the rear of the main casing. The impingement type separator is fitted with a knitted stainless steel mesh element which removes the majority of entrained oil from the discharge gas stream. Two sight-glasses, one each side, are provided to check the level of oil in the reservoir at the bottom of the separator. The reservoir is fitted with a 250 W heater. The integral oil separator is fitted with a built-in discharge check valve. As an option, for R134a applications only, the discharge connection can be fitted with a specially designed valve which combines the functions of a stop valve, non-return valve and head pressure control valve in one compact assembly; for further details refer to 6. 3N1 Three Function Valve for HSS 3200 Series Compressors (R134a Only). The 3N1 valve replaces the non-return valve otherwise fitted in the oil separator housing. 1.2.1. Internal Relief Valve The compressor is fitted with an internal suction/discharge relief valve to protect against overpressure, for example, in the event of operation with a closed delivery valve in the system. Adequate system relief valves designed to match the plant design pressure must be retained. 1.3. The Compression Process With single screw compressors the suction, compression and discharge process occurs in one continuous flow at each star wheel. In this process the suction gas fills the profile between the rotor, star tooth and casing. The volume is steadily reduced and the refrigerant gas thereby compressed. The high-pressure gas is discharged through a port, the size and geometry of which is determined by the internal volume ratio (ratio of the volume of gas at the start and finish of compression). This volume ratio must have a defined relationship to the mass flow and the working pressure ratio, to avoid losses in efficiency due to over and under compression. As the HallScrew is a positive displacement compressor, there are three separate stages in the compression cycle: suction, compression and discharge. These are illustrated in Fig 1.
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1. and 2. Suction Main rotor flutes 'a', 'b' and 'c' are in communication at one end with the suction chamber via the bevelled rotor end face, and are sealed at the other end by the teeth of star rotor A. As the main rotor turns, the effective length of the flutes increases with a corresponding increase in the volume open to the suction chamber: Diagram 1 clearly shows this process. As flute 'a' assumes the position of flutes 'b' and 'c' its volume increases, inducing suction vapour to enter the flute. Upon further rotation of the main rotor , the flutes which have been open to the suction chamber engage with the teeth of the other star rotor. This coincides with each flute being progressively sealed by the main rotor. Once the flute volume is closed off from the suction chamber, the suction stage of the compression cycle is complete.
1.
A c b a
Suction Gas
2.
c b a
3. Compression As the main rotor turns, the volume of gas trapped within the flute is reduced as the length of the flute shortens and compression occurs.
3.
c b a B
4. Discharge As the star rotor tooth approaches the end of a flute, the pressure of the trapped vapour reaches a maximum value occurring when the leading edge of the flute begins to overlap the triangular shaped discharge port. Compression immediately ceases as the gas is delivered into the discharge manifold. The star rotor tooth continues to scavenge the flute until the flute volume is reduced to zero. This compression process is repeated for each flute/star tooth in turn. Discharge While the compression process described above is occurring in the upper half of the compressor, there is an identical process taking place simultaneously in the lower half using star B, thus each main rotor flute is used twice per rotor revolution (one by one tooth in each star). The compression process may be likened to an assembly of six double-acting cylinders (the main rotor flutes) in which the star rotor teeth move as pistons (always in the same direction).
Gas a
4.
Oil separator not shown
Fig 1 Compression Process
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2.
Capacity Control and Volume Ratio

HallScrew HSS 3200 series compressors are provided with infinitely variable capacity control as standard. Since the HallScrew compressor utilises fixed intake and discharge ports instead of valves, the overall compression ratio is determined by the configuration of these ports. The degree of compression is governed by the ratio between the flute volume when it is sealed off by the star tooth at the beginning of the compression process, to that immediately before the discharge port is uncovered. This is known as the built-in volume ratio (VR) and is an important characteristic of all fixed-port compressors. In order to achieve maximum efficiency, the pressure within the flute volume at the end of the compression process should equal the pressure in the discharge line at the instant the flute volume opens to discharge. Should these conditions not prevail, either overcompression or undercompression will occur, both of which result in internal losses. Although in no way detrimental to the compressor, inefficient compression will increase power consumption. The compressor is fitted with a pair of sliding valves, one for each half of the symmetrical compression process. These valves reduce pumping capacity by delaying the sealing of the flute volume together with the opening of the discharge port, altering the effective length of the main rotor flutes. The valves permit stepless capacity control down to approximately 25 % of full load (actual minimum value varies with operating conditions).
B Oil Supply NC Load Unload NC
A Oil Vent to Suction
Yoke
Slide Spring
Piston
Permanent Vent to Suction
Fig 2 Capacity Control Mechanism
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HSS 3200 Series Application Manual Each slide valve is housed in a semicircular slot in the wall of the annular ring which encloses the main rotor. As the slide valve travels axially from the full load position it uncovers a port, which vents part of the gas trapped in the main rotor flute back to suction, before compression can begin. When the flute has passed beyond the port, compression commences with a reduced volume of gas. However, a simple bypass arrangement without any further refinement would produce an undesirable fall in the effective volume ratio which in turn causes under compression and inefficient part load operation. To overcome this problem, the slide valve is shaped so that it delays the opening of the discharge port at the same time as the bypass slot is created. 2.1. Slide Valve Actuation The method of operation is illustrated in Fig 2. The capacity control slides valves are joined together by a yoke which is connected to a hydraulic piston, housed inside a cylinder and mounted internally at the discharge end of the compressor. Variation in compressor pumping capacity is achieved by altering the forces acting on the slide valve/piston assembly. Internal drillings communicate pressurised oil to the capacity control cylinder and vent the oil from the cylinder. The flow of oil is controlled by two separate solenoid valves, A and B; the solenoids are normally closed (NC), energise to open. The piston cylinder incorporates a spring. When the compressor is running, a pressure difference is created across the slide valves: discharge pressure acts on one end of the slides, suction pressure at the other end. This differential pressure creates a force on the slides tending to drive them towards the maximum load position. Oil pressure assisted by the spring force acting on the piston, creates an opposing force tending to move the slides towards the minimum load position. When the compressor is required to stop, or if the compressor is stopped before minimum load is attained, for example, a fault condition or operating emergency, the pressures within the compressor equalise. Under these conditions the spring moves the piston and slide valves to the minimum load position, thereby ensuring that the compressor always starts at minimum load. 2.1.1. Minimum Load Interlock Starting at minimum load minimises motor starting current and starting torque. This in turn minimises stresses on the motor and mechanical parts, and also reduces the load on the power supply network. The control system must be interlocked to prevent the compressor starting unless the linear variable displacement transducer (LVDT) provides an at minimum load permit start signal. 2.2. Continuously Variable Capacity Control The plant controller energises and de-energises the solenoids to control the rate of loading/unloading. These signals must be provided by a suitable pulse timer with a minimum pulse length of 0.1 to 0.5 seconds, depending upon the accuracy of control required. Solenoid A is energised to load the compressor, solenoid B is energised to unload.
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HSS 3200 Series Application Manual 2.2.1. Controlled Stop When the compressor is required to stop from a loaded condition, solenoid valve B is energised (open). High pressure oil is admitted to the capacity control cylinder. Oil pressure supplements the force of the spring acting on the unload side of the piston. The combined force is sufficient to overcome the action of the suction/discharge differential pressure and move the slide valves towards the minimum load position. 2.2.2. Uncontrolled Stop When an uncontrolled stop occurs: safety control operating, emergency stop or power failure, the unloading spring automatically returns the slide valves to minimum load. Unlike a controlled stop, unless the compressor was at minimum load before the uncontrolled stop occurred, the capacity control cylinder may contain some refrigerant vapour instead of being completely filled with oil. In this event a hydraulic lock will not be present and uncontrolled loading may occur on restarting. This undesirable behaviour can be minimised by arranging for solenoid valve B to energise (open): If a compressor trip, emergency stop or power failure occurs. 60 seconds before (but not during) compressor start-up. Energised until the compressor is required to load; refer to Fig 3.
CAPACITY CONTROL ACTION Load compressor Oil is vented from the capacity control cylinder. The action of the suction/ discharge differential pressure on the slide/piston assembly overcomes the force of the unloading spring and moves the slide valves towards the maximum load position. Unload compressor High pressure oil is admitted to the capacity control cylinder. Oil pressure supplements the force of the spring acting on the unload side of the piston. The combined force is sufficient to overcome the action of the suction/discharge differential pressure and move the slide valves towards the minimum load position. Hold slide valve position The slide valve is hydraulically locked at the desired load position.
1
SOLENOID VALVE A
SOLENOID VALVE B
Energise (open)
De-energise (close)
De-energise (close)
Energise (open)
De-energise (close) Compressor Permitted to Load
De-energise (close)
Start-up
Start Requested
Compressor Starts (Loading Inhibited) 60 Seconds
Compressor Stopped
60 Seconds Time Solenoid Valve B Energised (Open) Until Compressor Required to Load
Solenoid Valve B Energised (Open)
Solenoid Valve B De-energised (Closed)
Refer to 2.2.2. Uncontrolled Stop.
Fig 3 Continuously Variable Capacity Control
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B Oil Supply Energised (Open)
A Oil Vent to Suction De-energised (Closed)
Unload
Compressor Unloading
Oil Pressure + Spring Force > Suction/Discharge Differential Pressure = Slides and Piston Move Towards Unload
B Oil Supply De-energised (Closed)
A Oil Vent to Suction Energised (Open)
Load
Compressor Loading
Suction/Discharge Differential Pressure > Spring Force = Slides and Piston Move Towards Load
Fig 3 (continued) Continuously Variable Capacity Control
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HSS 3200 Series Application Manual 2.3. Capacity Control by Inverter Drive Instead of using the slide valve, compressor capacity can be controlled using a frequency inverter (also know as Variable Speed Drive or Variable Frequency Drive). If an inverter is used, the load/unload solenoid valves need to be controlled to allow the compressor to start at minimum load but load to full load when the compressor is running. There are three methods of achieving this; Energise the load solenoid continuously irrespective of whether the compressor is running or not. Energise the load solenoid continuously when the compressor is running and the unload solenoid continuously when the compressor is stopped. Remove the plunger from the load solenoid valve (only) and do not fit the coils. When using an inverter, it is of utmost importance that it is both sized and set up correctly. 2.3.1. Inverter Size The inverter must be sized to deliver the maximum current taken by the compressor motor at the maximum power conditions in most cases this is during pull down. The current capacity of an inverter drive is not reduced by running at less than synchronous speed. During pull down, the current can be limited by either using the slide valve to run the compressor unloaded, or by throttling the suction. If it is required to use the slide valve during pull down, then normal manual slide valve control can be used; refer to 2.2. Continuously Variable Capacity Control. 2.3.2. Inverter Set-up The inverter drive used must have the following facilities as a minimum; Load type: constant torque. Control method: PID (automatic) with facility for manual frequency control. Particular attention has to paid to setting up the inverter with the correct minimum frequency, maximum frequency and acceleration time. Minimum frequency and maximum frequency must be set according to the operating conditions; refer to J & E Hall International.
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3.
Compressor Lubrication, Sealing and Cooling

