RT Series

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Contents
CHAPTER 1. INTRODUCTION ....................................................................................... 1
FEATURES ..................................................................................................................... 1
AMBIENCE...................................................................................................................... 1
CHAPTER 2. BASIC DESIGN ......................................................................................... 2
2.1 COMPRESSOR NOMENCLATURE .................................................................................. 2
2.2 APPLICATION LIMITS .................................................................................................. 2
2.3 COMPRESSOR SPECIFICATIONS .................................................................................. 4
2.4 COMPRESSOR OUTLINE ............................................................................................. 8
2.5 CONNECTIONS .........................................................................................................27
2.5.1 Suction/discharge/economizer flange size.................................................27
2.5.2 Size of bushings for motor liquid injection ................................................31
2.6 COMPRESSOR STRUCTURE .......................................................................................32
CHAPTER 3. CAPACITY CONTROL SYSTEM .............................................................33
3.1 INLET GUIDE VANES ..................................................................................................33
3.1.1 Control of inlet guide vanes .........................................................................35
3.2 VANE ACTUATOR CONTROL ......................................................................................36
3.2.1 Actuator data .................................................................................................36
3.2.2 Proportional control board setting ..............................................................36
3.2.3 Digital BCD switch setting ...........................................................................37
3.2.4 Duty cycle ......................................................................................................39
3.2.5 Wiring.............................................................................................................40
3.2.6 LED indicator lights ......................................................................................42
3.2.7 Manual operation ..........................................................................................43
3.2.8 Overload protection ......................................................................................43
3.2.9 Troubleshooting ...........................................................................................43
3.2.10 Actuator capacity control ...........................................................................43
3.3 SURGE AND STALL PHENOMENON .............................................................................44
3.3.1 Fixed-frequency capacity control and surge protection strategy ............46
3.3.2 Energy savings with variable frequency compressor ...............................48
3.4 HOT GAS BYPASS (HGBP) .......................................................................................53
CHAPTER 4. LUBRICATION SYSTEM .........................................................................56
4.1 OIL CIRCUIT .............................................................................................................56
4.2 OIL PUMP ................................................................................................................57
4.2.1 Specifications of the oil pump .....................................................................57
4.2.2 Features of oil pump.....................................................................................57
4.3 OIL COOLER ............................................................................................................58
4.4 EXTERNAL OIL FILTER...............................................................................................59
4.5 OIL & REFRIGERANT CIRCUITS ..................................................................................60
4.5.1 Oil temperature control in the oil tank ........................................................61
4.6 LUBRICANTS............................................................................................................64
4.6.1 Lubricant table ..............................................................................................64
4.6.2 Precautions in changing of oil .....................................................................64
4.6.3 Oil change .....................................................................................................66
CHAPTER 5. MOTOR ....................................................................................................67
5.1 MOTOR COOLING .....................................................................................................67
Vol. 2.6 © 2020 Hanbell Precise Machinery Co., Ltd. All rights reserved
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5.2 MOTOR PROTECTOR .................................................................................................70

5.3 ELECTRICAL DATA AND DESIGN .................................................................................73
5.3.1 Motor design：Y-ΔStarting ..........................................................................73
5.3.2 Characteristics of Starting ...........................................................................73
5.3.3 Motor design：Direct on line start/soft start/inverter start .......................74
5.3.4 MCC & LRA....................................................................................................76
5.3.5 Grounding .....................................................................................................78
5.3.6 Insulation for high voltage main terminals .................................................79
5.3.6.1 Method 1: ................................................................................................79
5.3.6.2 Method2: .................................................................................................79
5.3.7Protective measures of electric shock ........................................................80
5.4 COMPRESSOR ELECTRICAL AND SAFETY PRACTICES .................................................81
5.4.1 Electrical Safety Precautions: .....................................................................81
5.4.2 The Inspection and Preparation before Electrical Wiring .........................81
5.4.2.1 Inspection of Unpacking........................................................................81
5.4.2.2 Cable Selection: .....................................................................................82
5.4.3 Power Wiring Detail: .....................................................................................82
5.4.3.1 Caution for wiring...................................................................................82
5.4.3.2 Making of cable end and the connector ...............................................83
5.4.4 Limitation of power supply ..........................................................................85
CHAPTER 6 COMPRESSOR LIFTING AND INSTALLATION ......................................86
6.1 COMPRESSOR LIFTING ..............................................................................................86
6.2 COMPRESSOR MOUNTING .........................................................................................86
6.3 COMPRESSOR PROTECTION DEVICE ...........................................................................88
6.4 COMPRESSOR ACCESSORIES ....................................................................................89
6.5 OPERATION AND MAINTENANCE ................................................................................90
6.5.1 Compressor start-up ....................................................................................90
6.5.2 Compressor control logic ............................................................................92
6.6 TROUBLESHOOTING .................................................................................................94
6.7COMPRESSOR VIBRATION MEASURING POINT ..............................................................96
Chapter 1. Introduction
This manual is intended as a guide for application engineers, consultants, sales
engineers, and HVAC designers to use Hanbell RT series centrifugal compressors. The
copyright of content in this technical manual belongs to Hanbell Precise Machinery Co., Ltd.
Neither this publication nor any part of it may be reproduced or transmitted in any form or by
any means without the prior permission of Hanbell Precise Machinery Co., Ltd.
Features
 HFC-134a - chlorine-free refrigerant Zero ODP）.
 COP - the highest-efficiency centrifugal compressor for HFC-134ain the market.
 Maximum pressure – designed for the high pressure up to17 bar.
 Compressor - semi-hermetic design.
 Refrigerant cycle with - high-efficiency two-stage compression with economizer.
- High-efficiency motor.
 Shaft –made of high-strength alloy steel.
 Impellers –closed type made of high-strength aluminum.
 Bearings -durable for 50,000-hour operation without overhaul.
 Semi-hermetic motor –independent cooling by liquid refrigerant.
 Gear –less mechanical loss (JIS 0/ ISO Grade 4).
 Enclosure - IP54 protection.
Ambience
RT series compressors should be stored and operated within the following ambient
temperature.
Storage: -10℃ to 70℃ (14℉ to 158℉)

Operation(Water-cooled): ET:-8℃~20℃ (17℉to 68℉);CT：20℃~50℃(68℉ to 122℉)
Operation(Heat pump): ET:-8℃~20℃ (17℉ to 68℉);CT：20℃~60℃(68℉ to 140℉)
Note: Please refer to “Application limits” in page 2 for allowable operating conditions and
Hanbell selection software for detailed performance data.
Safety cautions
Safety cautions in this instruction manual are for users to take precaution measures in
order to reduce risks of personal injury and equipment damage. Please read these
instructions carefully before Installing, operating, and maintaining the equipment.
Danger: Indicates a personal safety hazard which, special precautions are required to
prevent users from danger or injury. Dangerous or unsafe items will result in
personal injury or death.
Warning: Indicates a personal safety hazard which, special precautions are required to
prevent users from potential danger or injury. Failure to follow the instructions
could result in personal injury or death.
Caution: Instructs user for general precautions. Failure to follow the instructions could
result in personal injury and/or damage to the equipment.
1
Chapter 2. Basic design

2.1 Compressor nomenclature
RT–xxxx
Empty – Standard
T – Dual-IGV
E – High Efficiency
0 – Air-conditioning ΔT = 30°C
1 – Heat pump ΔT = 40°C
Mod
－Centrifugal
RT model－
2.2 Application limits
Figure 2.1 RT series application limits
1. Pressure ratio: the ratio of discharge pressure (abs.) over suction pressure (abs.).
*pressure sensors should be installed on the compressor discharge and suction pipe.
If the sensors are installed on condenser and evaporator, pressure drop need to be
considered.Surge point:
2. Surge point: each IGV opening has a corresponding maximum pressure ratio
surge point.
3. Surge line: the curve formed by connecting surge points of each IGV opening.
4. Safety margin line: the line formed by translating the surge line to a safety margin
at the maximum upper limit of pressure ratio for each IGV opening.
2
5. Stall zone: Rotating stall is a local disruption of airflow within the compressor
which continues to provide compressed air but with reduced effectiveness. Stall zone is
defined to confine application of the compressor under unsteady flow with small volume
flow.
6. Allowable operating range: ranging from the maximum IGV opening (100%) to the
smallest IGV opening (10%),with the maximum operation load of (105%) and covering the
operating range from safety margin line to the minimum pressure ratio
3
2.3 Compressor specifications

RT-120 RT-130 RT-140
Model
(E,T) (E,T) (E,T)
Refrigerant R134a
Type Two-stage with speed-up gearing
LP HP LP HP LP HP
Pressure ratio*
1.63 1.55 1.63 1.55 1.63 1.55
Mass flow rate* kg/sec 11.95 13.54 13.01 14.73 13.43 15.21
Compressor
Volume flow (Suction)* ㎥/hr 2,466 1,740 2,684 1,893 2,711 1,954
Rated speed rpm 11,700 12,000 12,000
Inlet guide vane control IGV1 10~100% continuous(standard, *2)
Inlet guide vane control IGV2 10~100% continuous(optional, *3)
Type Helical gear
Transmission Lubrication Built-in oil pump
Lubricant charge Liter 38
Type 3 Phase, 2 Pole, Induction
Starting △ Starting, Direct starting
Y-△
Motor Voltage (50/60 Hz) V 380~600,10k/6k/4k/3k
Insulation Class F
Protection PTC,Pt100/Pt1000
Oil heater kW 2x0.5
Chamber heater kW 2x0.3
Maintenance butterfly valve 8” (optional)
Dimension (LxWxH) m 2.30 x 1.20 x 1.02
Weight kg 3,500
Hydrostatic pressure test kg/cm²g 22
Table 2.1 Refrigeration Compressor specifications
1. Under CT/ET=36℃/6℃(refer to ASHRAE 90.1-2015)

2. Setting IGV1=5% applied only in startup, in regular operation should set IGV1≧10%,
while for Dual IGV models IGV1≧5%.
3. IGV2 is optional, for Dual IGV models select RT-120T, RT-130T, RT-140T. These
models have good part load efficiency with IPLV=7.0~7.4
4. The available motor voltage specification is as follows：
Voltage RT-120~140(E,T)
380V~600V ○
3kV/3.3kV ○
6kV/6.6kV ○
10kV/11kV ○
4
RT-160 RT-180 RT-200

