Hallscrew Hs L/M 4200 Series Semi-Hermetic Single Screw Compressors

HallScrew HS L/M 4200 Series
Semi-hermetic Single Screw Compressors

HS L/M 4221, HS L/M 4222 and HS L/M 4223
Application Manual
HS L/M 4200 Series Application Manual
Contents
Contents .................................................................................................................................. 2
List of Figures.......................................................................................................................... 3
List of Tables ........................................................................................................................... 3
1. General Description .................................................................................................... 4
1.1. Main Features.......................................................................................................................4
1.2. Construction .........................................................................................................................4
1.2.1. Internal Relief Valve .........................................................................................................5
1.3. The Compression Process ...................................................................................................6
2. Capacity Control and Volume Ratio............................................................................ 8
2.1. Slide Valve Actuation............................................................................................................9
2.2. Continuously Variable Capacity Control ...............................................................................9
2.2.1. Controlled Stop ................................................................................................................9
2.2.2. Uncontrolled Stop ............................................................................................................9
3. Economiser Facility................................................................................................... 11
3.1. Subcooling of Liquid Refrigerant.........................................................................................12
3.2. Side Load Operation...........................................................................................................12
4. Compressor Lubrication, Sealing and Cooling ......................................................... 14
4.1. Capacity Control Actuation .................................................................................................14
4.2. Bearing Lubrication.............................................................................................................14
4.3. Oil Injection for Sealing and Cooling...................................................................................14
5. Oil Support System ................................................................................................... 15
5.1. Oil Injection/Lubrication ......................................................................................................16
5.2. Oil Drain..............................................................................................................................16
5.3. Oil Separation.....................................................................................................................16
5.3.1. Oil Separator Design......................................................................................................16
5.4. Oil Separator Provisions .....................................................................................................17
5.4.1. Multiple Compressors ....................................................................................................17
5.4.2. Oil Return.......................................................................................................................18
5.4.3. Discharge Non-return Valve...........................................................................................18
5.4.4. Oil Heater.......................................................................................................................18
5.4.5. Oil Low Level .................................................................................................................18
5.4.6. Oil Balance Lines ...........................................................................................................18
5.5. Oil Differential Pressure Monitoring ....................................................................................18
5.5.1. ODP1 .............................................................................................................................19
5.5.2. ODP2 .............................................................................................................................19
5.6. Maintaining Discharge Pressure at Start up .......................................................................19
5.7. External Oil Filter ................................................................................................................20
5.8. Compressor Cooling...........................................................................................................21
5.8.1. Liquid Injection Cooling ..................................................................................................21
5.8.2. Liquid Injection Valve Selection .....................................................................................23
5.8.3. External Oil Cooling .......................................................................................................23
6. Lubricating Oils ......................................................................................................... 25
6.1. Lubricant Types ..................................................................................................................25
6.1.1. Mineral Oils ....................................................................................................................25
6.1.2. Synthetic Lubricants.......................................................................................................25
6.1.3. Semi Synthetic Lubricants..............................................................................................26
7. Integration into the Refrigeration Circuit ................................................................... 27
7.1. Oil System ..........................................................................................................................27
7.2. Suction Line........................................................................................................................27
7.2.1. Liquid Separation in the Suction Line.............................................................................27
7.3. Discharge Line....................................................................................................................27
7.3.1. Discharge Superheat .....................................................................................................27
7.4. Liquid Injection Lines ..........................................................................................................27
7.5. Safety Requirements for Compressor Protection ...............................................................27
8. Electrical Connections .............................................................................................. 28
8.1. Compressor Starting...........................................................................................................28
Page 2 of 52 Issue 2.1 : 07/04

8.2. Motor Wiring Connections ..................................................................................................28

8.3. Thermistors.........................................................................................................................29
8.4. Capacity Control Solenoids ................................................................................................29
8.5. HB Linear Variable Displacement Transducer (LVDT) .......................................................29
Appendix 1 Physical Data, Limits of Operation and Safety Requirements ........................... 30
Appendix 2 Oil Support System Schematic Flow Diagrams ................................................. 36
Appendix 3 Limits of Operation Envelopes ........................................................................... 39
Appendix 4 Liquid Injection Pressure Graphs ....................................................................... 45
Appendix 5 Compressor Performance Data ......................................................................... 50
List of Figures
Fig 1 Compression Process ...................................................................................................................7
Fig 2 Capacity Control Mechanism.........................................................................................................8
Fig 3 Continuously Variable Capacity Control ......................................................................................10
Fig 4 Economiser Cycle on Pressure/Enthalpy (p-h) Diagram..............................................................11
Fig 5 Economiser Arrangements: Wiring to Liquid Line Solenoid Valves .............................................13
Fig 6 Oil Support System......................................................................................................................15
Fig 7 Maintaining Discharge Pressure at Start up ................................................................................20
Fig 8 Liquid Injection Cooling ...............................................................................................................21
Fig 9 Typical Methods of Providing Preferential Supply for Injection ....................................................22
Fig 10 Oil Cooler Temperature Control.................................................................................................24
Fig 11 Terminal Box Wiring (Star/Delta Starting)..................................................................................28
Fig 12 HBLVDT External Wiring Connections ......................................................................................29
Fig 13 Key to Fig 14 and 15 .................................................................................................................36
Fig 14 HS L/M 4200 Series Compressors Oil Support System.............................................................37
Fig 15 HS L/M 4200 Series Compressors Oil Support System – Common Oil Separator ....................38
List of Tables
Table 1 External Oil Filter Minimum Specification ................................................................................20
Table 2 Minimum Specification of Mineral Oils and Polyolester Lubricants ..........................................25
Issue 2.1 : 07/04 Page 3 of 52

1. General Description
The J & E Hall International HS L/M 4200 series of semi-hermetic
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 chillers and compressor packs using HFC
refrigerants or R22.
HS L/M 4200 series compressors are capable of operating without
cooling over a limited range, but when indicated, a suitable cooling
system is required; cooling by liquid injection is the recommended
method.
1.1. Main Features
• For use with R404a, R507, R22, R407c and R134a.
• 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.
• Single connection for oil injection/lubrication/capacity control.
• Economiser facility provided to improve operating efficiency,
especially at high compression ratios.
• Internal suction/discharge safety relief valve (approved for
R134a 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.
The compressor consists of two 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 start/rotor unit, cooling the windings in the process,
before entering the main rotor flutes.
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.
Page 4 of 52 Issue 2.1 : 07/04

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 one-
piece 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 two discharge outlets.
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 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.
To prevent reverse rotation of the compressor at shutdown it is necessary
to fit a non-return valve immediately after the oil separator discharge
outlet; refer to 5.4.3. Discharge Non-return Valve.
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.
At the present time the internal suction/discharge relief valve is only
approved for use with R134a. For all other refrigerants an external
discharge/suction bypass must be fitted to protect the compressor. For
refrigerants other that R134a contact J & E Hall International.
Issue 2.1 : 07/04 Page 5 of 52

1.3. The Compression Process

With single screw compressors the suction, compression and discharge
process occurs in one continuous flow at each star wheel. With this
process the suction gas is pressed into the profile between rotor, star
tooth and compressor case. The volume is steadily reduced and the
refrigerant gas thereby compressed. The high-pressure gas is then
discharged through a port whose size and geometry determine 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.
Page 6 of 52 Issue 2.1 : 07/04