HSS 3200 series compressors are fitted with an integral oil separator and oil filter. The oil performs three basic functions: 3.1. Capacity Control Actuation Oil pressure is used to actuate the compressor capacity control mechanism; refer to 2.1. Slide Valve Actuation. 3.2. Bearing Lubrication The rolling element bearings used in the construction of the HallScrew compressor require a steady but relatively small supply of oil for satisfactory operation and long life. Oil is supplied either directly via separate oil drillings or indirectly from the injection supply to the bearings. 3.3. Oil Injection for Sealing and Cooling The third oil supply, which is the predominant oil usage, provides oil for injection to seal the compression process. In the design of the compressor the star rotor teeth must form an effective seal with the flute profiles in the main rotor, while at the same time maintaining a satisfactory operating clearance. The main rotor flute/star tooth profile enables hydrodynamic and hydrostatic actions to combine to provide a wedge of oil at this point. Between the main rotor and the casing, and in several other positions where a pressure differential is separated by two surfaces moving relative to each other, the oil injected provides a sealing film enabling effective compression to take place. The oil also has a silencing effect. Oil is injected via fixed ports in the casing around the rotor. This provides a variable injection period within the compression process as the compressor unloads. This variation of injection period is so designed as to allow the compressor to operate at lower system pressure differentials at minimum load compared to operation at full load. This provides an element of additional safety during start up at reduced load before full system differentials may be achieved. This arrangement is different to previous HallScrew compressors, in which the compressor was required to load as quickly as possible so that the system pressure difference was built up as quickly as possible. This rapid loading is no longer required. Once normal system pressures have been achieved, oil is injected over a period in the compression process when the pressure of the gas trapped in the flutes is considerably lower than discharge pressure. This means that in the majority of instances the system pressure difference can be used to provide the required oil flow without the need for an oil pump running continuously, while the plant is in operation. The standard method of compressor cooling, when required, is via liquid refrigerant injection directly into the compressor; refer to 5. Compressor Cooling.
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4.
Oil Support System

HSS 3200 series compressors are fitted with an integral oil separator and oil filter. For most applications, an external oil support system is not necessary; refer to 4.5. External Oil Cooler/Oil Filter. The system into which the compressor is to be installed must fully comply with the recommendations in 4.1. to 4.6. Failure to do so could result in deterioration of the compressor, both mechanically and functionally. Typical oil support system schematic flow diagrams for different applications can be found in Appendix 2 Oil Support System Schematic Flow Diagrams. 4.1. Internal Oil Drain An oil drain facility, including a non-return valve (ball type), forms an integral part of HSS 3200 series compressors. Oil which collects inside the compressor casing automatically drains back to the integral oil separator via the internal drain. An external drain line is not required. 4.1.1. Oil Heater The compressor integral oil separator is fitted with a heater to maintain an oil temperature minimum 20 C above the ambient temperature, thereby preventing refrigerant migration into the oil and the resultant loss of viscosity and potential foaming. The oil heater must be electrically interlocked to energise when the compressor stops.
LP
ODP1 = Oil injection pressure Suction pressure