Model
(E,T) (E,T) (E,T)
Refrigerant R134a
LP HP LP HP LP HP
Pressure ratio*
1.63 1.55 1.63 1.55 1.63 1.55
Compressor
Rated speed rpm 9,400 8,900
Inlet guide vane control IGV2 10~100% continuous(optional, *3)
Type Helical gear
Y-△
Insulation Class F
Oil heater kW 2x0.5
Chamber heater kW 2X0.3
Weight kg 4,500

while for Dual IGV models IGV1≧5%.
3. IGV2 is optional, for Dual IGV models select RT-160T, RT-180T, RT-200T. These
models have good part load efficiency with IPLV=7.0~7.4
Voltage RT-160~200(E,T)
380V~600V ○
3kV/3.3kV ○
6kV/6.6kV ○
10kV/11kV ○
5
RT-240 RT-260 RT-280

Model
(E) (E) (E)
Refrigerant R134a
LP HP LP HP LP HP
Pressure ratio*
1.63 1.55 1.63 1.55 1.63 1.55
Compressor
Rated Speed rpm 8,200
Inlet guide vane control IGV1 10~100% continuous
Inlet guide vane control IGV2 Not applicable
Type Helical gear
Y-△
Insulation Class F
Oil heater kW 2x0.5
Chamber heater kW 2X0.3
Weight kg 4,500

3. Dual IGV structure is not available for this framework.
Voltage RT-240~280
380V~600V Optional
3kV/3.3kV ○
6kV/6.6kV ○
10kV/11kV ○
Caution：This series of low-voltage motor specifications are only for motor A. Motor B with
high evaporation conditions is not applicable due to low voltage start up and extremely
large running current.
6
Model RT-111 RT-161 RT-221

Refrigerant R134a
LP HP LP HP LP HP
Pressure ratio*
1.91 1.73 1.91 1.73 1.91 1.73
Compressor
Rated Speed rpm 12,000 9,400
Type Helical gear
Lubricant charge Liter 33 57 57
Y-△
Insulation Class F
Oil heater kW 2x0.5
Chamber heater kW 2x0.3
Maintenance butterfly valve 8” (optional) 10” (optional)
Weight kg 4,500
Table 2.4 Heating Compressor specifications

3. All standard heat pumps include dual IGV structure.
Voltage RT-111 ~ 161 RT-221

380V~600V ○ Optional
3kV/3.3kV ○ ○
6kV/6.6kV ○ ○
10kV/11kV ○ ○
Caution：RT-221 low-voltage motor is only for motor A. Motor B with high evaporation
conditions (due to extremely large start up current) is not applicable.
7
2.4 Compressor outline

Low voltage compressor outline RT-120~140(E,T)/RT-111 (motor A&B)
8
High voltage compressor outline RT-120~140(E,T)/RT-111 (motor A)
9
High voltage compressor outline RT-120~140(E,T)/RT-111 (motor B)
10
Low voltage compressor outline RT-160~200(E,T)/RT-221 (motor A)
11
High voltage compressor outline RT-160(T)(motor B)
12
Low voltage compressor outline RT-160(T)(motor B)
13
Low voltage compressor outline RT-180(T),RT-161(60Hz) (motor B)
14
Low voltage compressor outline RT-180~200(T),RT-161(50Hz) (motor B)
15
High voltage compressor outline RT-180~200(T),RT-161(50/60Hz)

(motor B)
16
Low voltage compressor outline RT-200(T) (60Hz) (motor B)
17
High voltage compressor outline RT-202,RT-221 (50/60Hz) (motor A)
18
High voltage compressor outline RT-202,RT-221 (50/60Hz) (motor B)
19
Low voltage compressor outline RT-221 (50Hz) (motor A)
20
21
Low voltage compressor outline RT-240~280 (50Hz) (motor A)
22
High voltage compressor outline RT-240~280 (50/60Hz) (motor A)
23
High voltage compressor outline RT-240~280 (50/60Hz) (motor B)
24
25
Low voltage compressor outline RT-260~280 (60Hz) (motor A)
26
2.5 Connections
2.5.1 Suction/discharge/economizer flange size
Figure 2.2 Flange size
Piping
A
Position Size B D E F G thick
(JIS) (GB) (GB)
Suction 8" 218 221.5 305 350 30 12 25 11
RT-120~140 Discharge 6" 167 170.5 260 305 28 12 25 10.5
RT-111
Mid.-press.
2 1/2" 77.5 77.5 140 175 20 8 19 7
(Eco.)
Suction 12" 320 327.5 430 480 36 16 27 14
RT-160~280 Discharge 8" 218 221.5 305 350 30 12 25 11
RT-161, RT-221 Mid.-press.
4" 116 116 185 225 24 8 23 8.5
(Eco.)
※ Material-standard JIS 20 kg/cm2g steel unit: mm
Remarks
※ thickness must be equal to the standard or larger
Table 2.5 Flange dimensions
Note：
1. Please weld steel pipes onto flanges by butt-welding and make sure debris has
been cleaned, otherwise the compressor might be damaged badly during running.
Flow velocity in the discharge side of the compressor could be as high as
15~20m/sec. High-speed discharge gas will make noise in discharge connection.
In order to decrease the noise level, it’s recommended to round sharp edges of
joints of piping.
27
2. The discharge and suction piping is recommended to be one size larger than that
of discharge and suction flanges to reduce pressure drop and noise level. If the
noise level is high in discharge side, it is suggested to increase the piping
thickness or enclose with acoustic foam shown in Figure 2.3&2.4.
3. To make the compressor maintenance easier, it is recommended to install butterfly
valve on the pipe between compressor discharge port and condenser. Therefore,
the remaining gas inside compressor can be led to the condenser without
additional refrigerant recovery procedure.
Flow Flow Pressure

Dimension Density
Model Resistance Speed Drop
(inch) (kg/m3)
Coefficient (m/s) (kPa)
(K)
RT-120 8〞 0.5 45 14.69 2.43
RT-130 8〞 0.5 45 15.98 2.87
RT-140 8〞 0.5 45 16.49 3.06
RT-160 10〞 0.51 45 12.70 1.9
RT-180 10〞 0.51 45 14.61 2.4
RT-200 10〞 0.51 45 15.72 2.8
RT-240 10〞 0.51 45 19.05 4.2
RT-260 10〞 0.51 45 20.85 5.0
RT-280 10〞 0.51 45 21.80 5.5
RT-111 8〞 0.5 59 10.94 1.77
RT-161 10〞 0.51 59 12.29 2.27
RT-221 10〞 0.51 59 14.19 3.03
※ 1.Density & volume flow operation condition: water-cooling machine CT/ET=36/6℃, Heat pump
CT/ET=46/6℃ .
※ 2.Install the butterfly valve close to the condenser inlet end.
Figure 2.2.1 Outline of butterfly valve
28
Butterfly valve A B C D E F G H J K L
dimensions
2 1/2〞 65mm 121 48 58 97 162 111 16 11 32 64 20
3〞 80mm 133 48 73 104 168 111 16 11 32 64 20
4〞 100mm 171 52 94 120 191 111 16 11 32 64 19
5〞 125mm 191 57 122 129 191 130 19 13 32 114 24
6〞 150mm 219 57 149 141 203 130 19 13 32 114 24
8〞 200mm 273 61 198 176 241 130 22 16 32 114 24
10〞 250mm 332 70 248 217 273 155 30 22 51 114 27
※Size ”C” is the minimum size when the valve is fully open. ：mm]
[unit：
※Operating Temperature: -29℃~260℃. Operating Pressure: 1480psi.
Remarks ※Material: Valve body is conformed to the standard of ASTAM351 GR CF8M
stainless steel; pressure rating is ASME 150.
※The butterfly valve is of wafer type butterfly valve and installed in between ANSI
class 150 flanges.
Table 2.5.1 Specifications of flange
Figure 2.3 Discharge and suction piping
Caution: Residue from welding might damage the compressor seriously.
29
1Heatproof rubber
2Laminated lead
(2~3mm)
3Acoustic foam
4Gummed tape
Figure 2.4 Enclosure of piping connection
Note 4：As the pipeline is susceptible to stress deformation after welding which will lead to
the incapability connection of compressor after dismantling. Thus, connection of
the evaporator and condenser pipe outlet should be equipped with a pair of locking
flange in order to increase the assembling clearance. These two flanges on
evaporator and condenser need to be released during the connection of the
compressor so as to reduce the effect of welding pipe deformation.
Caution ：Sometimes in order to prevent leakage at the connections of compressor, the
overtightening of flange bolts can happen. This could cause the suspension of the
compressor in the air, leading to excessive vibration and damage of the
compressor. Thus, please follow the instructions on compressor mounting (refer
to 6.2 Installation and fixation of the compressor) and the advice of using flange
connections.
30
2.5.2 Size of bushings for motor liquid injection
Figure 2.5 Size of bushings
Mode Size A B C D E F
Liquid injection inlet 3/4" Flare

RT-120~140
RT-111 Liquid injection
1 1/8" Copper 52 75 35 28.8 42 12
outlet
RT-160~280 Liquid injection inlet 7/8" Copper 52 60 35 22.6 42 12
RT-161, Liquid injection
RT-221 outlet 1 5/8" Copper 52 75 35 41.6 52 12
Remarks unit: mm
Table 2.6 Dimensions of bushings
Note：To effectively control motor temperature, some service valve can be installed in
the piping before the bushing for motor liquid injection to provide adequate amount.
31
2.6 Compressor structure
11
2
1 12
14
4
10
8 7
13 6 5
Figure 2.6 Compressor structure
NO. Description NO. Description

1 Suction 8 Oil drain valve
2 Discharge 9 Sight glass (oil level)
3 Sight glass (motor) 10 Oil return flange
4 Sight glass (refrigerant level) 11 Gas return pipe
5 Power bolt 12 Inlet flange for motor cooling
6 Oil return connection 13 Outlet flange for motor cooling
7 Oil pump 14 Actuator
32
Chapter 3. Capacity control system