1. and 2. Suction
Main rotor flutes 'a', 'b' and 'c' are in 1.
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 A
rotor A. As the main rotor turns, the effective
length of the flutes increases with a Suction
corresponding increase in the volume open to Gas
the suction chamber: Diagram 1 clearly c

shows this process. As flute 'a' assumes the b
position of flutes 'b' and 'c' its volume a
increases, inducing suction vapour to enter
the flute. B
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 2.
progressively sealed by the main rotor. Once
the flute volume is closed off from the suction
chamber, the suction stage of the A
compression cycle is complete.
b
c
a
3. Compression 3.
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.
c
b
a
4. Discharge 4.
As the star rotor tooth approaches the end of
Discharge
a flute, the pressure of the trapped vapour Gas
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 A
star rotor tooth continues to scavenge the flute
until the flute volume is reduced to zero. This b
compression process is repeated for each
flute/star tooth in turn. a
While the compression process described

above is occurring in the upper half of the
compressor, there is an identical process
B
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).
Fig 1 Compression Process
Issue 2.1 : 07/04 Page 7 of 52

2. Capacity Control and Volume Ratio

HS L/M 4200 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 not only permit stepless capacity control down to
approximately 25 % of full load (actual minimum value varies with
operating conditions), but also maintain the best possible VR over a wide
capacity control range.
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.
B A
Oil Supply Oil Vent

NC NC
Spring Piston Slide
Fig 2 Capacity Control Mechanism
Page 8 of 52 Issue 2.1 : 07/04

2.1. Slide Valve Actuation

While the compressor is running, the position of each slide valve is
controlled by a hydraulic piston actuated by oil pressure. Two solenoid
valves control the oil flow and venting of the piston cylinders.
Variation in compressor pumping capacity is achieved by altering the
forces acting on the slide valve/piston assemblies.
Each piston cylinder incorporates a spring. When the compressor is
running, a pressure difference is created across each slide valve:
discharge pressure acts on one end of the slide, 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 pistons, 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 springs move the slide valves to the minimum
load position, thereby ensuring that the compressor always starts at
minimum load. Starting at minimum load minimises motor starting
current, starting torque and acceleration times. This in turn minimises
stresses on the motor and mechanical parts, and also reduces the load
on the power supply network.
2.2. Continuously Variable Capacity Control
The method of operation is illustrated in Fig 3.
Internal drillings communicate pressurised oil to the capacity control
cylinders and vent the oil from the cylinders. The flow of oil is controlled
by two separate solenoid valves, A and B; the solenoids are normally
closed (NC), energise to open.
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 ≥0.5 second.
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 cylinders. Oil pressure supplements the force of the
spring acting on the unload side of each 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 springs automatically return 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 cylinders 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; ref Fig 3.
Issue 2.1 : 07/04 Page 9 of 52

B A
Oil Supply Oil Vent

Energised De-energised Compressor Unloading
(Open) (Closed)
Unload
Oil Pressure + Spring Force > Suction/Discharge Differential Pressure = Slide and Piston Move Towards Unload
B A
Oil Supply Oil Vent

De-energised Energised Compressor Loading
(Closed) (Open)
Load
Suction/Discharge Differential Pressure > Spring Force = Slide and Piston Move Towards Load
1
CAPACITY CONTROL ACTION SOLENOID VALVE A SOLENOID VALVE B
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 Energise (open) De-energise (close)
force of the unloading spring and moves the slide valve 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. De-energise (close) Energise (open)
The combined force is sufficient to overcome the action of the
suction/discharge differential pressure and move the slide valve towards the
minimum load position.
Hold slide valve position
De-energise (close)
The slide valve is hydraulically locked at the desired load position.
1
Start-up Start Compressor Starts Compressor
Requested (Loading Inhibited) Permitted to Load
Compressor Stopped 60 Seconds 60 Seconds

Time
Solenoid Valve B Solenoid Valve B Energised (Open)
Energised (Open) Solenoid Valve B Until Compressor Required to Load
De-energised
1 (Closed)
Refer to 2.2.2. Uncontrolled Stop.
Fig 3 Continuously Variable Capacity Control
Page 10 of 52 Issue 2.1 : 07/04

3. Economiser Facility
The HallScrew compressor is provided with an economiser facility. This
enables an additional charge of gas to be handled by the compressor,
over and above that which is normally pumped. It is, in effect, a form of
supercharging which has the net result of increasing refrigerating
capacity by a significantly greater percentage than power consumption,
hence improving the coefficient of performance (kW refrigeration/kW
power input) or Coefficient of Performance (COP) of the compressor.
The economiser principle is illustrated on a pressure/enthalpy (p-h)
diagram in Fig 4.
Suction gas is drawn into the main rotor flutes, these are sealed off in
sequence by the star rotor teeth and compression begins. An extra
charge of gas now enters the sealed flute through a port in the casing
enclosing the main rotor. This gas supply is taken from an intermediate
source at a slightly higher pressure than that prevailing in the flute at the
instant the gas is introduced, hence the gas is induced to enter the flute.
The original and additional charges of gas are then compressed and
discharged in the normal way. The full load pumping capacity of the
compressor at suction conditions is not affected by the additional flow
through the economiser connection.
In common with all screw compressors. as the compressor unloads, the
pressure at the economiser port falls towards suction pressure and the
additional capacity and improved efficiency economiser system is no
longer available.
As a guide to this effect, approximately half of the improvement due to
using an economiser system will be lost by the time the compressor
unloads to 90 % capacity, and falls to zero at around 70 % capacity.
Pressure
Subcooling
Condenser
Compressor
Economiser
Evaporator
Capacity Without Economiser
Capacity With Economiser
Enthalpy
Fig 4 Economiser Cycle on Pressure/Enthalpy (p-h) Diagram
Issue 2.1 : 07/04 Page 11 of 52

3.1. Subcooling of Liquid Refrigerant

The main liquid supply to the evaporator flows through a small heat
exchanger (the economiser). A small quantity of liquid, taken from the
main liquid supply before the economiser, is evaporated in the
economiser in order to subcool the remainder. The subcooled liquid,
when passed to the evaporator, provides a larger refrigeration capacity
per kg than if it was not subcooled; the compressor still pumps the same
mass of gas. Hence the net refrigeration capacity is increased.
The volume of gas capable of passing through the economiser
connections is dependent upon the pressure in the economiser line. The
volume of gas generated in the refrigeration system by the subcooling
process is dependent upon the system mass rate of flow, the operating
conditions and the subcooler performance. These two flows must be the
same and hence an equilibrium economiser pressure is reached in
practice.
The requirements outlined in the previous paragraphs are met by the
system outlined in Fig 5. Service components such as isolating valves
have been omitted for clarity.
Liquid is metered into the economiser vessel through a thermostatic
expansion valve (TEV) with the sensing bulb strapped to the vapour
return line to the compressor economiser connection. The TEV must be
fitted with the appropriate size orifice, and have a maximum operating
pressure (MOP) in excess of the highest expected economiser gauge
(20 °C to 25 °C).
A solenoid valve must be fitted in the liquid line feeding the TEV; refer to
Fig 5. This solenoid valve should be electrically interlocked to energise
(open) when compressor capacity exceeds approximately 50 %, and de-
energise (close) when capacity falls below 50 %. The capacity control
slide valve HB Linear Variable Displacement Transducer (LVDT) can be
used for this purpose, refer to 8.5.
For multiple compressor applications operating in parallel, the preferred
arrangement is to fit a separate economiser to each compressor, each
fed by its TEV; refer to Fig 5.
3.2. Side Load Operation
An alternative method of providing the intermediate gas supply is
available in some multi-temperature applications where, for example, a
higher temperature coldstore could operate at an elevated evaporating
temperature compatible with the economiser port pressure. The
refrigerant vapour generated by this store could then be returned to the
economiser port without significantly affecting the low temperature
capacity of the compressor.
Page 12 of 52 Issue 2.1 : 07/04

TEV Equalising Line
Economiser
TEV
Equaliser Evaporator
Line
Oil
Separator
Typical Single
Compressor Application
Condenser
Comp 1 Comp 2 Comp 3
Economiser Economiser Economiser
Liquid From Liquid to