HP
LP
ODP2 = Discharge pressure Oil injection pressure

HP
Suction Pressure Discharge Pressure Suction
Discharge
Oil Pressure
Integral Discharge Non-return Valve
The oil support system must conform with the provisions described in 4.1 to 4.6
Fig 4 Oil Differential Pressure Monitoring
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HSS 3200 Series Application Manual 4.2. Oil Low Level Sensor (Option) Provision is made to fit a level sensor to the oil separator at a point corresponding to a dangerously low oil level. The sensor must be electrically interlocked to stop the compressor if the oil level falls to the danger level. 4.3. Oil Differential Pressure Monitoring As already described in 3. Compressor Lubrication, Sealing and Cooling, HSS 3200 series compressors require an adequate supply of oil for injection, bearing lubrication and capacity control actuation. Under normal operating conditions this oil is supplied via the difference in pressure between discharge and suction pressures. On starting the suction/discharge pressure differential across the compressor builds rapidly. However, this pressure difference must be monitored to ensure it achieves the correct value within a specified time. Oil differential pressure monitoring must continue all the while the compressor is running in case operating conditions cause the differential to fall to an unacceptable level. Under these conditions operation of the compressor must be prevented or alternative oil injection arrangements made. The oil system must be protected by monitoring two oil differential pressures: ODP1 and ODP2. Two different methods are available: Electro-mechanical oil differential pressure switches. Transducers sensing the required pressures, connected to the plant controller with the differential pressure calculation performed by the software programme. 4.3.1. ODP1 This is the differential between oil injection pressure/suction pressure and determines if there is sufficient pressure difference for adequate oil injection to occur. ODP1 = Oil injection pressure Suction pressure Because oil injection takes place into a sealed flute during the compression process an estimate of the pressure in this flute must be made. This pressure is a ratio of the suction pressure and for maximum safety should be taken as twice absolute suction pressure. If ODP1 is sensed by transducers then the pressure ratio from suction to oil should be set to 2. If an oil differential pressure switch is used, this should be set to trip when oil pressure is below twice the maximum operating suction pressure (absolute). Example: Maximum suction pressure 3.0 bar abs (2 bar g) Minimum oil pressure 2 x 3.0 bar abs = 6.0 bar abs Oil differential switch setting (oil pressure suction pressure) = 6.0 3.0 = 3.0 bar On start up there is no system pressure differential, therefore, ODP1 must be timed out. The standard time out period is 30 seconds. If ODP1 is not achieved after this period alternative arrangements must be made. Refer to J & E Hall International for advice on the appropriate action. 4.3.2. ODP2 This is the differential across the oil injection line and should initially be set to 2.0 bar in order to prevent operation in the event of a blocked oil filter or similar obstruction in the oil injection line.
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HSS 3200 Series Application Manual ODP2 = Discharge pressure - Oil injection pressure If it is found that the normal operating ODP2 differential is above 2 bar with a clean filter, then the cut-out differential can be increased accordingly. ODP2 does not need to be timed out. 4.4. Maintaining Discharge Pressure at Start up Because oil pressure is generated by suction/discharge pressure differential, there is a minimum discharge pressure value which must be maintained in order to ensure adequate and reliable oil flow. In circumstances where the minimum discharge pressure is difficult to achieve, it is recommend to use the J & E Hall International three function valve; refer to 6. 3N1 Three Function Valve for HSS 3200 Series Compressors (R134a Only). 4.5. External Oil Cooler/Oil Filter HSS 3200 series compressors are fitted with an internal oil filter which is adequate for factory built chillers for which these compressors are designed, where system cleanliness can be guaranteed. The HSS 3200 series is also designed for liquid injection cooling, where necessary, to control the discharge temperature. High rates of liquid injection will derate the performance, so in these circumstances, particularly with refrigerants R407c and R22 with high condensing temperature, an external oil cooler can be used to enhance efficiency. If an external oil cooler is to be fitted and/or an external oil filter is preferred, then a special kit is available, part number M330874501, which allows the internal filter to be removed and provides an outlet for the oil to pass through an external circuit; refer to Fig 13. The minimum specification for an external oil filter is shown in Table 1.
PARAMETER Filter minimum particle size Filter absolute rating Synthetics: felts/glass fibre with in-depth filtration Minimum filter area Paper or cellulose Minimum dirt holding capacity Minimum filter element collapse pressure Complete filter assembly maximum clean pressure drop NOTE: All filter components must be suitable for use with the system oil and refrigerant.
VALUE Down to 5 micron (Beta 5 value >1) 25 micron (Beta 25 value >75) 1500 cm2 5000 cm2 >13.5 gm 20.0 bar 0.7 bar with oil flow of 50.0 lt/min
Table 1 External Oil Filter Minimum Specification
4.6.
Lubricating Oils The choice of lubricant depends on the refrigerant, the type of system and the operating conditions. For applications using R134a, R407c or other HFC refrigerants, ester lubricants must be used. The compressor is supplied already charged with oil, either Emkarate RL68H or ExxonMobil EAL Arctic 68. For applications using R22, the compressor is supplied already charged with Mobil Arctic 300 mineral oil.
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5.
Compressor Cooling
The standard method of cooling for HSS 3200 series compressors is by direct injection of liquid refrigerant into the compressor main rotor flute, part-way through the compression process. For further details refer to publication 2-122 Compressor Cooling. 5.1. Deciding if Liquid Injection is Required As the compressor unloads the condensing temperature decreases because the load on the condenser is reduced. For air conditioning applications in particular (not for process applications), there is a further reduction in condensing temperature associated with the reduced ambient for part load operation. This is added to the reduction in condensing temperature due to the reduced load. There is also a small increase in evaporating temperature. The No Cooling Load Limit envelopes illustrated in Appendix 3 and the examples in Fig 5 are divided into areas which show the compressor percentage load range for operation without liquid injection cooling. 5.2. Liquid Injection Control and Economiser Connections R134a The compressor is fitted as standard with a special liquid injection orifice plug in the top liquid injection/economiser connection only. This plug is used for R134a liquid injection cooling only. The bottom connection is fitted with a solid plug. R407c and R22 The standard arrangement for R22 and R407c is to use a thermostatic liquid injection valve. In this case the special orifice plug fitted in the top connection and the blank plug fitted in the bottom connection should be removed. It may be possible to use the R134a arrangement for R22 and R407C applications with limited maximum condensing temperature (approximately 50 C SDT), but this must be subject to verification by trial, undertaken by the chiller manufacturer, that the maximum discharge temperature is not exceeded when the maximum liquid injection demand is required (this may be at minimum load). Such trials must be at the chiller development stage (not on an end user installation) and must be sanctioned by J & E Hall International Ltd for the warranty to remain valid. Different connection arrangements are used depending on the application and the refrigerant, these are summarised in Fig 6. 5.3. Liquid Injection Valve Selection The liquid injection valve must be specifically designed for liquid injection cooling of screw refrigeration compressors. The valve may be thermostatically operated (e.g. Alco 935 series) or electronically via a temperature transducer, transmitter and controller. The liquid injection valve must be sized to control discharge temperature at 90 C. Select the valve as follows: Use the J & E Hall International HSS 3200 series compressor selection programme, available on CD, to obtain the cooling requirement for the required duty. Use the graphs in publication 2-122 Compressor Cooling to obtain the pressure difference for the operating conditions. Select the correct valve from manufacturers literature.
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Step 1 Plot the design operating conditions at maximum load on the envelope. If the plotted point is above the line Liquid Injection Cooling Always Required, liquid injection cooling is required at all loading conditions. If the point is somewhere below the line, liquid injection cooling is not required at full load, proceed to Step 2. Step 2 Plot the design operating conditions at minimum (25 %) load on the envelope, taking into consideration the reduction in condensing temperature, the increase in evaporating temperature and accounting for other compressors that may be running at maximum load. If the plotted point is within the 25 % to 100 % area, then the compressor can run without liquid injection at minimum (25 %) load. Liquid injection is not required at any loading conditions provided the design operating conditions at 50 % load, when plotted, is within the 50 % to 100 % area. If the minimum (25 %) load point is within the 50 % to 100 % area, then either: a) b) Liquid injection cooling will be necessary for operation at minimum (25 %) load, or If it is not intended to provide liquid injection, the compressor must be prevented from unloading below 50 %.
10 -20 -15 -10 70
Example 1
Liquid Injection Cooling Always Required Above This Line
60
Plotted Point at Maximum Load
75 % to 100 %
50
Full Load Only Compressor Unloads 50 % to 100 %
Plotted Point at 50 % Load
40
Plotted Point at Minimum (25 %) Load
30
25 % to 100 %
20
In this Example, Liquid injection is Not Required at Any Loading Conditions

-5 0 5 10 15
Example 2
70
If the 50 % load design point is within the 75 % to 100 % area, then either:
60
Plotted Point at Maximum Load
c) d)
Liquid injection cooling will be necessary for operation at 50 % load, or If it is not intended to provide liquid injection, the compressor must be prevented from unloading below 75 %.
50
75 % to 100 % Full Load Only Compressor Unloads 50 % to 100 %