3.1 Inlet guide vanes
The cooling capacity of RT Series centrifugal compressors are modulated with change
in angles of inlet guide vanes. Before refrigerant reaches the 1st impeller for compression,
a pre-rotation angle has developed for changing in adiabatic head for control of its cooling
capacity.
Actuator
Impeller
Suction
Inlet guide vane

Figure 3.1 Inlet guide vanes in the compressor
Figure 3.1 Compressor inlet
As illustrated in Figure 3.1, RT series standard water-cooled compressors have first inlet
guide van (IGV1). Refrigerant gas from the evaporator outlet flows through the suction
nozzle to the compressor suction inlet. After the inlet nozzle, gas flow velocity increases
due to the narrow passage. By changing angles of IGV1, refrigerant gas enters with a
pre-rotation angle into impellers. Both gas flow speed and pressure will increase with
rotation of impellers.
Double guide vane performance
Impeller of each stage in front of IGV can only control energy change of that particular
stage. In order to get wider energy change and larger operating range, addition of IGV2
structure at the second stage is necessary. IGV2 is the variable radial guide vanes located
before the inlet of second stage impeller, which can be controlled together with IGV1 to
achieve a greater unloading capacity, equivalent to better IPLV value. Currently in Hanbell,
all standard RT-120T~200T and heat pumps include dual IGV design.
33
Figure 3.2 System with an economizer
Figure 3.2.1
Figure 3.2.1 Refrigerant cycle diagram with economizer contributes to higher efficiency
and this is due to an approximately 7% capacity gain occurs between point 5 & point 6.
34
3.1.1 Control of inlet

nlet guide vanes
Angles of inlet
nlet guide vanes are automatically controlled through a vane actuator with a
lever arm. Automatic
utomatic adjustment of angles of guide vanes is made with loading, from full
load with vanes widely openeded to minimum load with guide vanes completely closed.
The percentage of Actuator opening and the controlling current (pressure) signal are
linearly proportional. But the angle change of the inlet guide vane does not show a
relationship with the capacity change, so the percentage of Actuator
Actuato opening is not
equivalent to the percentage of frozen capacity load.
load
1. When IGV1 is fully close,, a small opening is formed in the central portion to maintain
the basic flow of refrigerant to the compressor. The refrigerant flow is at minimum
when the inlet
nlet flow guide vane is completely closed. The freezing capacity at this point
is also at the minimum, but often in the surge zone which cannot be used. Normal
operation IGV1 ≧ 10% uses (T series IGV1 ≧ 5%).
Note 2: The lower pressure ratio stands for the lower minimum unloading capacity.
Therefore, it is NOT applied to all operation conditions that opening of the vane
Actuator could be set less than10％.
than1 Please refer to HANBELL selection software
for details of opening of guide vanes in percentage before
re operation.
3. When the inlet guide vane of the compressor inlet is fully close,, the Actuator motor will
continue to output torque while the Actuator micro o switch has not yet functioned.
functioned At this
point as the transmission mechanism (guide vain mechanism) has been fully close, the
Actuator motor is locked rotor leading to the temperature protection jump-off
jump (overload
phenomenon), and long-term term operation will cause adverse effects on the Actuator. In
order to solve this problem, the Actuator is set from the factory to operate range from
0% to 100% (input signal is 4mA ~ 20mA).
20mA) Please set to 5% ~ 100% (4.8mA ~ 20mA)
after the unit is switched on with self-test.
self test. Please set to 5 % (4.8mA) when starting and
turning off the unit to avoid operations
operation below 5%.
Min. mass flow
Figure
Figure3.3CloseInlet guide vanes completely
35
3.2 Vane Actuator control

3.2.1 Actuator data
Power Supply 220V AC 1PH, 50/ 60Hz, ±10%
Power control 220V AC 1PH, 50/ 60Hz, ±10%
Working Cycle(modulating) 70%, Max. 180 starts per hour
Motor Induction Motor
Motor operating temperature Built-in temperature protection, on 150±5℃ / off 97±5℃
Cable inlet Three 3/4”PF tap
Operating Temperature -10℃~+70℃
Operating humidity 90％ RH Max.(non-condensing)
Enclosure and protection class IP67/NEMA4
Control signal Input, output 4~20mADC,0~5VDC,0~10VDC,1~5VDC
Torque switch Open/close SPDT, 250VAC 10A Rating
Chamber heater 10W(HQ-015) / 5W(HQ-010) ceramic housed
Table 3.2.1 Actuator data
Maximum Operation
Rated
output time
Type Model current(A) Duty
torque (second) type
kg‧m 50/60Hz 50/60Hz
Actuator 1(for IGV1) HQ-015 15 21/25 0.72/0.84 70%
Actuator 2(for IGV2) HQ-010 10 17/20 0.47/0.46 70%
Note1. Please contact technicians from Hanbell if explosion-proof is required.
Note2. Started from 2017, standard version of actuator is in yellow color. Please contact
service center of Hanbell for other color requirements.
3.2.2 Proportional control board setting

The following picture is the appearance of the proportional board. All settings have been
completed in the factory. Please contact technicians from Hanbell for special setting
requirements.
Caution ：Only authorized and certified technicians are allowed to change the settings.
36
Figure 3.5 Control board of the Actuator
3.2.3 Digital BCD switch setting

Selection of input signal
User can select input signal type by adjusting DIP switches as follows:
Note：Actuator IGV1: terminal #15(+ve)，terminal #16(-ve)；Actuator IGV2: terminal

#10(+ve)，terminal #11(-ve).
Caution ：Do not adjust DIP switch when power is supplied to the actuator!
37
Selection of output signal

User can select output signal type by adjusting DIP switches as follows:
Note：Actuator IGV1: terminal #17(+ve)，terminal #18(-ve)；Actuator IGV2: terminal

#12(+ve)，terminal #13(-ve).
Caution ：Factory default setting of input signal is 4-20mA DC; output signal is 4-20mA DC;
Signal for valve body fully open is 20mA.
When necessary, adjust the key of ZERO or SPAN to match the input signal
When the Control signal is out of order, please adjust DIP switch to recover signal setting.
Note：Factory default setting is at the off position.
Delay working time

Delay setting is to avoid excess continuous operation of the actuator, which would result in
the overheating of the actuator motor. Delay time ranges from 0~7.5 seconds, and is
adjusted to 15 stages, with 0.5 seconds at each stage. Factory default setting scale 4 is 2
seconds.
Seconds 0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5 7.0 7.5
Dial 0 1 2 3 4 5 6 7 8 9 A B C D E F
Warning ：Only authorized and certified technicians are allowed to change this setting.
Deadband
When using 4 ~ 20mA as the input signal, if the dead band value (sensitivity) is set to 1%,
the input current changes need to be over 16/100 = 0.16mA to make a 1% movement.
38
Factory default setting of the dead band value is 2%, therefore an input current change of
0.32mA (2%) is required to make minimum movement.
% 0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5 7.0 7.5
Dial 0 1 2 3 4 5 6 7 8 9 A B C D E F
Deadband value (sensitivity) setting: The lower the set value, the more sensitive it will be.
Excessive sensitivity will cause actuator “hunting” (moving up and down while unable to
positioning). But if the deviation range on operation settings of the system unit controller is
too small, it will also lead to the same “hunting” problem. Therefore, when “hunting” occurs,
please make sure that both settings are appropriate.
Warning ：Setting of extremely low dead band value may cause actuator “hunting”.
Warning ：Only authorized and certified technicians are allowed to change this setting.
3.2.4 Duty cycle
This setting could be used as periodic setting. The settings for operating time and rest time
of the actuator are based on the standards of IEC (International Electrotechnical
Commission), IEC34-1 as follows:
Start frequency=operating time/(operating time + rest time)*100%
Rest time=operating time*(1-start frequency)/start frequency
 Example: Actuator duty cycle (start frequency) on the compressor of 50 Hz is 70%, the
operating time is 21 seconds:
Rest time = 21 * (1-70%) / 70% = 9 seconds, so when the controller is under command
to carry out:
1. Full capacity control (IGV=0%→100% or 100%→0%), time interval should be at least
21+9=30 seconds.
2. Partial capacity modulation, the interval time is:
Interval time= | Capacity difference% | *(21 +9)
 Example :IGV=65%→55% interval time=｜65%-55%｜*(21+9)=3 seconds
Note：It is complicated to split command time into many parts in control logic. Therefore, if
the operation opening for chilled water control is ≦10% for each operations, and the
chilled water response cycle is about 30~60seconds, then an operating time interval
of 30 seconds can be used.
Caution ：In order to prevent accumulated heating of the motor due to frequent operations, it
is advisable to set the start frequency to maximum 3 times/minute.
39
Local Operation Mode

This feature allows for temporary local operation by use of
the Zero/Close and Span/Open buttons on the PCU board
to open and close the guide vanes. To access this feature,
simultaneously push the Zero and Span buttons, hold for
two seconds, and release. The yellow Fault LED will be lit
to indicate Local operation mode. (If there is no operation
occurs within 15 seconds, the PCU will default to setpoint
control).
Automatic Calibration
This feature allows for automatic calibration of the PCU card to the preset limits, without the need
for a signal generator. To access this feature, press the A-Scan button one time. The white Auto
Scan LED will flash. The unit will then automatically stroke to the close limit, pause, then stroke to
the open limit and stop. The PCU will now be calibrated.
Note：1. Actuator is calibrated at the factory, and settings are stored in non-volatile memory. No
recalibration required unless the limits are changed.
2. When Actuator is in operation, the operating mode is repositioned to automatic mode.
Do not use Manual mode unless under troubleshooting situations. Using manual mode
is not recommended at normal conditions.
Split Range
This feature allows a range of set points for full open and full close
positions.
Close: 3 to 8mA DC
Open: 16 to 21mA DC
For example: If the user would like to assign 5mA to the fully
closed position, supply a 5mA signal and then allow the actuator to
move to the corresponding position. Move switch 4 (CH1) to the
on position, and press the Zero button one time. The actuator
acknowledges that position as fully closed and transmits 4mA.
Push the Span button to set the fully open position. Once the setting is complete, move switch 4
down to the off position.
Reverse Acting
Standard operation is clockwise rotation of the actuator to close. When reverse action, or
counterclockwise rotation to close is required, move switch 5 (CH2) to the on position (up). Move
actuator to mid position and push A-scan button. Supply signal and check rotation.
Switch 5 on (up) = 20mA Full Close Switch 5 off (down) = 4mA Full Close
4mA Full Open 20mA Full Close
3.2.5 Wiring
The terminals of the control elements in the actuator are connected inside the housing. Remove the
housing and connect the cable to the terminals. The connection method is shown in Figure 3.4 and
Figure 3.4.1. Please check if the power supply is in proper voltage. When all terminals are properly
connected, please adjust to half open level with manual control and test the grounding.
Caution ：Please turn off all power services before attempting to perform maintenance and
wiring of actuator. Before dismantling the actuator, make sure that the IGV is in
fully close and not pressurized condition.
40
Figure 3.4 Actuator1 wiring diagram (for IGV1)
1. Input signal #15(+ve) & #16(-ve)：4~20mA DC,0~5V DC,0~10V DC,1~5V DC，Factory setting
is 4-20mA DC
Output signal #17(+ve) & #18(-ve)：4~20mA DC,0~5V DC,0~10V DC,1~5V DC，Factory setting
is 4-20mA DC
Caution：All control signal wires need to be in shielded (isolated) wiring to avoid
interference. Length of the signal wire should not exceed more than 30m.
2 Power connecting point (220V AC 1PH,50/60Hz) #5 & #13：