Condenser Evaporator
Typical Multiple Compressor Application With Common Refrigerant Circuit
SOLENOID VALVE IN MAIN LIQUID LINE SOLENOID VALVE BEFORE THE REGULATOR
THROUGH THE ECONOMISER (THERMOSTATIC EXPANSION VALVE SHOWN)
Electrically interlocked to energise (open) when Electrically interlocked to energise (open) when
compressor x starts, de-energise (close) when compressor x capacity > 50 %, de-energise
compressor x stops. (close) when compressor x capacity < 50 %.
x = 1 for compressor 1, x = 2 for compressor 2, x = 3 for compressor 3.
Fig 5 Economiser Arrangements: Wiring to Liquid Line Solenoid Valves
Issue 2.1 : 07/04 Page 13 of 52

4. Compressor Lubrication, Sealing and Cooling

In common with other types of oil injected screw compressor, HS 4200
series compressors do not possess a built-in oil reservoir (sump) or oil
circulation pump. Instead, oil is supplied by a separate external oil
support system.
It is essential to supply the compressor with an
adequate supply of clean (filtered) oil at the correct
temperature; refer to 5. Oil Support System.
The oil performs three basic functions:
4.1. Capacity Control Actuation
Oil pressure is used to actuate the compressor capacity control
mechanism; refer to 2.1. Slide Valve Actuation.
4.2. 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.
4.3. 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.
Compressor cooling can be accomplished by the direct injection of liquid
refrigerant into the compression process; refer to 5.8.1. When liquid
injection is not used, the oil injected for sealing absorbs a large proportion
of the heat of compression, thus reducing the maximum discharge
temperature, and is cooled externally via an oil cooler; refer to 5.8.3.
Page 14 of 52 Issue 2.1 : 07/04

5. Oil Support System

HS L/M 4200 series compressors require an external oil separator and oil
support system; refer to Fig 6.
The system into which the compressor is to be installed
must fully comply with the recommendations in 5.1. to
5.8. and 6. Lubricating Oils Failure to do so could result
in deterioration of the compressor, both mechanically
and functionally.
LP
ODP1 = Oil injection/lubrication pressure – Suction pressure

HP
LP
ODP2 = Discharge pressure - Oil injection/lubrication pressure

HP
Suction
Discharge
Non-Return
Valve Required
Oil
1 to Open With
External Separator
Zero Head
Oil Filter
Oil Low Level
Oil Drain
Oil Heater
Oil Injection/Lubrication
The oil support system must conform with the provisions described in 5.1 to 5.8
1
It is recommended to fit an external oil filter if the compressor is not applied to a factory built complete package unit; refer
to 5.7. External Oil Filter.
Fig 6 Oil Support System
Issue 2.1 : 07/04 Page 15 of 52

5.1. Oil Injection/Lubrication

A single line provides oil for injection, lubrication and capacity control
actuation. The connection size at the compressor can be found in
Appendix 1.
If it is required to fit service valves in this line, these should be full-flow
ball valves to minimise pressure drop.
5.2. Oil Drain
Oil which collects inside the compressor casing must be allowed to drain
back to the oil separator when the compressor stops. An external drain
line must be provided from the oil drain connection on the bottom of the
compressor to the oil separator. The connection size can be found in
Appendix 1.
To ensure the oil drain line functions correctly:
• The drain line must slope down all the way to the separator
without traps or risers. If it is required to fit a service valve in
this line, this should be a full-flow ball valve to minimise
pressure drop.
If two or more compressors are used on the same oil separator,
the drain lines must be taken to the separate suction header
located below the level of the compressor; refer to 5.4.1.
• The drain line must incorporate a non-return valve to allow
oil to flow from the compressor to the separator during shut
down, but prevent flow in the opposite direction when the
compressor is running. The non-return valve is required to
open with zero head.
• If the oil separator is not supplied packaged with the
compressor, the separator must be sized and positioned to
provided adequate oil return; refer to 5.4.2.
• A discharge non-return valve must be fitted after the oil
separator to ensure that the compressor and separator are
maintained at the same relative pressures after shutdown;
refer to 5.4.3.
5.3. Oil Separation
All the oil injected into the compressor for lubrication, sealing and
capacity control actuation, ultimately ends up in the discharge gas
stream. During its passage through the compressor the oil is thoroughly
mixed with the refrigerant, eventually ending up in the discharge gas
stream as a fine mist of oil droplets. Before the oil can be recirculated it
must be separated from the discharge gas, filtered, cooled (if compressor
cooling is required and internal cooling by liquid injection is not used),
and then returned to the compressor. An oil separator is therefore
required in the discharge line. This vessel effectively removes the
majority of the oil constituent from the oil/gas mixture, the oil draining into
a reservoir which usually forms the lower portion of the separator vessel.
5.3.1. Oil Separator Design
The method of oil separation utilised by the oil separator is not important
in itself in that velocity, impingement coalescent or other types or
combination of types may be used. However it is important that the
separator operates at sufficient efficiency over the actual operating range,
with the compressor at all load conditions.
Page 16 of 52 Issue 2.1 : 07/04

Deciding the required level of efficiency is important and is dependant not

only on the compressor but also on the system design. No separator is
100 % efficient and some oil will always be carried over into the system.
On a small direct expansion system this oil will be rapidly recirculated
back to the compressor travelling with the refrigerant through the system
and returning via the suction line. In this case the separator can be sized
such that allowing for the extremes of operation, sufficient oil is
maintained in the oil separator to ensure an adequate head of oil to
match the specified oil flow rate from the separator into the compressor.
Additionally, as the separator efficiency changes with load and operating
conditions, then the amount of oil carried into the system through the
separator will also vary. Therefore the oil remaining in the separator will
vary by an equal amount. Thus either sufficient oil capacity must be
provided in the separator to allow for this change in oil quantity or a more
consistent separator performance must be attained.
As high quantities of oil in the evaporator are detrimental to system
performance it is normal to design the separator with as high an
efficiency as is economically achievable. Even in this case the separator
must provide sufficient oil volume above the normal operating volume to
cater for the variation in efficiency. In addition the separator must have
sufficient oil volume to provide an adequate dwell time to allow oil and
refrigerant to reach their equilibrium condition.
In systems such as those incorporating flooded evaporators where oil
carried over from the separator is not so readily or quickly returned then
greater care is required in oil separator design. The separator must be of
sufficient efficiency that oil carried over into the system can be returned
by the oil rectification system. For miscible oil/refrigerant combinations a
sample of refrigerant is taken from the evaporator the refrigerant boiled
off and the oil returned to the compressor. If this refrigerant is not boiled
off in a useful fashion then this is a direct loss on the system
performance. If conditions change rapidly then it can take considerable
time for equilibrium to be achieved. Under these conditions oil will build
up in the evaporator and be lost from the separator. Thus the separator
must be of a high efficiency type perhaps including coalescent elements
and at the same time must have sufficient oil volume above the minimum
requirement to cope with these variations in operating conditions.
5.4. Oil Separator Provisions
HS L/M 4200 series compressors are available packaged with the oil
separator and all necessary interconnecting pipework, ready for
installation into a package unit or site erected system; refer to
Appendix 1.
For bare compressor applications, in addition to the considerations
discussed in 5.3, the oil separator should comply with the following
recommendations:
5.4.1. Multiple Compressors
If two or more compressors are used on the same oil separator the
following provisions must be made in addition to those described in 5.4.2
to 5.4.6.
• For each compressor, a solenoid valve must be provided in
the oil injection line. The solenoid valve must be electrically
interlocked to energise (open) when the compressor starts
and de-energise (closed) when the compressor stops.
• For each compressor, a non-return valve must be provided
in the discharge line before the inlet to the oil separator.
This dispenses with the need for a suction non-return valve.
Issue 2.1 : 07/04 Page 17 of 52