40
Plotted Point at 50 % Load Plotted Point at Minimum (25 %) Load
NOTES If, by this processes, it is decided that liquid injection is not required, as a precaution, the actual discharge temperature must be checked at all loading conditions.
30
If load limiting is applied, ask J & E Hall International for the correct slide valve position to achieve this. Compressor capacity is infinitely variable from 100 % to approximately 25 % of full load (depends on the operating conditions). These load limit lines for liquid injection are approximate and are only intended to be used as a guide. More detailed analysis can be made using the compressor selection software.
20
25 % to 100 %
In this Example, Liquid injection is Required at Minimum (25 %) Load. Unloading Limited to 50 % For No Liquid Injection.
10 -20 -15 -10 -5 0 5 10 15
Fig 5 Deciding if Liquid Injection is Required
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Page 19 of 58
Thermostat set to 90 C with 5 C switch differential Liquid Supply For Injection Discharge Line to Condenser
Suction
Plug with orifice fitted to top liquid injection connection R134a Liquid Injection Only
Discharge Line to Condenser
Liquid Supply For Injection Remove plug with orifice from top liquid injection/economiser connection
Tee Return From Economiser
Branch lines after the tee must be of equal diameter and length so that liquid is distributed uniformly to both connections
All Other Applications
Remove blank plug from bottom liquid injection/economiser connection APPLICATION
REFRIGERANT
LIQUID INJECTION AND ECONOMISER
ECONOMISER ONLY
LIQUID INJECTION ONLY Connect liquid supply to plug with orifice in top connection. Interlock solenoid valve with thermostat as shown.
R134a
Remove plug with orifice from top connection, remove blank plug from bottom connection. Connect branch lines as shown in the diagram, but using R134a liquid injection line controls if necessary.
R22 and R407c
Remove plug with orifice from top connection, remove blank plug from bottom connection. Connect branch lines as shown in the diagram.
Fig 6 Liquid Injection and Economiser Arrangements
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6.
3N1 Three Function Valve for HSS 3200 Series Compressors (R134a Only)
As an option, for R134a applications only, the discharge connection can be fitted with a specially designed valve which combines the following functions in one compact assembly. Discharge stop valve. Discharge check valve. Head pressure control valve (useful for applications using an air cooled condenser). Note: when fitting or refitting the 3N1 valve, the pilot line between the valve and the connection provided on the compressor sensing suction pressure must be fitted. Failure to do so will prevent the valve from opening. The 3N1 valve replaces the non-return valve otherwise fitted in the oil separator housing discharge.
Suction Line
Pilot Line Sensing Suction Pressure
3N1 Three Function Valve Discharge Line
Pilot Line to Connection on Compressor Sensing Suction Pressure
Discharge Connection on 3N1 Three Function Valve: 2 NB (2 1/8 OD)
Discharge
Discharge Connection on Integral Separator
Fig 7 3N1 Three Function Valve for HSS 3200 Series Compressors (R134a Only)
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Page 21 of 58
7.
Integration into the Refrigeration Circuit

The HSS 3200 compressor is an oil injected screw type. The integral oil separator is an impingement type. Oil separators are not 100 % efficient, so the system must be designed to return any oil carried over into the system from the separator, back to the compressor. The system should therefore be single circuit and direct expansion. The suction return to the compressor must be dry gas in order to achieve full performance. Liquid return will be detrimental to performance although unlike reciprocating compressor is not harmful to the compressor in small quantities. However large quantities of liquid or oil returned to the compressor via the suction line can form an incompressible fluid in the rotor flutes with resultant damage to the compressor. Thus the system must be designed to prevent such occurrences. 7.1. Oil System The recommendation in 4. Oil Support System should be adhered to. 7.2. Suction Line The suction line should be designed to allow any build up of liquid to drain back to the evaporator. Refrigerant gas velocities should be sufficient to ensure recirculating oil is returned to the compressor. 7.3. Liquid Separation in the Suction Line If liquid is present in the suction line due to excessive carry over from the evaporator and velocities are low, separation of the liquid can occur. If Ubends are present in the suction line liquid can collect in these traps. If the flow rate is suddenly increased (due to sudden increase in compressor load) then this liquid can be carried through to the compressor as a slug. It is these large erratic slugs of liquid that are detrimental to the compressor rather than constant small amounts of liquid return. 7.4. Discharge Superheat Adequate discharge superheat is essential in order to prevent excessive liquid refrigerant dilution of the oil in the separator. If excessive refrigerant is present then oil viscosity will be reduced to an unacceptable level. The main problem however, is that for a small change in discharge pressure oil foaming and loss of oil from the separator can occur. Thus a safe minimum discharge superheat should be taken as 13.0 K for R134a and 20 K for R22 and R407c. 7.5. Liquid Injection Lines If liquid injection is required, different arrangements are used depending on the refrigerant; refer to 5. Compressor Cooling. 7.6. Safety Requirements for Compressor Protection There are a number of system pressures and temperatures which must be monitored to protect the compressor and obtain an overall view of performance; refer to Appendix 1 Compressor Data.
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8.
Electrical Connections
8.1. Compressor Starting The HSS 3200 series compressor motor is wired for star/delta starting. Soft-start or inverter drive starting methods can be accommodated using terminal links available from J & E Hall International. These links could be used for DOL starting, but this method of starting is not preferred by J & E Hall International. Installing the terminal links requires modification to the terminal insulators; refer to J & E Hall International. 8.2. Motor Wiring Connections Terminal box wiring is illustrated in Fig 8 and Fig 9. Refer to Appendix 1 Compressor Data for motor data. The standard terminal box rating is IP54, IP65 available to special order. 8.3. Thermistors Compressor motor and discharge high temperature thermistors are fitted as standard and should be wired as illustrated in Fig 8. 8.4. Capacity Control Solenoids The solenoids must be connected to a suitable plant controller that will energise the appropriate coil to load or unload the compressor via changes to the operation of the system into which the compressor is fitted. The measured variable may be chilled water temperature, suction pressure, etc. Power must be supplied to the solenoids via a suitable pulse timer with a minimum pulse length of 0.1 to 0.5 seconds, depending upon the accuracy of control required. Operation of the solenoid with load is not linear, more pulses will be required at low loads for the same change in load compared with operation at high load. 8.5. Linear Variable Displacement Transducer (LVDT) The LVDT provides a continuous 4 to 20 mA slide valve position signal between minimum load (25 %) and maximum load (100 %). Slide valve position is not linearly proportional to the actual capacity of the compressor and greater slide travel is required at low load compared with high loads for the same change in load. The LVDT is only available without calibration, this must be done on the controller. However, a signal conditioning module is available for applications where this is not possible. External wiring connections are shown in Fig 10. Set up instructions for the signal conditioning module can be found in Appendix 6 Pepperl & Fuchs Signal Conditioning Module KFU8-USC-1.D Set-up. 8.6. Oil Low Level Sensor (Option) External wiring connections are shown in Fig 11. A conditioning relay is required to provide a volt-free contact.
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Page 23 of 58
L2
NOTE: circuit must be connected as shown to ensure correct rotation of the motor/compressor
L1
Motor thermistors T1 and T2 (supplied) Motor Terminal Plate
Fuse
T2 6
2 4 3 5 T1
Limit of J & E Hall Supply Reset Motor and discharge thermistors may be connected in series. Thermistors must NOT be connected in parallel.
Limit of J & E Hall Supply Discharge Thermistor INT69TM Thermistor Controller (supplied)
L 11 1 2 N 14 12 Link Link
Thermistors fitted, located adjacent to each discharge port Discharge Thermistor
Compressor safety circuit
Thermistors Tripped
Limit of J & E Hall Supply
Fig 8 Motor Terminal Box Wiring: Star/Delta
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L1
L2
L3
Soft-start or inverter
Motor thermistors T1 and T2 (supplied) Motor Terminal Plate

1 T2 6 2 4 3 5 T1
For applications using a soft-starter or inverter, equipment must be carefully selected to match the operating conditions and must be able to accelerate the compressor smoothly to full load/speed without stalling.
Link motor terminals 1 to 6, 2 to 4 and 3 to 5.
Limit of J & E Hall Supply
Fig 9 Motor Terminal Box Wiring: Soft-start and Inverter Drive
Red 1 (+) Power Supply 24 V dc Black 2 White or Yellow 3 4 to 20 mA Output LVDT
(-)
Wiring for MSI LVDT

Red 1 Black 2 (+) Power Supply 24 V dc (+IN) 2 (-) 0 to 20 mA Input (-IN) 3 15 14 Pepperl & Fuchs Universal Signal Conditioning Module 8 (+OUT) 4 to 20 mA Output 7 (-OUT) Plant Controller White or Yellow 3 4 to 20 mA Output LVDT
12 11 10 KFU8-USC-1.D
Relay Switch
Wiring for LVDT and Pepperl & Fuchs Universal Signal Conditioning Module Fig 10 LVDT External Wiring Connections
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Henry S-9424DN Level Sensor J & E Hall Part Number 131024330 Voltage: 24 V ac/dc Resistive rating: 0.5 Amp Contacts power on and liquid present: NC Interface: DIN plug
Load
ORANGE/White
L1 ac (+ dc)
BLACK
L2 ac (- dc)
WHITE
Fig 11 Oil Low Level Switch External Wiring Connections
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Appendix 1 Compressor Data