Caution：An independent power supply is required for actuator power supply. Power source
should not be used in conjunction with other electrical equipment (particularly not
use in connection with two-phase power from compressor motor main power
source), and "isolation transformer" and "electric filter" have to be installed to
avoid voltage fluctuation (within 10% of permissible fluctuation) and noise
interference which will cause damage to the actuator board.
Caution ：It is required to install 2A fuse at the input end of the main power source to protect
the actuator.
41
Figure3.4.1 Actuator2 Wiring Figure (for IGV2)
1. Input signal #10(+ve) & #11(-ve)：4~20mA DC,0~5V DC,0~10V DC,1~5V DC，Factory setting
is 4-20mA DC
Output signal #12(+ve) & #13(-ve)：4~20mA DC,0~5V DC,0~10V DC,1~5V DC，Factory setting
is 4-20mA DC
2. Power connecting point(220V AC 1PH,50/60Hz) #4 & #5：

Note：Actuator 2 is used in heat pump models and T series (dual IGV), not for standard compressor
models.
3.2.6 LED indicator lights
LED Indication
Blue light Power on
Flickering
Auto calibrating
Blue light
Green light Fully closed
Flickering
Closing
Green light
Red light Fully open
Flickering
Opening
Red light
Yellow light Manual mode
Flickering Error indicator for one of the
Yellow light following situations :
No input signal;
4-20 mA polarity error;
Reversal of equipotential line.
Table 3.2.6 LED Indicator lights
42
3.2.7 Manual operation

To manually operate the actuator, pull the manual declutch lever towards the handwheel
until it remains in position. Turn the handwheel until the guide vanes reaches the desired
angle. Turn clockwise to close and counterclockwise to open.
Note：When the actuator is in power, manual mode will automatically switch to automatic
mode.
3.2.8 Overload protection

Overload protection device which detects the variation of torque during operation is
installed for preventing damage of valve and actuator under overload condition. Once the
operational torque exceeds the setting value, torque switch is tripped and actuator will be
stopped immediately.
Warning：Do not set the overload trip higher than the recommended maximum torque value.
3.2.9 Troubleshooting
PROBLEMS Checking Methods
Check the power supply of actuator.
Check that the voltage matches the rating on the actuator nameplate.
Actuator does not respond
Check internal wiring against actuator wiring diagram.
Check the limit switch cams.
Check the power supply of actuator.
Check actuator torque to see if it is greater than the valve torque.
Check the limit switch cams.
Check that the torque switches have not tripped.
Actuator is receiving power Check mechanical travel stop adjustment.
but does not operate Verify the actuator against valve rotation (standard units are
counterclockwise open).
Check internal wiring.
Check for corrosion or condensation.
Verify coupler/bracket are correctly installed and is not causing
binding.
Check ambient temperature.
Actuator runs erratically Verify that the duty cycle has not been exceeded.
Check the position of manual operation lever.
Check resistance value.
IGV position indicator Check whether the transmission gear is interfered.
Check board for damage.
Verify input signal.
Current / IGV position
Check DIP switch configuration.
converter
Check board for damage.
Table 3.2.9 Actuator troubleshooting
3.2.10 Actuator capacity control
43
When adjusting the compressor towards the target water temperature, as IGV1 opening is not
linearly proportional to the capacity change, it is recommended to refer to the following example in
Table 3.4 for IGV1 adjustment range. Generally, when IGV opening is adjusted from 100% to 40%,
the capacity change is only about 21%, but when the opening is adjusted from 40% to 10%, there
will be a 34% capacity change.
Target chilled water temperature (CHWT), 7℃
Range ＜6℃ 6~6.7℃ 7±0.3℃ 7.3~8℃ ＞8℃
Loading mode fast unloading normal unloading Neutral zone normal loading fast loading
When IGV≧40% IGV-10% IGV-5% no action IGV+5% IGV+10%
When IGV＜40% IGV-5% IGV-3% no action IGV+3% IGV+5%
Table 3.4 Capacity control table
Caution：1. Although under standard condition (CT/ET=36/6℃), the typical target chilled water
temperature (CHWT) is 7℃, the target CHWT can be set to the desired temperature
by the user. If the neutral zone is too small (<±0.3℃), it can be difficult to obtain a
stable target CHWT. The reason for this issue is due to the deadband of actuator
being set to 2%.
Caution：2. The adjustment for the target CHWT should be mainly based on the input signal as the
output signal is often susceptible to noise and harmonic interference which could
cause significant deviation between output and input signal. Therefore, it is
recommended to cancel output signal feedback during capacity control, which can
also avoids heavy duty cycle due to feedback “hunting”.
Caution：3. Each IGV1 opening has a corresponding limit pressure ratio. During the loading and
unloading capacity control process, the pressure ratio must be monitored that it's
within the limit pressure ratio to ensure no surge occurred. Please refer to 3.3.1 safety
margin formula section for more information.
3.3 Surge and Stall phenomenon

【Definition】
】
 Surge: When the flow rate continues to decrease after stalling, further breakdown of steady
through flow will occur which ultimately, leads to complete expansion of separation zone in
the flow path. This results in significant drop in discharge pressure and when the discharge
pressure is lower than the backpressure, reversal of flow will take place. Such phenomena
are periodic and detrimental due to heavy vibrations of compressor.
 Surge point：Each IGV opening has a corresponding maximum pressure ratio surge point.
 Surge line：The curve formed by connecting surge points of each IGV opening.
 Stall: When the flow rate decreases, the incidence angle increases, causing more severe flow
separation as well as larger separation zone and at this point, the performance of compressor
is significantly deteriorated. This phenomenon is known as stalling.
 Stall zone：Rotating stall is a local disruption of flow within the compressor at low flow rates
which limits the operating range of the compressor.
 Allowable operating range：Ranging from the maximum IGV opening (100%) to the smallest
IGV opening (10%),with the maximum operation load of (105%) and covering the operating
range from safety margin line to the minimum pressure ratio.
 Safety margin line：The curve is formed by translating the surge line to a safety margin at the
maximum upper limit of pressure ratio for each IGV opening.
 Pressure ratio：Pressure ratio is the absolute pressure ratio between compressor discharge
and suction inlet.
When the centrifugal compressor is operating at part load, the angle of guide vanes will become
smaller, and the flow rate of refrigerant entering the compressor will also become smaller. The
surging and stalling phenomena occur when the flow rate is reduced beyond a critical limit. As
shown in Figure 3.5, when compressor operates above the surge line, stalling or surging may occur.
When surging occurs, the discharge pressure of compressor will reduce drastically, lower than the
44
pressure in condenser, and as a result, high pressure gas flows reversely back into the compressor
and the airflow inside the compressor becomes unsteady and turbulence which leads to heavy
vibrations and noise. During surging, high speed shaft can be damaged due to heat accumulation
inside the compressor. In addition, the rotating parts will experience an alternating stress induced
by periodically varying pressure due to reversal of flow which increases the loads on bearings and
may destroys the bearings. Therefore, the operation of compressor must be limited within the
allowable operating range under the safety margin line.
Figure 3.5 illustrates the operating range of a fixed-frequency water-cooled compressor.
Surge occurred due to dramatic change of working condition can be detected by measuring the
current value of motor as the compressor will be in a state of unsteady loading due to the reversal
of flow during surging. With an approximately 5 seconds/cycle of surge frequency, the compressor
can be considered as surging when three consecutive peak current differential is 10% higher than
the average current within 15 seconds (except during loading control of the compressor). Please
refer to section 3.3.1 for surge protection strategy (mechanism).
Note：RT series compressors use rigid bearings and are capable of withstanding short-term surge
up to 15 seconds. However, the compressor cannot withstand long-term surge, thus using
only current detection for surge protection is not allowed. Safety margin line formula should
always be used as primary surging protection.
：Once surging occurred, labyrinth seal gaps will become larger, which increases the
Warning：
leakage of labyrinth seals. In addition, the vibration of compressor will also become larger
due to greater imbalance. Such effects are detrimental and should be avoided.
Warning：Normal operations of compressor should always be within the allowable operating range.
Current detection is mainly used when surging occurred due to dramatic change of
working condition.
45
3.3.1 Fixed-frequency capacity control and surge protection