• The suction to each compressor must be taken from a

separate suction header located below the level of the
compressor. The header should be insulated with the
suction line in the normal way.
If there is any possibility of liquid refrigerant collecting in the header
during the off cycle, the header should be fitted with heater(s) or
wound with heater tape underneath the insulation. The heater(s)
must be electrically interlocked to de-energise when the first
compressor starts and energise when the last compressor stops.
The oil drain line from each compressor must be taken to the
suction header.
A typical arrangement is shown in Fig 15 in Appendix 2.
5.4.2. Oil Return
As already mentioned in 5.2. a drain line must be installed between the
compressor casing and the oil separator (or low level suction header in
the case of multiple compressors; refer to 5.4.1). Therefore, the
separator must be positioned at a suitable height such that the standing
oil level (compressor stopped) is significantly below the bottom of the
compressor.
The oil separator must have a sufficient free volume to accommodate the
oil drainage from the compressor or oil returned from another part of the
system.
5.4.3. Discharge Non-return Valve
A discharge non-return valve must be fitted after the oil separator to
ensure adequate oil return from the compressor; refer to 5.2. Oil Drain.
5.4.4. Oil Heater
The separator must be fitted with an oil heater of sufficient capacity to
maintain an oil temperature 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.
If the plant is sited in a cold environment then oil lines must be suitably
lagged and if necessary heater tape applied in order to prevent oil
foaming.
5.4.5. Oil Low Level
A level switch or sensor must be fitted to the oil separator or the main oil
line at a point corresponding to a dangerously low oil level. The switch or
sensor must be electrically interlocked to prevent the compressor starting
unless there is sufficient oil in the reservoir, and stop the compressor
should the oil level fall below the danger level.
5.4.6. Oil Balance Lines
In installations using multiple compressors/oil separator units on the
same refrigeration circuit, oil returning from the system must be
distributed such that an adequate oil level is maintained in each oil
separator. If an oil balance system is adopted that relies on solenoid
valves to prevent oil returning to the separator when the compressor is
stopped, these solenoid valves must be selected and tested as suitable
for use with refrigeration oils. Many such valves fail to close, with the
possibility of oil flowing through the non running oil system/compressor
and filling the compressor. This can occur even when a non-return valve
is fitted after the separator.
5.5. Oil Differential Pressure Monitoring
As already described in 4. Compressor Lubrication, Sealing and Cooling,
HS L/M 4200 series compressors require an adequate supply of oil for
injection, bearing lubrication and capacity control actuation.
Page 18 of 52 Issue 2.1 : 07/04

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.
5.5.1. ODP1
This is the differential between oil pressure (or discharge pressure) and
suction pressure and determines if there is sufficient pressure difference
for adequate oil injection to occur.
ODP1 = Oil injection/lubrication 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 suction pressure. If ODP1 is sensed by
transducers then the pressure ratio from suction to oil (discharge) should
be set to 2. If an oil differential pressure switch is used, this should be
set to the maximum intended operating suction gauge, thus the switch
will trip when the oil pressure is below twice the maximum operating
suction pressure. 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.
5.5.2. ODP2
This is the differential across the oil injection line and should 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.
ODP2 = Discharge pressure - Oil injection/lubrication pressure
5.6. Maintaining Discharge Pressure at Start up
Because oil pressure is generated by discharge pressure, a minimum
discharge pressure must be maintained, this minimum pressure
increases as suction pressure increases in order to maintain the required
pressure differential.
In circumstances where the minimum discharge pressure is difficult to
achieve, even with the help of condenser head pressure control devices,
a differential pressure regulator must be fitted in the discharge line
immediately after the oil separator. Fig 7 shows a typical arrangement
using a Danfoss PM 1 main valve and CVPP pilot valve.
Discharge pressure, inlet pressure to the main valve, is applied to the
space below the pilot valve diaphragm. Suction pressure is applied via a
pilot line to the space above the diaphragm. The main valve, therefore,
controls on the differential between suction and discharge pressure.
Issue 2.1 : 07/04 Page 19 of 52

CVPP Pilot Line

Suction Sensing Suction
Line Pressure
Danfoss PM 1
Discharge Main Valve +
Line CVPP Pilot Valve
Discharge
Line
Oil Separator/Reservoir
Fig 7 Maintaining Discharge Pressure at Start up
The differential pressure regulator allows discharge pressure to build up

quickly on starting to achieve the necessary oil differential pressure
before the start delay time expires (usually 30 seconds). If the
suction/discharge pressure differential falls below the minimum
requirement to maintain adequate oil flow, the pilot valve throttles the
main valve to maintain the differential pressure, thereby ensuring
adequate oil flow to the compressor. During normal operation the main
valve will usually be fully open with little detrimental effect on compressor
performance.
5.7. External Oil Filter
HS L/M 4200 series compressors are fitted with a built-in oil filter. This
filter is adequate for complete package unit applications where standards
of system cleanliness can be guaranteed. However, for part packaged
site erected systems or when the compressor is applied to an existing
installation, the high levels of dirt likely to be encountered mean that the
built-in filter will need to be changed at frequent intervals. For these
applications it is recommended to fit an external oil filter to the minimum
specification shown in Table 1. A bypass must NOT be included in the
filter assembly.
When it is necessary to use an external oil filter, the integral oil filter can
be retained for initial commissioning and then removed together with the
internal oil filter locating spigot piece.
PARAMETER VALUE
Filter minimum particle size Down to 5 micron (Beta 5 value >1)
Filter absolute rating 25 micron (Beta 25 value >75)

2
Synthetics: felts/glass fibre with in-depth filtration 2500 cm
Minimum filter area
2
Paper or cellulose 10400 cm
Minimum dirt holding capacity >22.5 gm

Minimum filter element collapse pressure 20.0 bar
Complete filter assembly maximum clean pressure drop 0.7 bar with oil flow of 83.0 lt/min
NOTE: All filter components must be suitable for use with POE oils and R134a refrigerant.
Table 1 External Oil Filter Minimum Specification
Page 20 of 52 Issue 2.1 : 07/04

5.8. Compressor Cooling

The heat of compression must be removed either by the evaporation of
liquid refrigerant injected directly into the compression process (liquid
injection), or by using an external heat exchanger to cool the oil injected
to seal the compression process.
5.8.1. Liquid Injection Cooling
Liquid refrigerant is injected into the compressor main rotor flute, part-
way through the compression process; a small reduction in compressor
capacity may result.
Pilot Operated Main Valve
Liquid
Main Valve Inlet
LO
Discharge
Line
To Oil Separator
Meters a precise quantity of refrigerant into the compressor

Thermostatic injection valve
according to changes in discharge gas temperature.
The main valve is pilot operated by the thermostatic injection

Main control valve
valve
Visual indication that the line is full of liquid and provides

Sight-glass (in line)
early indication of a choked strainer.
Non-return valve Prevents reverse flow of liquid.
Electrically interlocked to energise (open) when the

Solenoid valve compressor starts and de-energise (close) when the
compressor stops.
Prevents dirt from entering and damaging the injection valve

Strainer
or solenoid valve.
Purge valve (normally closed and capped)
Stop valve Facilitate cleaning the strainer and servicing components.
Stop valve (locked open)

LO
Fig 8 Liquid Injection Cooling
Issue 2.1 : 07/04 Page 21 of 52

The rate of injection is thermostatically controlled by a liquid injection

valve which meters a precise quantity of refrigerant into the compressor
according to changes in discharge gas temperature.
The injection valve’s sensing bulb is either strapped to the discharge line,
or installed in a bulb pocket in the line. The injection valve is normally set
to limit discharge temperature to 75 °C, or 25 °C above condensation
temperature if this is above 50 °C, whichever is the higher, to ensure
satisfactory oil separator performance.
Liquid injection line components are illustrated and described in Fig 8.
The liquid injection system requires a preferential supply of high pressure
liquid through an adequately sized supply line, taken from a source which
ensures a preferential supply to the liquid injection valve. The line
between the take-off point for the preferential supply and the entrance to
the liquid injection valve must, at all times, be full of liquid refrigerant.
Typical methods of achieving a preferential supply are illustrated in Fig 9.
LP System – Liquid Receiver with Sump LP System – Liquid Receiver with Weir
Liquid fills sump to provide preferential supply. Liquid fills weir side of receiver to provide preferential
Remainder flows to evaporator. supply. Remainder over-flows weir to evaporator.
Condensate From
Condenser
Liquid Receiver Weir Liquid Receiver
Sump
Main Liquid Supply Main Liquid Supply
to Evaporator to Evaporator
LP or HP System HP System with Separate Level Control Vessel