HSS 3200 Series: Compressor Model Nomenclature. HSS 3200 Series: Physical Data. HSS 3200 Series: Motor Data - 50 Hz Operation. HSS 3200 Series: Motor Data - 60 Hz Operation. HSS 3200 Series: Limits of Operation. Safety Requirements for Compressor Protection. HSS 3200 Series: Physical Dimensions and Connections 82 kW @ 50 Hz and 98 kW @ 60 Hz Motors. HSS 3200 Series: Physical Dimensions and Connections 138 kW @ 50 Hz and 166 kW @ 60 Hz Motors.
Issue 2.3 : 07/11
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HSS 3200 Series: Compressor Model Nomenclature

Capacity Control Slide VR Stop Valves and Flanges Economiser Kit X Motor Voltage Compressor Motor Power (Nominal) Application Refrigerant Discharge Thermistor X
Voltage (Auxiliary) X
HallScrew
Lubricant
HS
X S 32X 2 3
Capacity Indicator X R407c Other 24 V dc 24 V ac
Application Compressor Capacity Control Slide VR
Semi-hermetic compressor for air conditioning application Series 3200 Twin Star 16, 18, 20 or 21 2.2 VR 3.0 VR Ester oil Mineral oil 82/98 kW @ 50/60 Hz 138/166 kW @ 50/60 Hz 400/460 V 3 ph 50/60 Hz 380 V 3 ph 60 Hz 208 V 3 ph 60 Hz R134a R22 115 V 1 ph 50/60 Hz 230 V 1 ph 50/60 Hz No capacity indicator (standard) Capacity indicator (not self-setting) Capacity indicator (not self-setting + signal conditioning module) Suction and discharge flanges Suction flange and discharge stop valve (standard) Suction flange and 3N1 three function discharge valve Suction and discharge stop valves Suction stop valve and discharge flange Suction stop valve and 3N1 three function discharge valve No economiser kit Economiser kit (standard) Discharge thermistor (max temp 100 C) and Kriwan INT 69 TM controller (standard) D V X C X 3 4 500/575 V 3 ph 50/60 Hz 230 V 3 ph 60 Hz Special voltage
Lubricant
E M
Motor Power (Nominal)
A H
Motor Voltage
Q U B
Refrigerant
A B
Voltage (Auxiliary)
1 2
Capacity Indicator
0 D E
Stop Valves and Flanges
A B C D E F
Economiser Kit
0 1
Discharge Thermistor Example: HSS 3218/2/M/A/D/B/2
This describes a HallScrew 3218 twin star semi-hermetic compressor for air conditioning application fitted with 2.2 VR capacity control slide valves, supplied with mineral oil, fitted with a 82 kW motor suitable for 500/575 V 3 ph 50/60 Hz supply. Compressor for operation with R22. Solenoid/oil heater voltage 230 V 1 ph 50/60 Hz.
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HSS 3200 Series: Physical Data

Compressor Type Compressor Rotation Method of Drive Speed Range Physical Dimensions Capacity and Power Capacity Control Single screw, integral, semi-hermetic. Anti-clockwise looking on the motor end. Under no circumstances should the compressor run in the reverse direction. Suction gas cooled 3-phase, 2-pole stator/rotor arranged for start/delta, soft-start or inverter drive. Maximum of 6 starts per hour. Refer to Motor Data for kW ratings. Depends on the supply frequency, 50 Hz or 60 Hz, refer to Motor Data. Refer to Physical Dimensions and Connections. Refer to selection data. Compressor capacity infinitely variable from 100 % to approximately 25 % of full load (depends on the operating conditions). Slide valve position indication by 4 to 20 mA Linear Variable Displacement Transducer (LVDT). DIN plug terminal box rating IP65. Capacity Control Solenoids Suction Strainer Motor Terminal Box Rating Integral Oil Separator 115 V or 240 V ac (other voltages available on request). Terminal box rating IP65. Integral. 60 mesh x 37 SWG. IP54 (standard), IP65 (available to special order) 250 W heater. Sump capacity 18 litres.
Swept Volume
SWEPT VOLUME (M3/HR) Compressor running @ 50 Hz (2 pole speed) Compressor running @ 60 Hz (2 pole speed)
HSS 3216 286 343
HSS 3218 343 411
HSS 3220 415 498
HSS 3221 471 565
Weights
COMPRESSOR HSS 3200i with 82 kW or 98 kW motor (all models) HSS 3200i with 138 kW or 166 kW motor (all models) 3N1 three function valve (HSS 3200i series only)
1
WEIGHT (KG) 719 840 12
Excluding suction and discharge stop valves
Sound Pressure Levels @ 50 Hz (2 pole speed)
COMPRESSOR HSS 3216 HSS 3218 HSS 3220 HSS 3221
TOTAL DB A 78 78 79 79
CENTRE FREQUENCY HZ 125 63 63 63 63 250 75 76 76 76 500 71 71 74 74 1K 74 75 76 76 2K 69 70 72 72 4K 65 67 68 68 8K 63 66 68 68
Sound pressure level data refers to free-field conditions at a distance of 1 metre from the compressor periphery. It is important to remember that on a specific installation the actual sound pressure level is considerably affected by the size and type of room, material of construction and plant design. Adjoining pipework, including suction, can have a very substantial effect on the noise level. Sound pressure levels given in dB refer to 2 x 10-5 N/m2 RMS.
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HSS 3200 Series: Motor Data 50 Hz Operation

COMPRESSOR RUNNING @ 50 HZ (2980 RPM) Motor nominal output (kW) Refrigerant Capacity control slide valve VR (refer to Appendix 3 for limits of operation) Motor maximum input (kW) Maximum running current (A) @ 400 V Starting current (locked rotor) in Y (A) @ 400 V Starting current (locked rotor) in (A) @ 400 V Standard voltage range (V) R134A 2.2/3.0 73 123 288 906 HSS 3216 82 138 R407C AND R22 2.2 83 135 3.0 110 179 455 1480 400 10 % R134A 2.2/3.0 88 146 288 906 HSS 3218 82 138 R407C AND R22 2.2 99 159 3.0 132 211 455 1480
COMPRESSOR RUNNING @ 50 HZ (2980 RPM) Motor nominal output (kW) Refrigerant Capacity control slide valve VR (refer to Appendix 3 for limits of operation) Motor maximum input (kW) Maximum running current (A) @ 400 V Starting current (locked rotor) in Y (A) @ 400 V Starting current (locked rotor) in (A) @ 400 V Standard voltage range (V) R134A 2.2/3.0 108 177
HSS 3220 82 138 R407C AND R22 2.2 120 191 288 906 3.0 160 253 455 1480 400 10 % R134A 2.2/3.0 122 199
HSS 3221 82 138 R407C AND R22 2.2 135 215 288 906 3.0 181 286 455 1480
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HSS 3200 Series: Motor Data 60 Hz Operation

COMPRESSOR RUNNING @ 60 HZ (3575 RPM) Motor nominal output (kW) Refrigerant Capacity control slide valve VR (refer to Appendix 3 for limits of operation) Motor maximum input (kW) Maximum running current (A) @ 460 V Starting current (locked rotor) in Y (A) @ 460 V Starting current (locked rotor) in (A) @ 460 V Standard voltage range (V) R134A 2.2/3.0 88 122 285 893 HSS 3216 98 166 R407C AND R22 2.2 100 138 3.0 132 182 461 1499 460 10 % R134A 2.2/3.0 106 146 285 893 HSS 3218 98 166 R407C AND R22 2.2 119 163 3.0 158 216 461 1499
COMPRESSOR RUNNING @ 60 HZ (3575 RPM) Motor nominal output (kW) Refrigerant Capacity control slide valve VR (refer to Appendix 3 for limits of operation) Motor maximum input (kW) Maximum running current (A) @ 460 V Starting current (locked rotor) in Y (A) @ 460 V Starting current (locked rotor) in (A) @ 460 V Standard voltage range (V) R134A 2.2/3.0 130 177
HSS 3220 98 166 R407C AND R22 2.2 144 197 285 893 3.0 192 263 461 1499 460 10 % R134A 2.2/3.0 146 201
HSS 3221 98 166 R407C AND R22 2.2 162 222 285 893 3.0 217 297 461 1499
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HSS 3200 Series: Limits of Operation