strategy
The capacity control of a fixed-frequency compressor is generally divided into constant pressure
ratio modulation and constant load modulation.
【Constant pressure ratio modulation】Taking point P of Figure 3.5 at a certain constant pressure
ratio as an example, if the outlet temperature of the chilled water (CHWT) is higher than the target
temperature, then the loading should be increased by increasing IGV opening (P shifts right) until
reaching the temperature at target CHWT±0.3℃. If the outlet temperature of the chilled water
(CHWT) is lower than the target temperature, then the loading should be reduced by decreasing
IGV opening (P shifts left) while making sure that the operating pressure ratio does not exceeds the
limit. If further reduction of IGV opening is required when the pressure ratio reaches the limit, then
hot gas bypass valve should be opened to balance the system.
【Constant load modulation】Taking point P of Figure 3.5 at a certain constant load as an example,
if the pressure ratio is required to be increased (P shifts upward) when the outlet temperature of
cooling water increases, then IGV opening should be increased while making sure the operating
pressure ratio does not exceeds the limit during the process. Start surge protection if the outlet
temperature of cooling water rises continuously. If the outlet temperature of cooling water drops,
then IGV opening should be decreased to reduce the pressure ratio (P shifts downward), this
process
Surge protection mechanism of a fixed-frequency compressor is generally divided into two modes:
unloading mode and loading mode
【Unloading mode】If surge occurs during unloading mode of cooling water, then open the hot gas
bypass valve for 1-2 minutes to reduce the operating pressure ratio (raising the lower pressure).
The system can return to normal operating mode after the hot gas bypass valve is closed.
【Loading mode】If surge occurs during loading mode of cooling water, then increase the opening of
IGV by 5-10% each increment. If compressor surge still persists when the IGV opening is increased
to 100% then the system should be shut down.
Caution：The timing of compressor surge should be flagged, typically for 10 minutes, if there are
three consecutive surge occurrences during this period, then the compressor must be shut down
and investigation is required to identify and eliminate the cause(s), e.g. high cooling water outlet
temperature due to inefficient in heat exchange of the condenser, then cleaning of the condenser is
required. Otherwise, temporarily increase the target outlet temperature of cooling water (reduce
operating pressure ratio) to allow temporary operation of the compressor until cleaning is
completed.
Fixed-frequency unit safety margin line formula

Fixed-frequency compressor allowable operating range：Ranging from the maximum IGV opening
(100%) to the smallest IGV opening (10%),with the maximum operation load of (105%) and
covering the operating range from safety margin line to the minimum pressure ratio.
The safety margin line formula is a polynomial of IGV opening and should be monitored when the
compressor is under capacity control to avoid operating pressure ratio from exceeding the
precaution safety margin line.
Pr=pressure ratio (safety margin line) =y=a+bx+cx2+dx3+ex4

Where a, b, c, d, e are constants and x is the IGV opening.
46
Pr=a+bx+cx 2+dx 3+ex 4

Model
x=IGV opening(10~100) y=Pr (Max.safety pressure ratio)
y=2.69848+1.23309E-02x-1.28291E-04x 2+3.21830E-07x 3+1.58931E-09x 4
a b c d e
constant
RT-120(E) 2.69848E+00 1.23309E-02 -1.28291E-04 3.21830E-07 1.58931E-09
IGV(%) 100 90 80 70 60 50 40 30 20 10
Pr 3.13 3.11 3.09 3.08 3.07 3.04 3.01 2.96 2.90 2.81
2 3 4
y=2.44328+1.70194E-02x-1.69203E-04x +7.33557E-07x -6.12448E-10x
a b c d e
constant
RT-120T 2.44328E+00 1.70194E-02 -1.69203E-04 7.33557E-07 -6.12448E-10
IGV(%) 100 90 80 70 60 50 40 30 20 10
Pr 3.13 3.10 3.07 3.04 3.01 2.96 2.90 2.82 2.72 2.60
2 3 4
y=2.77262+1.25863E-02x-1.31003E-04x +3.29367E-07x +1.61811E-09x
RT-130(E) a b c d e
constant
RT-140(E) 2.77262E+00 1.25863E-02 -1.31003E-04 3.29367E-07 1.61811E-09
IGV(%) 100 90 80 70 60 50 40 30 20 10
Pr 3.21 3.19 3.18 3.16 3.15 3.13 3.09 3.04 2.97 2.89
2 3 4
y=2.51204+1.73806E-02x-1.72966E-04x +7.51568E-07x -6.36018E-10x
a b c d e
RT-130T constant
2.51204E+00 1.73806E-02 -1.72966E-04 7.51568E-07 -6.36018E-10
RT-140T
IGV(%) 100 90 80 70 60 50 40 30 20 10
Pr 3.21 3.18 3.15 3.12 3.09 3.04 2.98 2.90 2.80 2.67
2 3 4
y=2.55474+1.18314E-02x-1.22987E-04x +3.07100E-07x +1.53292E-09x
RT-160(E) a b c d e
constant
⌇ 2.55474E+00 1.18314E-02 -1.22987E-04 3.07100E-07 1.53292E-09
RT-280(E) IGV(%) 100 90 80 70 60 50 40 30 20 10
Pr 2.97 2.95 2.93 2.92 2.91 2.89 2.85 2.81 2.74 2.66
2 3 4
y=2.3101+1.6313E-02x-1.6185E-04x +6.9836E-07x -5.6646E-10x
RT-160T a b c d e
constant
⌇ 2.31010E+00 1.63130E-02 -1.61850E-04 6.98360E-07 -5.66460E-10
RT-280T IGV(%) 100 90 80 70 60 50 40 30 20 10
Pr 2.96 2.94 2.91 2.88 2.85 2.80 2.75 2.67 2.58 2.46
2 3 4
y=2.27349+4.16545E-02x-3.06201E-04x -1.38454E-06x +1.66588E-08x
RT-111 a b c d e
constant
RT-161 2.27349E+00 4.16545E-02 -3.06201E-04 -1.38454E-06 1.66588E-08
RT-221 IGV(%) 100 90 80 70 60 50 40 30 20 10
Pr 3.66 3.63 3.62 3.61 3.59 3.52 3.40 3.22 2.98 2.66
Table 3.5 Fixed-frequency compressor safety margin line formula
：Safety margin line formula is the primary protection of compressor surge, DO NOT use
Warning：
current detection only for surge protection as it only passively activated when surge
occurs. Compressor will be seriously damaged by repeating occurrence of surge.
47
Dual IGV relationship for different models

Both RT series and heat pump are equipped with double IGV mechanism. The actuators
are set up separately while the operations of IGV1 and IGV2 are coupled. The formula is as
follows:
1.When 100≧IGV1≧70，IGV2=100
Model
2.When 70＞IGV1＞0， y=a+bx+cx2+dx3+ex4,其中 x=IGV1,y=IGV2
y = 7.849+ 2.320x-1.440E-02x2
RT-120T
a b c d e
RT-130T constant
7.849E+00 2.320E+00 -1.440E-02 0.000E+00 0.000E+00
RT-140T
RT-111 IGV1 100 90 80 70 60 50 40 30 20 10
IGV2 100 100 100 100 95.2 87.8 77.6 64.5 48.5 29.6
1.When 100≧IGV1＞90，IGV2=100
Model
2.When 90≧IGV1＞0,y=a+bx+cx2+dx3+ex4 ,其中 x=IGV1,y=IGV2
y =5.464E+00+3.317E+00x-5.588E-02x2+5.023E-04x3 -1.808E-06x4
RT-160T
a b c d e
RT-180T constant
5.464E+00 3.317E+00 -5.588E-02 5.023E-04 -1.808E-06
RT-200T
RT-161 IGV1 100 90 80 70 60 50 40 30 20 10
IGV2 100 98.9 96.3 92.7 88.4 83.1 76.3 66.8 53.2 33.5
y = 5.5+1.969x -1.020E-02x2 ,其中 x=IGV1,y=IGV2
Model
a b c d e
constant
5.500E+00 1.969E+00 -1.020E-02 0.000E+00 0.000E+00
RT-221 IGV1 100 90 80 70 60 50 40 30 20 10
IGV2 100 100 97.7 93.4 86.9 78.5 67.9 55.4 40.8 24.2
Table 3.3.1 Equations describing the relationship between the two IGVs
3.3.2 Energy savings with variable frequency compressor

Centrifugal compressors are equipped with a motor which drives the high speed shaft
through speed-up gears. Refrigerant gas is compressed and accelerated by the centrifugal
effect of the impellers which rotating at high speed. In the diffuser, most of the kinetic
energy gained is converted into pressure energy.
Obviously, the energy gained from the impeller is ultimately applied by the motor.
Compressor Input power is as follows:
P=H．m/η
P = compressor input power
H = energy head
m = mass flow rate of refrigerant
η = motor efficiency
According to the Laws of Similarity in fluid mechanics:
48
m = mass flow rate of refrigerant

H = compressor head (enthalpy difference)
P = compressor input power
Combining compressor input power and similarity laws shows that H is proportional to the square of
the speed, m is proportional to the speed, while motor power is proportional to the cube of motor
rotational speed. Thus, by reducing the rotational speed, power input will be greatly reduced and as
a result, improving the efficiency of the compressor and reducing the power consumption of the
chiller system (Refer to Figure 3.6, for the capability of fixed/variable frequency unit and shaft power
map).
Figure 3.6 Performance map of a fixed/variable frequency unit
Chilled water temperature modulation

The VSD inverter optimizes the rotational speed of the motor and the opening of IGVs based on the
chilled water outlet temperature and the compressor head (pressure ratio), so that the unit always
operates under the best condition.
The basic parameter of VSD control is the temperature difference between the actual value of the
chilled water outlet temperature and the set value.
1. When the unit is operating at full load, the IGVs are fully opened and the motor rotational
speed control logic is completely based on the temperature difference. As the cooling load
decreases, the motor rotational speed decreases. The motor rotational speed is controlled by
the compressor head (pressure ratio) and the system minimum allowable rotational speed,
until the rotational speed reaches the minimum value. At this point, motor will remain at
minimum speed.
2. When the load demand reduces, motor rotational speed will provide signal for the logical
control of the IGVs so that IGV opening can be decreased. As the cooling load continues to
drop, speed signal from the compressor continues to turn off the guide vanes and increase
motor rotational speed.
49
VSD capacity modulation strategy & variable frequency surge formulae