Liquid fills vertical section of liquid line before Level control system maintains constant liquid
overflowing to evaporator level in control vessel. Preferential supply taken
from bottom of vessel
Condensate From Condensate From
Condenser Condenser Level
Main Liquid Supply Controller
to Evaporator
Main Liquid
Vertical section larger Supply to
in diameter than rest Evaporator
of liquid line Liquid Transducer
Control Column Provides
Vessel Level Signal
Liquid to
Injection Valve
Fig 9 Typical Methods of Providing Preferential Supply for Injection
Page 22 of 52 Issue 2.1 : 07/04

5.8.2. 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. Danfoss TEAT range) or electronically via
a temperature transducer, transmitter and controller.
The liquid injection valve must be sized to control discharge temperature
at 75 °C or 25 °C above the discharge gauge, whichever is higher.
Select the valve as follows:
• Use the J & E Hall International HS L/M 4200 series
compressor selection programme, available on CD, to obtain
the cooling requirement for the required duty.
• Use the graphs in Appendix 4 to obtain the pressure
difference for the operating conditions.
• Select the correct valve from manufacturer’s literature.
5.8.3. External Oil Cooling
While offering savings in initial capital cost, liquid injection cooling can
result in a small loss of refrigeration capacity and increased power
requirement at higher pressure ratios.
As an alternative to liquid injection, the oil injected for lubricating and
sealing also performs the essential task of cooling the discharge gas by
absorbing the heat of compression. The warm oil is cooled externally
using a water, air or refrigerant cooled heat exchanger.
The oil cooler must be provided with some form of temperature control,
otherwise the oil injection temperature may fall too low to provide a
adequate discharge superheat and oil separation problems may be
encountered. Suitable means of oil temperature control include a bypass
around the heat exchanger, a pressure or temperature operated valve in
the water inlet line (water cooled cooler) or fan dampers (air cooled
cooler).
Examples of bypass temperature control are illustrated in Fig 10. Of the
two methods, using a 3-way valve is preferred as this provides
modulating control of oil temperature.
Issue 2.1 : 07/04 Page 23 of 52

3-Way Valve
3-Way Valve,
Thermostatically
Controlled
Oil to Compressor
Oil From Lubrication and Oil
Separator Injection Connection(s)
Oil cooler may be water

Water or cooled (pumped
Refrigerant Oil Cooler circulation) or refrigerant
cooled (thermosiphon
circulation).
Oil to Oil to
Oil From Compressor Oil From Compressor
Separator Separator
Oil to Cooler Oil From Cooler Oil to Cooler Oil From Cooler
Cold Oil (Start-up) Oil Warm Oil at Control Temperature

Ports A – B connected: the 3-way → Warms → Ports A – C connected: the 3-way
valve diverts oil around the cooler. up valve permits flow through the cooler.
Solenoid Valve and Thermostat Oil to Compressor

Lubrication and Oil
Thermostat Injection Connection(s)
Oil From
Separator
Water or Oil cooler may be water

Refrigerant Oil Cooler cooled (pumped
circulation) or refrigerant
cooled (thermosiphon
circulation).
Oil From Oil to Oil From

Separator Compressor Separator
Oil to Cooler Oil From Cooler Oil to Cooler Oil From Cooler
Warm Oil at Control Temperature

Cold Oil (Start-up) Oil
→ Warms → Thermostat contacts open, solenoid
Thermostat contacts closed: solenoid
up valve de-energises (closes) to permit
valve energised (open).
flow through the cooler.
Fig 10 Oil Cooler Temperature Control
Page 24 of 52 Issue 2.1 : 07/04

6. Lubricating Oils
Lubricants used in the HallScrew compressor not only provide sealing
and cooling functions. The grade and type of lubricant chosen must
provide these functions at the actual operating environment existing
inside the compressor. In addition, as no oil separation system can be
100 % effective, the refrigeration system must be designed to adequately
return any oil carried over into the system to the compressor. Therefore,
the lubricant must be compatible with the refrigerant and the refrigeration
system as a whole.
The lubrication criteria can be met for standard operating conditions by
using a refrigeration quality oil as specified in Table 2 which is generally
in accordance with BS 2626 : 1992 Lubricating Oils for Refrigeration
Compressors. Depending on the refrigerant, the compressor is supplied
with the appropriate mineral oil or synthetic lubricant to this specification.
If the end user desires to use a different lubricant, approval MUST be
obtained from J & E Hall International if guarantees are not to be
invalidated. Different types and makes of oils must not be mixed.
POLYOLESTER
MINERAL OILS
LUBRICANTS
PARAMETER 2 3
1 LIQUID LIQUID INJECTION
EXTERNAL
INJECTION AND EXTERNAL
OIL COOLING
OIL COOLING OIL COOLING
4
Minimum ISO viscosity grade 68 100 68
Minimum viscosity index 45 33 45

Maximum pour point -30 °C -20 °C -25 °C
Minimum specific gravity @ 15 °C 0.88
Maximum water content 40 ppm 50 ppm

Acid number <0.05 <0.15
1
Including liquid injection oil cooling where the condensing temperature is below 45 °C.
2
For condensing temperatures above 45 °C.
3
All condensing temperatures.
4
ISO grade 150 or 220 oil is preferred, where available and suitable for the system.
Higher grades enhance compressor performance.
Table 2 Minimum Specification of Mineral Oils and Polyolester

Lubricants
6.1. Lubricant Types

Refrigeration compressor lubricants can be divided into three categories:
6.1.1. Mineral Oils
These are the standard choice for use with R22 refrigerant.
6.1.2. Synthetic Lubricants
Synthetic lubricants can have completely different characteristics,
depending on the type.
Polyolester (POE) lubricants are the only lubricants that are approved for
use with the new HFC refrigerants such as R134a, and are selected to
provide suitable miscibility with HFC refrigerants.
Because of the high refrigerant content in polyolester lubricant, the
required viscosity grade is higher than that necessary with mineral oils.
NOTE: polyolester oils are very hygroscopic and,
typically, saturate at approximately 1,000 parts per
million (ppm) from atmospheric moisture; this is some
ten times the saturation of a typical mineral oil.
Issue 2.1 : 07/04 Page 25 of 52

Oil for use in the compressor and refrigeration system

must be kept in properly closing containers. Exposure
to atmosphere for extended periods may result in the oil
becoming contaminated with moisture and dirt which
can cause harmful reactions in the system. For similar
reasons, oil reclaimed from the system should not be
reused.
Polyalphaolefin (PAO) lubricants have low pour points and low vapour
pressures. These oil types are partially miscible with R22 and are
available in high viscosity grades with high viscosity indexes. PAO
lubricants can, therefore, be used in suitably designed direct expansion
R22 systems. J & E Hall International should be consulted before using
PAO lubricants.
Alkylbenzene lubricants have good miscibility with R22 refrigerant and
can assist in oil recovery in low temperature flooded R22 systems.
However, their very high refrigerant content can reduce the performance
of screw compressors and increase oil injection rates into the
compressor. In order to maintain adequate viscosity, higher viscosity
grades are required. Because of this, these lubricants should only be
used with HallScrew compressors if no other lubricant type is compatible
with the system and only after prior consultation with J & E Hall
International.
Polyglycol lubricants are not approved for use in
HallScrew compressors using halocarbon refrigerants.
6.1.3. Semi Synthetic Lubricants
These oil types can be further subdivided into synthetic/mineral oil blends
and hydrotreated mineral oils. The former type consists of a blend of
mineral oil and alkylbenzene lubricant, which attempts to combine the
advantages of both oil types; some grades are approved for use with
HallScrew compressors in R22 systems and are preferable to
alkylbenzene types.
Page 26 of 52 Issue 2.1 : 07/04