Pressure Limits The pressure limits detailed below MUST NOT be exceeded during installation, commissioning or operation of the plant. Refer to Appendix 3 Limits of Operation Envelopes for further details. R134a Maximum Design Pressures
2 1
R22 32.9 bar g 6.4 bar g 27.9 bar g 24.0 bar 3.0 bar
R407c 32.9 bar g 6.0 bar g 29.6 bar g 26.0 bar 3.0 bar
High side/low side test pressure 2.2 or 3.0 VR
23.6 bar g 3.5 bar g 19.4 bar g 17.5 bar 2.0 bar
Operational Pressures
Maximum compressor operating suction pressure
Maximum compressor operating discharge pressure Maximum compressor operating pressure differential (discharge suction) Minimum compressor operating pressure differential at minimum load
Temperature Limits Temperature Limits Discharge temperature Discharge minimum superheat 100 C (standard) 120 C (special) R134a = 13.0 K R22 and R407c = 20.0 K Compressors must NOT be subjected to pressures higher than those indicated. This may require isolation of the compressor during system strength pressure testing. 2 Oil separator pressure limits may be less than those applicable to the compressor.
1
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Safety Requirements for Compressor Protection

Parameter Discharge pressure Discharge pressure Trip High Low HP cut-out Pressure control or pressure transducer and programmable controller with suitable analogue inputs Thermistor (fitted as standard) Device Setting According to the operating conditions According to the operating conditions Remarks Connected to compressor discharge -
Discharge temperature
High
100 C (standard) 120 C (special)
For 120 C (special) refer to J & E Hall International. The discharge thermistors can be wired in series with the motor thermistor; refer to Fig 8.
Suction pressure
Low
LP cut-out or pressure transducer and programmable controller with suitable analogue inputs Preferred method: Pressure transducers and programmable controller with suitable analogue inputs Alternative method: Differential pressure switch; refer to Fig 4
According to the operating conditions
Prevents operation at low suction gauge pressures
Oil differential pressure 1 Oil injection pressure suction pressure
Low
Pressure ratio 2
Oil pressure should be twice suction pressure (absolute) 30 second delay required on starting only
Value of the differential to be equal to the value of the highest operational suction pressure (absolute) 2 bar (standard) 3 bar (maximum)
30 second delay required on starting only
Oil differential pressure 2 Discharge pressure - oil injection/lubrication pressure
High
Differential pressure switch (refer to Fig 4) or pressure transducers and programmable controller with suitable analogue inputs
Should be approximately 1 bar above difference when filter is new. ODP2 is not mandatory but is recommended to detect when the oil filter is becoming blocked and it is time to renew the filter element.
Oil separator oil level
Low
Level switch or sensor
Trip on low level
Time delay (5 secs max) required during operation to prevent spurious trips Mandatory requirement if compressor fitted with external oil cooling The motor thermistor can be wired in series with the discharge thermistor; refer to Fig 8. Prevents operation above the maximum rated motor power
Oil temperature
High
Thermistor or HT cut-out
80 C
Compressor motor high temperature
High
Thermistor (fitted as standard)
Compressor motor current
High
Current limiter, or current transformer and programmable controller with suitable analogue inputs
Set according to the compressor motor size
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HSS 3200 Series: Physical Dimensions and Connections 82 kW @ 50 Hz and 98 kW @ 60 Hz Motors

W
Discharge
Oil Temperature Sensor Pocket. Also used for oil level sensor (option) Oil Drain Oil Heater
Sight-glass (Upper) Sight-glass (Lower)
Oil filter removal = 130 mm A Liquid Injection/ Economiser (Bottom)
Dimensions in mm unless otherwise stated. Data provided as a guide only, refer to certified drawing D100454 DESCRIPTION Length
1
SIZE L H W A 1661 mm 647 mm 565.6 mm 380 mm 420 mm 4 x M12 x 1.75P x 21 full thread 2 x M16 x 2P x 27 full thread
Overall
Height Width
Dimensions Holding-down bolt centres B Holding-down bolts Lifting eyebolts -
DESCRIPTION Suction Discharge Suction pressure gauge Discharge pressure gauge Oil pressure gauge (2 positions) Connections 3N1 three function valve HP cut-out Liquid injection/economiser (top and bottom) Oil drain Oil temperature sensor pocket Oil return from external cooler
1
NO OFF 1 1 1 1 1 1 1 2 1 1 1
SIZE 3 NB (3 1/8 OD) 2 NB (2 1/8 OD) 1/8 NPT NPT NPT 1/8 NPT 1/8 NPT 1 1/16 (12 UNF) (16 UNF) NPT 7/8 (14 UNF)
Including discharge stop valve.
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Load Solenoid Valve
Discharge Pressure Gauge
Discharge
Oil Pressure Gauge (2 Positions) Holding-down Bolt Motor housing removal = 450 mm
Oil Drain Connection Star removal = 105 mm B Oil Return From External Cooler Oil Pressure Gauge (2 Positions) Heater
L Liquid Injection/ Lifting Eyebolt Economiser (Top) Star removal = 250 mm
Discharge Thermistor Rotor/shaft assembly removal = 750 mm
Suction Suction Pressure Gauge
3N1 Valve Suction Pressure Connection
Unload Solenoid Valve
HP Cut-out
Lifting Eyebolt
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HSS 3200 Series: Physical Dimensions and Connections 138 kW @ 50 Hz and 166 kW @ 60 Hz Motors
W
Oil Temperature Sensor Pocket. Also used for oil level sensor (option) Oil Drain
Sight-glass (Upper) Sight-glass (Lower)
A B
Oil filter removal = 130 mm Liquid Injection/ Economiser (Bottom)
Dimensions in mm unless otherwise stated. Data provided as a guide only, refer to certified drawing D100359 DESCRIPTION Length
1
SIZE L H W A B C Motor housing 1820 mm 647 mm 565.6 mm 320 mm 380 mm 938 mm 4 x M12 x 1.75P x 21 full thread M20 x 2.5P x 35 full thread 2 x M16 x 2P x 27 full thread
Overall
Height Width Motor housing
Dimensions
Holding-down bolt centres Holding-down bolts Lifting eyebolts
Compressor Compressor/motor housing
Compressor and separator
DESCRIPTION Suction Discharge Suction pressure gauge Discharge pressure gauge Oil pressure gauge Connections 3N1 three function valve HP cut-out Liquid injection/economiser (top and bottom) Oil drain Oil temperature sensor pocket Oil return from external cooler
1
NO OFF 1 1 1 1 1 1 1 2 1 1 1
SIZE 4 NB (4 1/8 OD) 2 NB (2 1/8 OD) 1/8 NPT 1/4 NPT 1/4 NPT 1/8 NPT 1/8 NPT 1 1/16 (12 UNF) 3/4 (16 UNF) NPT 7/8 (14 UNF)
Including discharge stop valve.
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Discharge Pressure Gauge Suction Pressure Gauge H Load Solenoid Valve
Discharge
Oil Drain Connection Holding-down Bolt Star removal = 105 mm C Motor housing removal = 450 mm
Oil Return From External Cooler Oil Pressure Gauge (2 Positions)
Heater
L Lifting Liquid Injection/ Eyebolt Economiser (Top) Lifting Eyebolt Star removal = 250 mm Discharge Thermistor Rotor/shaft assembly removal = 750 mm
Suction
3N1 Valve
Unload Solenoid Valve
HP Cut-out
Lifting Eyebolt
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Appendix 2 Oil Support System Schematic Flow Diagrams
Suction
PI PSLL
HP OD P1 LP PI
LP OD P2 HP
Discharge
PI PSHH
Oil
Evacuation
PT
Suction
Discharge
HT (Del)
TE
Integral Discharge Non-return Valve
Normally Open
Locked Open
Normally Closed
Normally Closed and Capped Valve, straight through
Valve, right angle
Strainer
Non-return valve
Dual relief valve (to atmosphere)
PT
Pressure Transmitter
PI
Pressure Indication (pressure gauge or transducer) Pressure Switch High (discharge high pressure cut-out or transducer) Pressure Switch Low (suction low pressure cut-out or transducer)
ODP
Oil Differential Pressure Switch
PSHH
LLS
Low Level Switch (optional)
PSLL
TE
Thermistor or high temperature cut-out
Fig 12 Oil Support System
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Suction
PI PSLL
HP OD P1 LP PI
LP OD P2 HP
Discharge
PI PSHH
Oil
Evacuation
PT
Suction
Discharge Integral Discharge Non-return Valve HT (Del)