VSD capacity control takes variable speed as priority and IGV as auxiliary for modulation to reach
the optimum efficiency. Thus, VSD compressor surge formulae mainly control the compressor
frequency. The expressions are as follows:
:
Z=a+bx+cy+dx2+ey2+fxy+gx3+hy3+ixy2+jx2y
where a、b、c、d、e are constants (refer to Table 3.7 VSD compressor surge formula);
x=IGV(%) opening (10~100);
y=pressure ratio, Pr;
Z (minimum allowable operating frequency) = Frequency (Hz)
※Insert the value of y (pressure ratio) and x (IGV opening) at the operating point into the formula
to obtain the minimum allowable operating frequency. The recommended compressor operating
frequency is Z+1 to 1.5Hz in order to reach the maximum efficiency. Reasons for setting value
range of +1 ~ 1.5Hz is:
a. To avoid forced increase in frequency at small IGV openings when IGV opening value is
inserted into the formula (could cause fluctuation of chilled water temperature).
b. To avoid surge formula deviation or inaccurate measuring sensor;
c. This formula does not have safety margin.
Z= a+bx+cy+dx2+ey2+fxy+gx3+hy3+ixy2+jx2y
Model
x=IGV opening(10~100%)，y=pressure ratio Pr，Z=Frequency (Hz)
a b c d e
-3.99639E+01 -5.25339E-02 7.47371E+01 1.28399E-03 -2.21462E+01
RT-120E
f g h i j
-2.20465E-02 -8.07113E-06 2.51895E+00 -1.42502E-03 1.35207E-04
a b c d e
RT-130E -2.10165E+01 1.11192E-01 4.57809E+01 -7.54248E-04 -1.00315E+01
RT-140E f g h i j
-5.47750E-02 -6.23802E-06 1.06767E+00 -1.95358E-02 9.99493E-04
a b c d e
RT-160E~ -3.28481E+01 -1.40837E-02 6.87195E+01 2.73888E-04 -2.00618E+01
RT-280E f g h i j
-3.93628E-02 -9.02008E-07 2.22521E+00 3.62232E-03 1.55530E-04
Table 3.7 VSD compressor (50Hz) surge formula (without safety margin)
1. Start-up frequency: As high and medium pressure has not been established before start-up, it
is impossible to calculate the required minimum rotational speed based on the pressure ratio
when the compressor starts, therefore it is necessary to estimate the condensing temperature
by using cooling water inlet temperature plus a temperature difference (7~8K) to obtain the
expected condensing pressure. Then, using chilled water outlet temperature minus a
temperature difference (1~2K) as the expected evaporation temperature to obtain the
evaporation pressure. Finally, insert the pressure ratio based the estimated pressures and
IGV=10% into the formula to calculate the minimum operable frequency+1Hz; otherwise
start-up with the highest operating frequency.
50
※It is suggested to complete the accelerating time within 20 seconds for start-ups (0 to rated speed
time). Excessive accelerating time can easily lead to discontinuity of gear thrust which will
cause crash and bearing damage from slippage due to excessively low bearing loading. The
compressor will also stay longer in the surge zone.
2. Unloading: Frequency control in priority, when the frequency drops continuously to below (Z+1)
Hz into zone A, the compressor needs to start unloading. It is recommended that each decline
for IGV≤20% is 2%, for 20<IGV<50% is 5%,and for IGV ≧ 50% is 8%.
3. Loading: When the frequency is increased to Z+2~3Hz, the compressor needs to start
increasing the loading. Load increment is recommended as mentioned above.
4. For a 60Hz VSD compressor, please apply Table 3.7 VSD compressor (50Hz) surge formula
and multiply the calculated value by 1.2.
VSD allowable operating range: as shown in Figure 3.7, the allowable operating range of a VSD
compressor is formed by the maximum operable capacity (105%), VSD surge formula and pressure
ratio, IGV opening and surge line.
※Surge line: Insert Z = 50Hz (fixed frequency), IGV opening (10-100%) into VSD surge formula,
the values of y (pressure ratio) obtained forms the surge line, alternatively, it can also be obtained
by using fixed frequency safety margin line formula.
：The maximum operable frequency is the rated frequency of the compressor. Do not
Warning：
overclock for higher compressor capacity. Overclocking to a critical speed will cause
structural collapse of high-speed shaft due to resonance.
Warning：The minimum operable rotational speed of the compressor is 60% of its rated speed.
Excessively low speed will cause inefficient discharge of motor cooling liquid, oil leakage
and bearing slippage due to low loading, in extreme cases, can lead to catastrophic
failure of compressor.
Figure 3.7 A schematic diagram of inverter operating range
51
Adjustment of inverter’s frequency for capacity modulation
1. The increment and decrement of inverter frequency is differentiated according to the loading
mode. When the output cycle time arrives (for example, 30 second), determine the adjustment
of frequency based on the difference between current CHWT and target CHWT.
※Taking 800RT as an example, 1Hz is approximately 7.2% (58RT) of cooling capacity change
rate.
2. Assuming that the set value of cooling water output temperature is 7°C, neutral zone temperature
difference is ± 0.2°C, output cycle time is 30 seconds, rapid loading and unloading frequency is 1 Hz.
Normal loading and unloading temperature difference is 0.5°C and frequency increase and decrease is
0.5Hz. Change of CHWT and inverter output are listed in the following table
Target chilled water temperature (CHWT), 7℃
Range ＜6.8℃ 6.5~6.8℃ 6.8~7.2℃ 7.2~7.5℃ ＞7.5℃
Loading mode fast unloading normal unloading Neutral zone normal loading fast loading
Inverter output -1Hz -0.5Hz no action +0.5Hz +1Hz
52
3.4 Hot gas bypass (HGBP)

Centrifugal compressors are of non-positive displacement types. They raise pressure
and temperature of refrigerant by converting kinetic energy into an increase in static
pressure. Hot gas bypass is to bypass or liquid refrigerant from condenser into evaporator
through a proportional valve.
Function 1: When the load reaches certain value the surge would happen. To continue
the low load operation, the hot gas by pass valve can be opened to increase suction
pressure and lower compression ratio.
Function 2: Apply during start up to lower starting current.
Function 3: Unloading modulation
Because hot gas bypass method is to transfer compressed gas from the condenser
(high-pressure side) to the evaporator (low-pressure side), it should be noticed that this
volume flow might make enormous noise. It is recommended to enlarge the inner diameter
of piping after the HGBP valve to keep flow speed under 10 m/sec.
In piping, the proportional valve should be installed as close as possible to the
evaporator, and also at another side of suction entry (motor side), to lower the noises at
suction side. Setting the piping on suction pipe can also prevent liquid strike.
Besides, a muffler should be installed at the evaporator. Hot gas bypasses to the
evaporator should be prevented from liquid refrigerant inside the evaporator. If liquid
refrigerant splashes and sucks into the compressor, it will result in liquid compression,
which damages the compressor.
Note1: The system with hot gas bypass is inefficient. It should be avoided whenever
possible. Many system applications still require hot gas bypass in order to avoid
surge or maintain constant chilled water temperatures from zero load to full load.
Note2: Required flow for HGBP depends on the difference between required minimum
cooling capacity and the minimum load compressor can reach. If the IGV is at
minimum opening and cooling capacity is 50%, and end user needs 20%. The pipe
diameter and flow need to be considered based on the 30% difference.
Figure 3.7 Refrigerant Circuit & Motor Cooling systems
53
3.5 Proportional valve

Single IGV model:
When the compressor operates at low pressure ratio with IGV1≤10%, the inlet flow will have higher
pressure loss due to the angle of IGVs. As shown in Figure 3.8(a), from point to 9 to 1 the pressure
loss becomes larger, leading to a lower intermediate pressure closing to evaporation pressure and
the economizer may have higher liquid level due to higher difficulty in controlling expansion valve
and orifice plate at low pressure end. As a result, liquid refrigerant may be drawn into compressor
intermediate inlet (ECO port). Therefore, it is recommended to install an intermediate pressure
valve between ECO port and economizer, near the compressor. Close the intermediate pressure
valve when IGV’s opening <10%, while fully open the valve when IGV opening is ≥10%.
Dual IGV Model:

For dual IGV models, IGV2 is adjustable radial guide vane. IGV2 opening can be used to control the
pressure in the economizer to maintain a certain pressure difference between intermediate
pressure and low pressure when operating in low pressure ratio. Thus, the intermediate inlet is less
likely to suffer from the phenomenon of liquid absorption, as shown in Figure 3.8(b), so double IGV
model users do not need additional intermediate pressure valve.
Note: 1. For dual IGV models, intermediate inlet is less likely to have liquid absorption issue, thus
the minimum operating opening is ≥5%. The link relationship between IGV1 and IGV2
should be applied by Hanbell to ensure that the compressor intermediate pressure control
is at the best point.
2. Intermediate pressure valve: Due to part load requirements (such as pure orifice plate
expansion valve unit), some unit designs require lower economizer (flash tank) pressure to
ensure smooth discharge of motor cooling liquid. In this case, the intermediate pressure
valve requires proportional control and thus, a proportional valve should be used.
Otherwise, an ON-OFF type shut-off valve is applicable.
Figure 3.8 (a) Single IGV enthalpy diagram of Figure 3.8 (b) Dual IGV enthalpy diagram
2-stage compression of 2-stage compression
54
Compressor medium pressure formula
1. Water-cooled compressor intermediate pressure (absolute pressure) relationship

1. RT-120~280
When IGV>0,
Pm= 1.025*(IGV%/IGV100%)^0.08*(Pe*Pc)^0.5
When IGV=0,
Pm= 1.025*0.82*(Pe*Pc)^0.5
E.g.,
Pe= 3.62 bar where,
Pc= 9.63 bar Pe=evaporator pressure
IGV= 100 % Pc=condenser pressure
Pm= 6.05 bar Pm=intermediate pressure
2. Heat pump compressor intermediate pressure (absolute pressure) relationship

1. RT-111
When IGV>0,
Pm= 1.025*(IGV%/IGV100%)^0.5*(Pe*Pc)^0.5+Pe/Pc*1.9
When IGV=0,
Pm= 1.025*0.82*(Pe*Pc)^0.5
E.g.,
Pe= 3.62 bar where,
2. RT-161,221
When IGV>0,
Pm= 1.025*(IGV%/IGV100%)^0.035*(Pe*Pc)^0.5+Pe/Pc*0.55
When IGV=0,
Pm= 1.025*0.9*(Pe*Pc)^0.5+Pe/Pc*0.55
E.g.,
Pe= 3.62 bar where,
55
Chapter 4. Lubrication system
4.1 Oil circuit