7. Integration into the Refrigeration Circuit

The compressor is an oil injected screw type. For HS L/M 4200 series
compressors, the system must contain an oil separator of sufficient
capacity. The system must be designed to return any oil carried over into
the system from the separator, back to the compressor.
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 recommendations in 5. 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.
7.2.1. 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 U-
bends 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.
7.3. Discharge Line
The discharge line must slope downwards or be so sized to ensure that
oil is carried through with the discharge gas to the oil separator.
7.3.1. 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 20 oC.
7.4. Liquid Injection Lines
Liquid injection lines should be constructed such that injection is
uniformly distributed to the upper and lower connections. However, when
compressor cooling loads are low it is permissible to inject liquid into the
top liquid injection connection only.
7.5. 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.
Issue 2.1 : 07/04 Page 27 of 52

8. Electrical Connections
8.1. Compressor Starting
The HS L/M 4200 series compressor motor is wired for star/delta starting
which is the recommended method. Direct on line starting is not
recommended.
Soft-starting may be used as an alternative, however, the starter must be
carefully selected to match the operating conditions and be able to
accelerate the compressor smoothly to full load without stalling.
8.2. Motor Wiring Connections
Terminal box wiring is illustrated in Fig 11. Refer to Appendix 1 for motor
data. The standard terminal box rating is IP21.
L1
NOTE: circuit must be
connected as shown to
L2 ensure correct rotation
of the motor/compressor
L3
C Motor D S
Thermistor
1
6
2
4
3
Terminal 5
Plate
Motor
Thermistor Discharge
Thermistor
Thermistors may be Fitted as standard,
connected in series to a located adjacent to
common thermistor each discharge port
controller or separately Discharge
to individual controllers, Thermistor
but must NOT be
connected in parallel
Thermistor
Controller
Link
Not J & E Hall International supply.
Fig 11 Terminal Box Wiring (Star/Delta Starting)
Page 28 of 52 Issue 2.1 : 07/04

8.3. Thermistors
Compressor motor and discharge high temperature thermistors are fitted
as standard and should be wired as illustrated in Fig 11.
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
gauge pressure, etc.
Power must be supplied to the solenoid via a suitable pulse timer that
must be capable of supplying a minimum pulse length of ≥0.5 second.
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. HB Linear Variable Displacement Transducer (LVDT)
The HBLVDT 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 must be calibrated via suitable software within the plant
controller in order for the extremes of load to be set.
Slide valve position transducer wiring is shown in Fig 12.
2 1 3
4 to 20 mA Output Signal
For Remote Indication of
Slide Valve Position
FW FW FW FW
154 153 152 151
3 2 1 Link
Connections to J & E Hall International
4 to 20 mA - + Fridgewatch 2000 and 2100 Controllers
Out 24 V dc
Supply
Fig 12 HBLVDT External Wiring Connections
Issue 2.1 : 07/04 Page 29 of 52

Appendix 1 Physical Data, Limits of Operation and Safety Requirements
Compressor Model Nomenclature

HS X 4 2 X X X X X X X
Solenoid Voltage
1 = 115 V 1 ph 50/60 Hz
2 = 230 V 1 ph 50/60 Hz
Refrigerants
A = R134a
B = R22
C = R407c
D = Not allocated
E = R507
F = R404a
For other refrigerants refer to
J & E Hall International.
Motor Voltages
Q = 400/460 V 3 ph 50/60 Hz
U = 380 V 3 ph 60 Hz
B = 208 V 3 ph 60 Hz
D = 500/575 V 3 ph 50/60 Hz
V = 230 V 3 ph 60 Hz
X = Special voltage
Motor Power
14 = 145 kW
Lubricating Oil
E = Ester oil
M = Mineral oil
Capacity Control Slide Valve VR

3 = 3.0 VR
4 = 4.9 VR
21, 22 or 23
2 = Twin star Compressor
4 = Series 4000
Application
M = Semi-hermetic compressor for
medium temperature application.
L = Semi-hermetic compressor for
low temperature application.
HS = HallScrew
Example: HSM 4222/2/M/10/D/B/2

This describes a HallScrew 4222 twin star semi-hermetic compressor for medium temperature application fitted with 2.2 VR
capacity control slide valves, supplied with mineral oil, fitted with a 102 kW motor suitable for 500/575 V 3 ph 50/60 Hz
supply. Compressor for operation with R22. Solenoid voltage 230 V 1 ph 50/60 Hz.
Page 30 of 52 Issue 2.1 : 07/04

Physical Data
Compressor Type Single screw, semi-hermetic.
Compressor Rotation Clockwise looking on the motor end. Under no circumstances should the compressor
run in the reverse direction.
Method of Drive Suction gas cooled 3-phase, 2-pole stator/rotor arranged for start/delta or soft starting.
Maximum of 6 starts per hour. Refer to Motor Data for kW ratings.
Speed Range Depends on the supply frequency, 50 Hz or 60 Hz; refer to Motor Data.
Physical Dimensions Refer to Physical Dimensions and Connections.
Weight 730 kg (all models).

Capacity and Power Refer to selection data.
Capacity Control 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 HB Linear Variable Displacement
Transducer (HBLVDT). DIN plug terminal box rating IP65.
Capacity Control Solenoids 115 V or 240 V ac (other voltages available on request). Terminal box rating IP65.
Suction Strainer Integral. 60 mesh x 37 SWG.
Motor Terminal Box Rating IP21.
3
Swept Volume SWEPT VOLUME (M /HR) HS L/M 4221 HS L/M 4222 HS L/M 4223
Compressor running @ 50 Hz
508 616 722
(2 pole speed)
Compressor running @ 60 Hz
609 739 866
(2 pole speed)
1
Sound Pressure Levels TOTAL CENTRE FREQUENCY – HZ
@ 2980 rpm (50 Hz) Compressor
DB ‘A’
125 250 500 1K 2K 4K 8K
HS L/M 4221 81 62 73 73 77 75 69 62
HS L/M 4222 82 62 74 74 79 76 70 63
HS L/M 4223 83 61 75 75 80 77 71 64
1
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.
-5 2
Sound pressure levels given in dB refer to 2 x 10 N/m RMS.
Issue 2.1 : 07/04 Page 31 of 52

Motor Data
145 kW motor for 50 Hz operation. Refer to Appendix 3 Limits of Operation Envelopes for motor selection
COMPRESSOR RUNNING @ 50 HZ (2980 RPM) HS L/M 4221 HS L/M 4222 HS L/M 4223
Motor nominal output (kW) 145 145 145
Motor maximum output (kW) 156 189 222

Maximum running current (A) @ 400 V 254 303 354
Starting current (locked rotor) in Y (A) @ 400 V 367 631 808
Starting current (locked rotor) in ∆ (A) @ 400 V 1182 2031 2585
Standard voltage range (V) 400 ± 10 %
174 kW motor for 60 Hz operation. Refer to Appendix 3 Limits of Operation Envelopes for motor selection
COMPRESSOR RUNNING @ 60 HZ (3575 RPM) HS L/M 4221 HS L/M 4222 HS L/M 4223
Motor nominal output (kW) 174 174 174

Motor maximum output (kW) 187 227 266
Maximum running current (A) @ 460 V 259 312 366

Starting current (locked rotor) in Y (A) @ 460 V 364 640 875
Starting current (locked rotor) in ∆ (A) @ 460 V 1184 2061 2801
Standard voltage range (V) 460 ± 10 %
Page 32 of 52 Issue 2.1 : 07/04