TE
Break Flanges to Allow Oil Filter Removal
Break Flanges on Oil Line to Allow Compressor Removal
Oil Filling Connection Purge
TE
HT (Oil) Oil Filter Circuit Completion When Using Liquid Injection Cooling
Oil Cooler
Second Filter if Double (Duplex) Oil Filters Required
NOTE: internal oil filter must be replaced using special adaptor kit part number M330874501 available from J & E Hall International; refer to 4.5. External Oil Cooler/Oil Filter.
Fig 13 Oil Support System With External Oil Cooler/Oil Filter
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Appendix 3 Limits of Operation Envelopes
Limits of Operation R134a - Standard

70
60
82 kW Motor
50
3.0 VR
Discharge Gauge C
82 kW Motor
40
2.2 VR
30
20
10 -20 -15 -10 -5

Suction Gauge C This diagram is approximate, for guidance only. Refer to HallScrew selection software for definitive envelopes.
10
15
Page 40 of 58
Issue 2.3 : 07/11
Limits of Operation R134a - Economised

70
60
82 kW Motor
50
3.0 VR
Discharge Gauge C
40
30
20
10 -20 -15 -10 -5

10
15
Issue 2.3 : 07/11
Page 41 of 58
Limits of Operation R407c - Standard

70
138 kW/3.0 VR can be used for the whole envelope, but in the 82 kW/2.2 VR area it will be less efficient. 82 kW/2.2 VR can be used up to the motor limit (dashed) line, but in the 138 kW/3.0 VR area it will be less efficient.
60
138 kW Motor
50
82 kW/2.2 VR Motor Limit
Discharge Gauge C
3.0 VR
40
82 kW Motor
30
2.2 VR
20
10 -20 -15 -10 -5

10
15
Page 42 of 58
Issue 2.3 : 07/11
Limits of Operation R407c - Economised

70
60
138 kW Motor
50
Discharge Gauge C
3.0 VR
40
30
20
10 -20 -15 -10 -5

10
15
Issue 2.3 : 07/11
Page 43 of 58
Limits of Operation R22 - Standard

70
138 kW/3.0 VR can be used for the whole envelope, but in the 82 kW/2.2 VR area it will be less efficient. 82 kW/2.2 VR can be used up to the motor limit (dashed) line, but in the 138 kW/3.0 VR area it will be less efficient.
60
138 kW Motor
50
82 kW/2.2 VR Motor Limit
3.0 VR
Discharge Gauge C
82 kW Motor
40
30
2.2 VR
20
10 -20 -15 -10 -5

10
15
Page 44 of 58
Issue 2.3 : 07/11
Limits of Operation R22 - Economised

70
60
138 kW Motor
50
3.0 VR
Discharge Gauge C
40
30
20
10 -20 -15 -10 -5

10
15
Issue 2.3 : 07/11
Page 45 of 58
Appendix 4 No Cooling Load Limits
No Cooling Load Limits R134a - Standard

70
60
Full Load Only
75 % to 100 %
50
Discharge Gauge C
50 % to 100 %
40
30
25 % to 100 %
20
10 -20 -15 -10 -5

10
15
Page 46 of 58
Issue 2.3 : 07/11
No Cooling Load Limits R134a - Economised

70
60
Full Load Only
75 % to 100 %
50
Discharge Gauge C
50 % to 100 %
40
30
25 % to 100 %
20
10 -20 -15 -10 -5

10
15
Issue 2.3 : 07/11
Page 47 of 58
No Cooling Load Limits R407c - Standard

70
60
50
75 % to 100 %
Discharge Gauge C
40
Full Load Only
50 % to 100 %
30
20
25 % to 100 %
10 -20 -15 -10 -5

10
15
Page 48 of 58
Issue 2.3 : 07/11
No Cooling Load Limits R407c - Economised

70
60
50
75 % to 100 %
Discharge Gauge C
Full Load Only
40
50 % to 100 %
30
25 % to 100 %
20
10 -20 -15 -10 -5

10
15
Issue 2.3 : 07/11
Page 49 of 58
No Cooling Load Limits R22 - Standard

70
60
50
75 % to 100 %
Discharge Gauge C
Full Load Only
40
50 % to 100 %
30
25 % to 100 %
20
10 -20 -15 -10 -5

10
15
Page 50 of 58
Issue 2.3 : 07/11
No Cooling Load Limits R22 - Economised

70
60
50
75 % to 100 %
Full Load Only
Discharge Gauge C
40
50 % to 100 %
30
25 % to 100 %
20
10 -20 -15 -10 -5

10
15
Issue 2.3 : 07/11
Page 51 of 58
Appendix 5 Compressor Performance Data

For detailed selection use the J & E Hall International HallScrew compressor selection software, available on CD. Continuous research and development may necessitate changes to specifications and data in this Application Manual and the J & E Hall International Compressor Selection Software. Subcooling & Superheat Correction Factors The performance data is based on 5.0 C suction superheat and 5.0 C liquid subcooling. The suction superheat is assumed to be usefully obtained. Such superheat can be obtained in the evaporator or in a liquid to suction heat exchanger or similar vessel in the refrigeration circuit producing a beneficial effect. The approximate effect of an increase in useful suction superheat is an o increase in capacity of 0.17 % for every additional 1.0 C superheat. Non usefully obtained superheat (such that might be picked up in the suction line due to heat exchange with the environment) will have a detrimental effect on performance. The approximate effect is a loss in performance of approximately 0.7 % o for each additional 1.0 C of non useful suction superheat. It is important to ensure adequate suction superheat. Insufficient superheat can result in liquid carry over into the compressor, reducing performance and also resulting in inadequate discharge superheat for satisfactory oil separation. Additional subcooling will have a beneficial effect on the system performance. The approximate effect of an increase in liquid subcooling is an increase o in capacity of 1.1 % for every additional 1.0 C subcooling. If the useful superheat is obtained in a suction to liquid heat exchanger then only the effect of the increase in suction superheat should be taken in to account. Otherwise the effect on performance will be added twice. Using the increase in suction superheat also includes the effect of the change in specific volume at the compressor suction.
o o
Page 52 of 58
Issue 2.3 : 07/11
Appendix 6 Pepperl & Fuchs Signal Conditioning Module KFU8-USC-1.D Set-up