Lubricant is driven by built-in oil pump in the compressor. Oil passes front / back
bearings of motors since gears and bearings are around the high-speed shaft for
lubrication. The oil system consists of an oil pump, a relief valve, an oil filter, oil cooler and
other control valves.
Figure 4.1 Schematic diagram of oil piping
After lubricant is pressurized by built-in oil pump, it passes the relief valve for modulation
of pressure and flows through pipe 1. The oil circuit is then divided into two passages, Pipe
2 & 3, which is after the oil cooler and the oil filter. Oil in pipe 3 lubricates bearings in the
back of the motor and returns to the oil tank by pipe 3’. Oil in Pipe 2 enters gear box on the
top, and lubricates bearings in front of the motor, the gears, and the front/ back bearings,
which are around the high-speed shaft, and returns to the oil tank finally.
Caution：RT-series centrifugal compressor uses positive displacement gear pumps which release
pulsating wave at the discharge of the oil pump. Therefore, a buffer tube and a steel wire hose
(length> 40cm) should be added at the outlet of the oil pump to absorb the shock.
Definition:
 R1: Resistance in pipe, R1=P1-P2. It includes pressure drop in pipe itself, oil
cooler, and oil filter. Please pay attention to the pressure sensor installing point.
 R2：Internal resistance in compressor. Its fixed value 2.0~2.2 bar indicates the
necessary pressure difference for compressor lubrication.
Pipeline resistance (R1) protection

Oil filter is the only component in the pipeline that has variable resistance while the rests are
constants, thus the pressure difference of P1-P2 should be monitored to prevent lack of lubrication
caused by oil filter blockage.
56
R1=P1-P2 ≥ 1.0 bar warning

R1=P1-P2 ≥ 1.5 bar shut down
Note：
1. Unexpected power trip often occurs in many areas, causing the system to shut down
abnormally and compressor shuts down when the oil pump is stopped. For compressors using
hydrodynamic bearings, lack of lubrication can cause jamming and damage of the rotor.
Hanbell RT-series compressors use rigid bearings which does not require additional power trip
protection as the residual oil can be used for free rotating shut down.
2. Compared to hydrodynamic bearings, rigid bearings have the advantage of less mechanical
loss and less lubrication required.
3. Pressure sensor installation point: Pressure sensing point P1 should to be installed behind the
buffer tube, while P2 should installed before the inlet of gearbox lubrication.
4.2 Oil pump

4.2.1 Specifications of the oil pump
The built-in oil pumps of RT series centrifugal compressors are of the positive
displacement gerotor type.
Item Specifications
Flow rate L/min. 26~30 32~36
Oil pump
Pressure difference
operating range
bar 2~4.5
Output W 446 560

Voltage V 3ψ/220V/50Hz 3ψ/380V/50Hz 3ψ/220V/60Hz 3ψ/380V/60Hz
motor
Max. operating
current
A 3.6 2.1 3.5 2
LRA A 19.1 11.06 17.6 10.2
Table 4.1 Specifications of the oil pump
Note：Voltage Specifications: 3ψ/220V 50Hz & 60Hz are shared oil pump. With different power
supply frequencies, the motor output and oil flow rate will also be different. This is similar for
3ψ/380V 50Hz & 60Hz. However, the internal windings of oil pump motor for 220V and 380V
are different, therefore please contact Hanbell service technicians for different power supply
voltage.
4.2.2 Features of oil pump

The primary function of the oil pump is to provide enough lubricant for lubrication and cooling of
the bearings and gear, and the flow rate of lubricant and the temperature of bearings and gear after
cooling are the decisive factor. Thus, protection mechanism is necessary to ensure the oil pump
overcomes the internal resistance of compressor (R2) and provides adequate flow rate of oil.
Compressor internal resistance (R2) protection

Hanbell RT-series centrifugal compressor has been tested and verified that the optimum flow rate of
oil is 20~25L/min. in the form of oil-jet and ensures the bearing outer ring temperature to be less
than 80°C after cooling. Therefore, the pressure difference between oil pressure before entering the
compressor P2 and oil tank pressure P3 is the key to overcome compressor internal resistance R2.
57
P2-P3<2.5kg/cm² warning
P2-P3≤2.0kg/cm² shutdown
Note：1. This oil pump internal resistance (R2) protection is based on the current specifications of
3/4HP oil pump (@60Hz). Please contact Hanbell technicians for other specification
configuration requirements.
2. Bearings used by RT series compressor require stable supply of lubricant.
3. Before / after compressor start-up, the start-up and shut down of oil pump must be
advanced and delayed by 3 seconds to provide sufficient lubrication.
4. Excessive lubricating oil will lead to rapid rise of bearing temperature while insufficient oil
will lead to lack of cooling and lubrication, thus the oil pump flow rate should not be
arbitrarily adjusted.
Warning：Only authorized and certified technicians are allowed to modify the oil pump setting.
Warning：Oil pump flow rate decreases as outlet pressure decreases (non-linear). Thus, do not
adjust the pump outlet pressure to deactivate the oil filter alarm (filter pressure-drop will
be smaller as oil pump outlet pressure becomes smaller) as the reduction in oil flow rate
will lead to inadequate lubrication of bearings and gears and will result in burning.
4.3 Oil cooler

The system must be equipped with external oil cooler. As built-in oil pump is used in all
models and the oil flow rate is fixed at 20~25L/min., the oil cooler should be the same for all
models (excessive oil discharged will be bypassed back into the oil tank through an internal valve).
Taking highest oil tank temperature as the temperature of oil entering the oil cooler, while the
temperature of cooled oil needs to be around 30~40°C and it is recommended to use refrigerant for
the cooling so that no further maintenance is required, then:
Q = m& C p ∆Tρ r ,
Specific gravity=Please refer to section 4.6.1
Specific heat capacity=0.45 kcal/kg°C
Oil temperature settings for the oil cooler

After the oil in the oil tank is compressed by the built-in oil pump, it enters into the oil cooler
and cooled down to a temperature between 30 and 45°C. Filtered by a high-density oil filter, the oil
lubricates the bearings and gear in the form of oil-jet, and finally returns to the lower pressure oil
tank. The cooling medium can either be the liquid refrigerant from the condenser or the liquid
refrigerant from the outlet motor cooling. A temperature sensor must be installed at the oil cooler
outlet to control the refrigerant flow and to maintain oil temperature of the oil cooler (Tco) between
30 ~ 40 ℃. The gaseous refrigerant in the heat exchanger can be directed back to the economizer
for reuse.
℃ or Tco< 25℃
Tco>45℃ ℃ alarm
℃ or Tco< 20℃
Tco>50℃ ℃ shut down
Note：Refer to Hanbell selection software for heat load of the oil cooler.
58
4.4 External oil filter
The external oil filter is a must in the oil circuit. It should be installed in the oil line after
the oil cooler. The function of external oil filters is to filter out debris so it does not act as
abrasive when oil re-circulates. The filter shell should be able to withstand oil pressure as
high as 12 to 15 bars.
Hanbell external oil filter must be used. Its filtering material could be cellulose (paper)
or synthetic fiber (15~25μm). Paper can withstand flow of high-pressured oil without
being torn apart. The material has to be able to block small debris without restricting oil
flow too much. Cellulose (paper) as filter material is economical and works fine. Cellulose
as the filter may block particles while allowing oil to pass through. There is synthetic fiber
for high-end filters that has smaller passages to block smaller particles but still make fluid
pass it through. There is also a kind of material that is a blend of these two materials.
HANBELL provides oil filter with spec. below:

Working pressure：15bar
Working temperature：-20~100℃
Filter accuracy：15~20μm
Rated flow：100L/min
Note：The centrifugal compressor is of delicate type. It is a must to use above materials for
filtering.
Caution：If the filter material is a non-precision graded metal, the particles may get into
the compressor and cause serious damage to the bearings.
Caution：In addition to the pressure difference judging as a protection system program,
mechanical differential pressure switch can also be added as protection.
59
4.5 Oil & refrigerant circuits
In the compressor, oil is sealed and separa ted from the discharge volute and
the motor by labyrinth ring assembly. A labyrinth ring is a non-contact ring so some amount of
gas may still leak to the low-pressured oil tank. Two oil heaters are equipped in the bottom of
the oil tank for heating to separate liquid refrigerant from oil. Thereafter, gas reaches the
internal oil separator for the second oil separation. Purified gas then returns to the suction
casing through the refrigerant return pipe.
The other possible oil leak is in lubricant circuits. When the compressor starts, oil for
lubrication of front & back bearings around the motor shaft might lead to the motor casing
because medium pressure in the motor has not been built up completely. Leaked oil will
accumulate in the evaporator. In general, an ejector is applied to recirculation of leaked oil.
Power of ejection comes from high pressure in the condenser or middle pressure in the
economizer. Gas with oil will be separated firstly by internal oil separator in the oil tank, and
gas will re-circulate stably without fluctuation of oil level. For better evaporation of liquid
refrigerant in the oil tank, oil heaters in the bottom of the oil tank are used for heating.
Figure 4.3 Schematic diagrams of oil & refrigerant circuits
Some amount of oil might mix with suction gas and would flow to the compressor from
the evaporator. After the inlet nozzle, there is a mechanism which can bring oil to the
bottom of suction casing for oil separation. An ejector should be applied to oil recirculation
from the suction casing to the oil tank as shown in Figure 4.3. Power of ejection comes
from high pressure in the condenser or middle pressure in the economizer.
Note：RT series compressors are equipped with ball and radial bearings. Therefore, the
amount of lubricant need is much lesser. This design minimizes possibility of oil
leakage to the system.
60
4.5.1 Oil temperature control in the oil tank