Limits of Operation
Pressure Limits The pressure limits detailed below MUST NOT be exceeded during installation,
commissioning or operation of the plant.
R134a R407c
1 2
Maximum Design Pressures High side 23.6 bar g 32.8 bar g
Low side 10.1 bar g 14.8 bar g

3
Operational Pressures Maximum compressor operating suction
3.0 or 4.9VR 3.5 bar g 6.0 bar g
pressure
Maximum compressor operating discharge pressure 19.4 bar g 29.0 bar g
Maximum compressor operating pressure differential
17.5 bar 26.0 bar
(discharge – suction)
Minimum compressor operating pressure differential at

minimum load (refer to Appendix 3 Limits of Operation 2.0 bar 3.0 bar
Envelopes for further details)
R22 R404a R507
1 2
Maximum Design Pressures High side 32.9 bar g 32.9 bar g 32.9 bar g
Low side 15.6 bar g 18.7 bar g 19.3 bar g

3
Operational Pressures Maximum compressor 3.0 VR 6.4 bar g 6.7 bar g 7.0 bar g
operating suction pressure 4.9 VR 4.0 bar g 4.0 bar g 4.0 bar g
Maximum compressor operating discharge
27.9 bar g 24.4 bar g 27.6 bar g
pressure
Maximum compressor operating pressure
20.0 bar 23.0 bar g 23.0 bar g
differential (discharge – suction)
Minimum compressor operating pressure

differential at minimum load (refer to operational 2.0 bar 2.0 bar 2.0 bar
envelope for further details)
Temperature Limits For normal refrigeration and air conditioning applications, the following temperature limits
should be observed.
Temperature Limits With Liquid Discharge temperature 100 °C (standard)
Injection Oil Cooling (Standard) 120 °C (special)
Discharge minimum superheat 20.0 °C

Temperature Limits With Discharge temperature 100 °C
External Oil Cooling 4
Discharge minimum superheat 20.0 °C
1
Compressors must NOT be subjected to pressures higher than those indicated. This may require isolation of the
compressor during system strength pressure testing.
2
In conformity with EEC standards, system relief valve opens.
3
Oil separator pressure limits may be less than those applicable to the compressor.
4
For values below 20.0 °C contact J & E Hall International.
Issue 2.1 : 07/04 Page 33 of 52

Safety Requirements for Compressor Protection

Parameter Trip Device Setting Remarks
Discharge pressure High HP cut-out According to the Connected to compressor

operating discharge, refer to
conditions Appendix 1.
Discharge pressure Low Pressure control or pressure According to the -
transducer and programmable operating
controller with suitable conditions
analogue inputs
Discharge temperature High Thermistor (fitted as standard) 100 °C (standard) Standard recommended
120 °C (special) when liquid injection is
controlled to 75 °C or within
25 °C of discharge gauge
Suction pressure Low LP cut-out or pressure According to the Prevents operation at low
transducer and programmable operating suction gauge pressures
controller with suitable conditions
analogue inputs
Maximum compressor High Pressure transducers and Pressure ratio If a programmable controller
operating pressure ratio programmable controller with (discharge/ is not used, set HP cut-out to
(discharge/suction) suitable analogue inputs suction) discharge pressure = 7 x
Set according to suction pressure (if this is
the operating below the maximum setting
conditions above)
Oil differential pressure 1 Low Preferred method: Pressure ratio 2 Oil pressure should be twice
Oil injection pressure/suction Pressure transducers and suction pressure
pressure programmable controller with
suitable analogue inputs
Alternative method: Differential equal -
Differential pressure switch to highest
operational
suction pressure
Oil differential pressure 2 High Differential pressure switch or 2 bar (max) 30 second delay required on
Discharge pressure - oil programmable controller with starting only
injection/lubrication pressure suitable analogue inputs
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
Oil temperature High Thermistor or HT cut-out 80 °C Mandatory requirement if
compressor fitted with
external oil cooling
Compressor motor high High Thermistor (fitted as standard) - -
temperature
Compressor motor current High Current limiter, or current Set according to Prevents motor operation
transformer and programmable motor size above maximum rated
controller with suitable power
analogue inputs
Page 34 of 52 Issue 2.1 : 07/04

HS L/M 4200 Series Physical Dimensions and Connections
Discharge (Top)
L
W
H
Liquid
Injection
(Top) Lifting
Discharge Eyebolts
Pressure Gauge
Oil For
(2 Positions)
Injection/Lubrication Suction Pressure Gauge
Liquid
Injection
(Bottom) Discharge (Side) Suction
A B
1
Oil Drain Discharge Thermistor (2 Positions)
Connection
Dimensions in mm unless otherwise stated. Data provided as a guide only, refer to J & E Hall International certified drawing
DESCRIPTION SIZE
Length – Normal Motor L 1432 mm
Length – Large Motor L 1451 mm
Overall
Height H 546.5 mm
Dimensions Width W 629 mm
A 320 mm
Holding-down bolt centres
B 652 mm
Holding-down bolt - 4 off M12 x 50 mm

Lifting eyebolts (2 off) - M20
DESCRIPTION NO OFF SIZE

Suction 1 4” NB (4 1/8” OD)
Discharge (top and side) 2 2 1/2” NB (2 5/8” OD)
Suction pressure gauge 1 1/8” NPT

Connections
Discharge pressure gauge (2 positions) 2 1/8” NPT
Liquid injection (top and bottom) 2 3/4” (16 UNF)

Oil injection/lubrication 1 1 1/16” (12 UNF)
Oil drain 1 3/4” (16 UNF)

1
Both discharge high temperature thermistors must be used, wired in series; refer to Fig 11.
Issue 2.1 : 07/04 Page 35 of 52

Appendix 2 Oil Support System Schematic Flow Diagrams
Normally Closed
Normally Open Locked Open Normally Closed
and Capped
Valve, straight through
Valve, right angle
Ball valve Non-return valve
Quick-acting drain valve, normally closed

Control valve
and capped
Relief valve Solenoid valve (normally open)
Relief valve (to atmosphere) Solenoid valve (normally closed)
Dual relief valve (to atmosphere) Thermostatic expansion valve
Sight-glass (on vessel) Liquid drainer
Sight-glass (in line) Heater
Strainer FS Opto sensor in drain line
Oil filter Oil pump
Pressure Indication (pressure gauge or

PI DPS Differential Pressure Switch
transducer)
Pressure Switch High (discharge high

PSH LSL Level Switch (opto sensor or level switch)
pressure cut-out or transducer)
Pressure Switch Low (suction low pressure

PSL TE Thermistor or high temperature cut-out
cut-out or transducer)
Fig 13 Key to Fig 14 and 15
Page 36 of 52 Issue 2.1 : 07/04

Suction
HP
PI PSL ODP PI
LP Oil
PT Suction
Evacuation
TE HT (Del)
Break Flanges on Oil

Injection Line to Allow
Compressor Removal
Discharge
Individual
Compressor PSH PI Discharge
Discharge
Lines
A
LSL Sight-glass
View A - A
A
Oil Drain
Oil Filling
Connection Purge
HT (Oil) TE
Oil
Filter
Circuit Completion
Second Filter if When Using Liquid
Double (Duplex) Oil Injection Cooling
Filters Required
Oil Cooler
(Water, Air or Refrigerant Cooled)
Instead of Liquid Injection;
refer to 5.8. Compressor Cooling
Fig 14 HS L/M 4200 Series Compressors Oil Support System
Issue 2.1 : 07/04 Page 37 of 52

Suction Suction
HP HP
PI ODP PSL PI PI ODP PSL PI
LP LP
Discharge Discharge
PSH PI PI PSH
HT HT TE
TE
(Del) (Del)
* *
*Break Flanges on Oil
Injection Line to Allow
Compressor Removal
Discharge
LSL
Oil Drain
Purge
Oil Filling
Connection
HT (Oil) TE
Oil
Filter
Circuit Completion
When Using Liquid
Second Filter if Injection Cooling
Double (Duplex) Oil
Filters Required
Oil Cooler
(Water, Air or Refrigerant Cooled)
Instead of Liquid Injection;
refer to 5.8. Compressor Cooling
Suction Header Located Below The Compressor.