Basic Set up for 4 mA and 20 mA Output Values at Minimum and Maximum Slide Valve Positions Refer to Table 2. The KFU8-USC-1.D module can be used simply to calibrate the output from the MSI LVDT to provide 4 mA and 20 mA signals, at the compressor minimum and maximum slide valve positions respectively, by following the instructions in Table 2. Setting the Start Value (at minimum load) and setting the End Value (at maximum load) are independent processes. The End Value setting can be made at any time after the Start Value setting. The values can be reset at any time. If necessary, the unit can be reset to the factory settings by following the instructions in the Pepperl & Fuchs manual included with the unit. Setting the Display to Read 0 at Minimum Load and 100 at Maximum Load Refer to Table 3. This procedure is optional and not necessary for the basic calibration of the signal from the MSI LVDT, however it is useful for setting a slide valve position for the relay switch. It also provides a visual display of the slide position as if it were a percentage value. NOTE: although % is a unit option in the module, this cannot be used as the units for this application because it has a pre-programmed function which does not allow the required Factor to be set up (also mA cannot be used as a unit because this is the same as the input units). It is therefore recommended that l is used for the units; this allows the Zero and Factor to be set to give the 0 to 100 numerical values required even though the actual unit is not meaningful. Unless the units are reconfigured, the value displayed on the module is always the actual input value in mA from the LVDT. This is not particularly meaningful for the user. To set the relay switch trip point, the value must be in the units displayed, so if not reconfigured, this would need to be calculated from the input mA for a given slide valve position. It is therefore easier to set the trip point if the display reads 0 at minimum load and 100 at maximum load, then the switch point trip value can be set as if it were a percentage slide valve position. Setting the Relay Switch Value Refer to Table 4. Once the display units have been reconfigured to l and the display values at minimum and maximum load slide positions are 0 and 100 respectively, the switch (Trip) point can be set as a value as if it were a percentage. The Hysteresis value can also be set as equivalent to a percentage. Depending on how it is required for the switch hysteresis to operate with rising and falling values, the module can be configured accordingly; refer to the note at the bottom of Table 4. This is also demonstrated fully in the Pepperl & Fuchs manual included with the unit).
Issue 2.3 : 07/11
Page 53 of 58
KFU8-USC-1.D Display Slide Valve Position Minimum load Input Action Display Record value displayed on unit Press buttons on Display: ESC + OK (together) Unit Input Output OK Relay Analogue Out OK OK Characteristic 0 to 20 mA 4 to 20 mA NE4 OK ESC 4 to 20 mA NE4 Characteristic Start Value OK Numeric Teach In OK OK ESC ESC ESC ESC Minimum load ESC 6.235 mA 6.235 mA Teach In Start Value Analogue Out Output 6.235 mA Default screen 4 mA Flashing Start value saved 9.0 mA 4 mA Minimum load set Flashing Flashing Set (saved) 6.235 mA 9.0 mA Temporary value 6.235 mA Comment For example Value 6.235 mA Comment Start Output
Table 2 Basic Set up for 4 mA and 20 mA Output Values at Minimum and Maximum Slide Valve Positions
Page 54 of 58
Issue 2.3 : 07/11
Slide Valve Position Maximum load
Input Action Display Record value displayed on unit Press buttons on Display ESC + OK (together) Unit Input Output OK Relay Analogue Out OK Characteristic Start Value End Vlaue OK Numeric Teach In OK OK ESC ESC ESC ESC 15.76 mA 15.76 mA Teach In End Value Analogue Out Output 15.76 mA 6.235 mA Default screen 20 mA 4 mA Flashing End value saved 15.1 mA 20 mA 15.76 mA Comment For example Value 15.1mA
Output Comment Temporary value
Maximum load set
Maximum load Minimum load
ESC
Finish
NOTE: Setting the Start Value (at minimum load) and setting the End Value (at maximum load) are independent processes. The End Value setting can be made at any time after the Start value setting.
Table 2 (continued) Basic Set up for 4 mA and 20 mA Output Values at Minimum and Maximum Slide Valve Positions
Issue 2.3 : 07/11
Page 55 of 58
This procedure is optional but recommended for easy set up of the relay switch point (if used); refer to Table 4
KFU8-USC-1.D Display Slide Valve Position

1
Input Action Display 6.235 mA Press the following buttons ESC+OK (together) OK Unit mA
2
Comment For example
Output Value 4 mA
Min load
Flashing Flashing Flashing Unit set
% l l
2 2
OK ESC
Unit Input
OK
Type Zero
OK
4.000 6.23 mA
Flashing Set value = min load input value Zero set
OK ESC
6.23 mA Zero Factor
OK
1.000 10.49
Flashing Set value = 100/(15.765 - 6.235) Multiplying factor set
OK ESC ESC Min load Max load

1 2
10.49 Factor Input 0.000 100.0
ESC
% slide valve setting % slide valve setting
4 mA 20 mA
Operation can be done with the slide valve in any position. The unit of % cannot be chosen for this application because of the special functionality given to it inbuilt in the unit (for example, if % is chosen as the unit then the required Factor cannot be set). Therefore it is suggested that l is chosen as the unit for simplicity although it must be recognised that for this application the unit does not any real meaning, i.e. the value is dimensionless or can be interpreted as a percentage value.
Table 3 Setting the Display to Read 0 at Minimum Load and 100 at Maximum Load
Page 56 of 58
Issue 2.3 : 07/11
Set the display to read 0 at minimum load and 100 at maximum load before setting the relay switch value
KFU8-USC-1.D Display Slide Valve Position

1
Input Action Display 0.000 Press the following buttons ESC + OK (together) Unit Input Output OK OK
2
Comment For example
Output Value 4 mA
Min load
Relay MIN/MAX Trip Default set to MIN
OK
102.4 70.00
For example Flashing Set value (for example) Flashing Trip value set
OK ESC
70.00 Trip Hysteresis
OK
20.98 2.000
For example Flashing Set value (for example) Flashing Hysteresis value set
OK ESC ESC ESC Min load

1 2
2.000 Hysteresis Relay Output 0.000
ESC
4 mA
Operation can be done with the slide valve in any position. MIN setting will make/break switch at Trip value when value is falling. When value is rising, the switch will break/make at the Trip value + Hysteresis value. MAX setting will make/break switch at Trip value when value is rising. When value is falling, the switch will break/make at the Trip value Hysteresis value; refer to pages 18 and 19 of the Pepperl & Fuchs manual included with the unit.
Table 4 Setting the Relay Switch Value
Issue 2.3 : 07/11
Page 57 of 58
J & E Hall International 2011 All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording or by any information storage or retrieval system, without permission in writing from the copyright holder. The copyright in this publication shall be and remain the sole property of J & E Hall International.
Questor House, 191 Hawley Road, Dartford, Kent DA1 1PU England Telephone: +44 (0) 1322 223 456 Facsimile: +44 (0) 1322 291 458 www.jehall.co.uk
Page 58 of 58
Issue 2.3 : 07/11

Hss 3200 App Iss 2.3 07 11

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HallScrew HSS 3200 Series Semi-hermetic Integral Single Screw Compressors

HSS 3216, HSS 3218, HSS 3220 and HSS 3221

HSS 3200 Series Application Manual

Issue 2.3 : 07/11

HSS 3200 Series Application Manual

General Description .................................................................................................... 5

Capacity Control and Volume Ratio ............................................................................ 9

Compressor Lubrication, Sealing and Cooling ......................................................... 14

Oil Support System ................................................................................................... 15

Compressor Cooling ................................................................................................. 18

Electrical Connections .............................................................................................. 23

Issue 2.3 : 07/11

Issue 2.3 : 07/11

HSS 3200 Series Application Manual

Issue 2.3 : 07/11

Issue 2.3 : 07/11

Issue 2.3 : 07/11

HSS 3200 Series Application Manual

Oil separator not shown

Fig 1 Compression Process

Issue 2.3 : 07/11

HSS 3200 Series Application Manual

Capacity Control and Volume Ratio

B Oil Supply NC Load Unload NC

A Oil Vent to Suction

Permanent Vent to Suction

Fig 2 Capacity Control Mechanism

Issue 2.3 : 07/11

Issue 2.3 : 07/11

De-energise (close) Compressor Permitted to Load

Compressor Starts (Loading Inhibited) 60 Seconds

Solenoid Valve B Energised (Open)

Solenoid Valve B De-energised (Closed)

Refer to 2.2.2. Uncontrolled Stop.

Fig 3 Continuously Variable Capacity Control

Issue 2.3 : 07/11

HSS 3200 Series Application Manual

B Oil Supply Energised (Open)

A Oil Vent to Suction De-energised (Closed)

Permanent Vent to Suction

B Oil Supply De-energised (Closed)

A Oil Vent to Suction Energised (Open)

Permanent Vent to Suction

Fig 3 (continued) Continuously Variable Capacity Control

Issue 2.3 : 07/11

Issue 2.3 : 07/11

HSS 3200 Series Application Manual

Compressor Lubrication, Sealing and Cooling

Issue 2.3 : 07/11

HSS 3200 Series Application Manual

Oil Support System

ODP1 = Oil injection pressure Suction pressure

ODP2 = Discharge pressure Oil injection pressure

Suction Pressure Discharge Pressure Suction

Integral Discharge Non-return Valve

Fig 4 Oil Differential Pressure Monitoring

Issue 2.3 : 07/11

Issue 2.3 : 07/11

Table 1 External Oil Filter Minimum Specification