Heater Tape Under Insulation (If Required) PT
Suction
Fig 15 HS L/M 4200 Series Compressors Oil Support System – Common Oil Separator
Page 38 of 52 Issue 2.1 : 07/04

Appendix 3 Limits of Operation Envelopes
Limits of Operation R404a and R507 - Standard
60
50
40
HS 4200 L
30 HS 4200 M
Discharge Gauge °C
20
10 Limit of HS 4200 L
BOOSTER
-10
-20
-30
-50 -40 -30 -20 -10 0 10 20
Suction Gauge °C
Issue 2.1 : 07/04 Page 39 of 52

Limits of Operation R404a and R507 - Economised
60
50
40
HS 4200 L
30 Limit of HS 4200 L
HS 4200 M
Discharge Gauge °C
20
10
-10
-20
-30
-50 -40 -30 -20 -10 0 10 20
Suction Gauge °C
Page 40 of 52 Issue 2.1 : 07/04

Limits of Operation R22 - Standard
60
50
External oil
cooling only
40
HS 4200 L
30
HS 4200 M
Limit of HS 4200 L
Discharge Gauge °C
20
10
BOOSTER
-10
-20
-30
-50 -40 -30 -20 -10 0 10 20
Suction Gauge °C
Issue 2.1 : 07/04 Page 41 of 52

Limits of Operation R22 - Economised
60
50
External oil
40 cooling only Limit of HS 4200 L
HS 4200 L HS 4200 M
30
Discharge Gauge °C
20
10
-10
-20
-30
-50 -40 -30 -20 -10 0 10 20
Suction Gauge °C
Page 42 of 52 Issue 2.1 : 07/04

Limits of Operation R134a - Standard
70
60
50
HS 4200 M
40
30
Discharge Gauge °C
20
10
-10
-20
-30
-30 -20 -10 0 10 20
Suction Gauge °C
Issue 2.1 : 07/04 Page 43 of 52

Limits of Operation R134a - Economised
70
60
50
HS 4200 M
40
30
Discharge Gauge °C
20
10
-10
-20
-30
-30 -20 -10 0 10 20
Suction Gauge °C
Page 44 of 52 Issue 2.1 : 07/04

Appendix 4 Liquid Injection Pressure Graphs
Liquid Injection Pressure R134a
16
Discharge Gauge °C
60 °C
14
12
50 °C Available Injection
Pressure Difference Injection Port Pressure
10
Liquid Injection Pressure bar
40 °C
8
6
30 °C
4
20 °C
0
-50 -40 -30 -20 -10 0 10 20
Suction Gauge °C
Issue 2.1 : 07/04 Page 45 of 52

Liquid Injection Pressures R407c
25
Discharge Gauge °C
60 °C
20
50 °C Available Injection
Pressure Difference
Injection Port Pressure
15
40 °C
10
30 °C
20 °C
0
-50 -40 -30 -20 -10 0 10 20
Suction Gauge °C
Page 46 of 52 Issue 2.1 : 07/04

Liquid Injection Pressures R22
25
Discharge Gauge °C
60 °C
20
50 °C
Available Injection Injection Port Pressure
Pressure Difference
15
40 °C
10
30 °C
20 °C
0
-50 -40 -30 -20 -10 0 10 20
Suction Gauge °C
Issue 2.1 : 07/04 Page 47 of 52

Liquid Injection Pressure R404a
30
Discharge Gauge °C
60 °C
25
50 °C
20
Available Injection Injection Port Pressure
Pressure Difference
40 °C
15
30 °C
10
20 °C
0
-50 -40 -30 -20 -10 0 10 20
Suction Gauge °C
Page 48 of 52 Issue 2.1 : 07/04

Liquid Injection Pressures R507
30
Discharge Gauge °C
60 °C
25
Available Injection
50 °C Pressure Difference
20
Injection Port Pressure
40 °C
15
30 °C
10
20 °C
0
-50 -40 -30 -20 -10 0 10 20
Suction Gauge °C
Issue 2.1 : 07/04 Page 49 of 52

Appendix 5 Compressor Performance Data

Approximate compressor selection can be made from the performance
data provided in this publication in tabular form. For detailed selection
use the J & E Hall International HallScrew HS L/M 4200 series
compressor selection programme, available on CD.
Subcooling & Superheat Correction Factors
The performance data is based on 5.0 oC suction superheat and 5.0 oC
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
increase in capacity of 0.17 % for every additional 1.0 oC 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 %
for each additional 1.0 oC 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
in capacity of 1.1 % for every additional 1.0 oC 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.
Page 50 of 52 Issue 2.1 : 07/04

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Issue 2.1 : 07/04 Page 51 of 52

©J & E Hall International 2004

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 52 of 52 Issue 2.1 : 07/04

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Semi-hermetic Single Screw Compressors

Page 2 of 52 Issue 2.1 : 07/04

8.2. Motor Wiring Connections ..................................................................................................28

Issue 2.1 : 07/04 Page 3 of 52

Page 4 of 52 Issue 2.1 : 07/04

Issue 2.1 : 07/04 Page 5 of 52

1.3. The Compression Process

Page 6 of 52 Issue 2.1 : 07/04

the suction chamber: Diagram 1 clearly c

While the compression process described

Fig 1 Compression Process

Issue 2.1 : 07/04 Page 7 of 52

2. Capacity Control and Volume Ratio

Oil Supply Oil Vent

Spring Piston Slide

Fig 2 Capacity Control Mechanism

Page 8 of 52 Issue 2.1 : 07/04

2.1. Slide Valve Actuation

Issue 2.1 : 07/04 Page 9 of 52

Oil Supply Oil Vent

Oil Supply Oil Vent

Compressor Stopped 60 Seconds 60 Seconds

Fig 3 Continuously Variable Capacity Control

Page 10 of 52 Issue 2.1 : 07/04

Capacity Without Economiser

Capacity With Economiser

Fig 4 Economiser Cycle on Pressure/Enthalpy (p-h) Diagram

Issue 2.1 : 07/04 Page 11 of 52

3.1. Subcooling of Liquid Refrigerant

Page 12 of 52 Issue 2.1 : 07/04

TEV Equalising Line

Comp 1 Comp 2 Comp 3

Economiser Economiser Economiser

Liquid From Liquid to

Fig 5 Economiser Arrangements: Wiring to Liquid Line Solenoid Valves

Issue 2.1 : 07/04 Page 13 of 52

4. Compressor Lubrication, Sealing and Cooling

Page 14 of 52 Issue 2.1 : 07/04

5. Oil Support System

ODP1 = Oil injection/lubrication pressure – Suction pressure

ODP2 = Discharge pressure - Oil injection/lubrication pressure

Fig 6 Oil Support System

Issue 2.1 : 07/04 Page 15 of 52

5.1. Oil Injection/Lubrication

Page 16 of 52 Issue 2.1 : 07/04

Deciding the required level of efficiency is important and is dependant not

Issue 2.1 : 07/04 Page 17 of 52

• The suction to each compressor must be taken from a

Page 18 of 52 Issue 2.1 : 07/04

Issue 2.1 : 07/04 Page 19 of 52

CVPP Pilot Line

Fig 7 Maintaining Discharge Pressure at Start up

The differential pressure regulator allows discharge pressure to build up

Filter minimum particle size Down to 5 micron (Beta 5 value >1)

Filter absolute rating 25 micron (Beta 25 value >75)

Minimum dirt holding capacity >22.5 gm

Table 1 External Oil Filter Minimum Specification

Page 20 of 52 Issue 2.1 : 07/04