Oil temperature should be kept above ET+20°C by oil heater to avoid the liquid refrigerant
remains in the oil tank. If the concentration of refrigeration dissolved in the lubricant is too high,
then it will reduce the viscosity and effectiveness of the lubricating oil and the bearings will be more
easily damaged. Therefore, the heater must be used to evaporate the liquid refrigerant and
recirculate back into the system. By using temperature sensor, the oil temperature inside the tank
can be controlled and when the oil temperature is lower than ET+20°C, the heaters should be
turned on to evaporate the liquid refrigerant; when the oil temperature is higher than 45°C, the
heater is turned off. In general, when the compressor is running, the heat generated by the rotating
parts can help maintaining the oil temperature.
T3＜ET+20°C turn on oil heater Compressor running is strictly prohibited

T3＞45°C turn off oil heater
T3＞CT+10°C warning
T3＞CT+15°C shut down
Note：
1. ET is the evaporation temperature of the system during operation and shut down. Saturated
temperature can be obtained by using the evaporator pressure.
2. CT is the condensation temperature of the system during operation. Saturated temperature can
be obtained by using the condenser pressure.
3. The oil heater must be controlled independently and needs to be turned on during temporary
shut down or 24 hours before restart. Oil temperature control stated above is still required during
operation.
Warning：Do not start the machine when the oil temperature is lower than ET + 20 ℃！
Warning：Excessively high oil temperature indicates insufficient oil for compressor circulation or
heat imbalance. Continuous running will cause damage to the machine.
Oil heater specifications
Two UL approved 500W oil heaters have been equipped in the oil tank as standard
accessories. Specifications：500W/ 220V; IP 54; UL approved
Note1: The oil temperature inside the oil tank could be kept in normal range because heat
is transferred to oil from bearings and gear during running. But if large amount of
oil is returned from the evaporator or ambient temperature is low, oil temperature
might be insufficient. Hence, oil heaters should be used to make sure the oil from
oil pump is free of liquid refrigerant and temperature in oil tank is in safe range.
Warning：If lubricant mixes with liquid refrigerant, bearings and gears cannot be lubricated
effectively. This will result in damage to the compressor.
Note2: There are oil separators installed for effective oil separation at oil return and
refrigerant return ports in RT series compressors. Please refer to item 13&14 in
Figure 4.4. Besides, gears are installed in the gear casing to efficiently minimize
fluctuation of oil level due to high-speed rotation. Furthermore, the gear casing
also reduces oil to mix with refrigerant flow so oil flow from the compressor to the
system could be minimized.
61
Figure4.4 Oil separator
Refrigerant heater specifications

specification
Two UL approved 300W oil heaters have been installed in the compressor casing.
Before restart of the compressor after shutdown for a long time, please turn on refrigerant
heaters at least 24 hours to make temperature inside the compressor higher than system
syste
temperature and ambient temperature.
temperature Therefore, it can prevent condensation of
refrigerant inside the compression
compress chamber.
Figure 4.5 Refrigerant heater
Specifications： 300W; 110V or 220V; IP 54; UL approved
Note: If ambient temperature is low, it is recommended to turn on refrigerant heaters

during stop of compressors.
62
Oil pressure in the oil tank

Pressure in the oil tank must be kept as low as possible for oil return to the oil tank finally.
A pipe is connected between the oil tank and the suction casing (item 15 in Figure 4.4).
Therefore, in normal condition the pressure difference between oil tank and suction side
is-0.2~0.5bar.
Note：1. If oil pressure is abnormal inside the oil tank, the possible cause might be that the
labyrinth ring for separating high/ low pressure is damaged and a large amount
of refrigerant leak as shown in Figure 4.6.
2. When the oil tank pressure (P3) is 0.6 kg/cm² higher than the suction pressure
(Ps), system should provide an alarm signal
to users. When the oil tank pressure is 0.8
kg/cm² higher than the suction pressure,
system should be stopped for protection
and troubleshooting.
P3-Ps ≧ 0.6kgf/cm2alarm
2
P3-Ps ≧0.8kgf/cm shut down
Figure 4.6 Labyrinth ring
RT series compressors are equipped with rigid bearings and fine oil separators.
Therefore, oil carry-over in the system is much less. For oil return from the evaporator,
orifice size of the oil return outlet of the evaporator should be confined. Suggested orifice
sizes are shown as the table as below. Too much liquid refrigerant will cause poor
lubrication for bearings resulting in serious damage to the compressor.
Model Size of orifice

RT-120~140
φ2
RT-111
RT-160~200
φ3
RT-221, 161
RT-240~280 φ4
Unit: mm
63
4.6 Lubricants
The main functions of lubricant in the centrifugal compressor are lubrication and cooling.
Bearings used in RT series compressors require a small but steady volume of oil for
lubrication. Please pay more attention to oil temperature which is crucial to compressor
bearing life. High oil temperature will reduce oil viscosity and result in poor lubrication and
heat dissipation in the compressor as well. It is recommended to keep oil temperature
between 30~40℃.
4.6.1 Lubricant table

Type HBR-B12 HBR-B05 Unit
Specific gravity 0.944 0.955 g/ml
@40℃ 32 68 mm2/sec
Viscosity (cst)
@100℃ 5.3 8.5
Flash point 215 255 ℃

Pour point -48 -39 ℃
Acid number 0.01 0.01 mg KOH/g
Water content <50 <50 ppm
Table 4.2 Specifications of lubricants
Note: 1. Use of lubricant other than the specified lubricant will result in HANBELL’s non-warranty.
2. Standard lubricant model is HBR-B12. If the operating condition of evaporation
temperature is > 14 degrees, then the concentration of refrigerant inside the lubricant will
be higher resulting in lower oil viscosity. Therefore, please use HBR-B05 oil instead.
4.6.2 Precautions in changing of oil
1. Use HANBELL approved oil and does not mix different brands of oil together. Choices
of oil should match characteristics of refrigerant. Some types of synthetic oil are
incompatible with mineral oil. Oil in the compressor should be totally cleaned up in the
system before charging different brands of oil. Charge the compressor with oil for the
first start to ensure that there is no mix at all.
2. When using polyester oil for chiller systems, please make sure that oil does not expose
to the atmosphere for prevention of change in its quality. Therefore, it is necessary to
vacuum the system completely when installing the compressor.
3. In order to secure no moisture in the system, it is suggested to clean the system by
charging it with dry Nitrogen and then vacuum it repeatedly as long as possible.
Note: When vacuuming the system, please notice that into consideration “When pressure
is low, moisture will be condensed sore charge of some dry Nitrogen is necessary.
64
4. If the motor has burned out, acid debris may still remain inside the system and the oil
becomes acid which will deteriorate the insulation of the motor. Therefore, it is a must to
change oil and clean the system when changing the motor. Please follow the
procedures mentioned above to change oil in the system. Check acidity of oil after 72
hours of operation and then change it again until acidity of oil becomes normal.
5. Please contact Hanbell local distributors/agents for choices of oil.
Hi
gh Mid
Figure 4.6Oil sight glass (Oil level)
Note: Users can refer to Figure 4.4 for charging of oil. After opening the oil separator flange,
oil can be charged at the port, item16; or oil could be charged by vacuuming the
angle valve, item13.
Warning ：When the compressor is running, please check white floating ball inside as oil
level indicator and it’s recommended to maintain oil level between High and Middle; if the
level is higher than High, oil must be drained to keep the level below the bottom of gears; if
the level is between Middle and Low, oil return must be done or oil charge must be
replenished; else if the level is lower than Low, the compressor must be stopped
emergently to prevent dry wear of oil pump and bearing failure.
65
4.6.3 Oil change
Check oil periodically lubricant every 10,000-hour running. For the first operation of the
compressor, it is recommended to change oil and the external oil filter after 2,000 -hour
running. Check the system whether clean or not and then change oil every 20,000 hour or
after 3-year continuous running under good condition.
Item Maintenance(hr) Note
2,000hrs After the first operation

Change oil and external filter
Check oil 10,000hrs After continuous running
20,000 hrs
Change oil or After continuous running
3 years
Table 4.2 Maintenance for oil change
In order to avoid debris in the oil filter which may lead to bearing failure, the oil pressure
differential switch is recommended to be installed. The switch will sense when oil pressure
differentials between the primary and secondary sides exceeds the critical point. Then the
compressor will be shut down automatically to prevent bearings from damage due to oil
loss
Note1: Pressure gauges should be installed separately at P1 (the outlet of the oil pump)
and P2 (the outlet of the oil filter). An oil pressure differential switch should be
installed on piping in between for prevention of oil loss. (Please refer to the Figure
4.1 Schematic diagram of oil piping)
Note2: It is recommended replacing the external oil filter core after test of the chiller in the
factory. Otherwise, debris might clog up the external oil filter.
Note3: It is not necessary to fill additional oil when compressor working in chiller normally.
Unless there is oil carry-over or oil pumps maintenance. To fill the refrigeration oil,
the oil pump should be connected to the service valve beneath compressor oil tank.
(The amount of the oil should be ensured before restart the chiller.
Note4: Using refrigeration oil incorrectly, including using non-dedicated HANBELL oil, over
filling, inferior quality filter, improper mesh specification and improper operation
might damage the compressor. Only trained technicians are allowed to finish the
maintenance work. Any proper service requirement, please contact HANBELL
technicians.
66
Chapter 5. Motor
5.1 Motor cooling

The motor in RT series compressor is cooled by liquid refrigerant that comes from the
condenser. Solenoid valves, expansion valves, or orifices should be installed on piping
before the suction flange as a throttle for inflow control. In order to keep the motor
temperature between30~90℃, it is estimated that heat exchange is equal to around 6~10%
of motor power input for motor cooling.
Figure 5.1Motor cooling system
2 aux injection
Main injection inlets
inlet
Aux injection
outlet Main injection outlet
Figure 5.2 Two aux inlets for cooling
Note1: Two auxiliary injection inlets on the motor casing are the main source of motor coil
cooling; please make sure both of them are connected.
Note2：Change of the two auxiliary liquid injection connectors is prohibited.
67
Liquid returned from motor:

In heat pump, VFD application, or low compression ratio system, the liquid refrigerant might
accumulate inside the motor casing. This is because in low compression ratio condition, the
pressure difference between Economizer (PECO) and motor casing (Pmotor) is not enough to
cover the pressure drops in the piping line and the liquid refrigerant could accumulate in
motor casing. Auxiliary injection outlet should be connected to the evaporator to prevent
possible liquid flooding.
It is a must to install the auxiliary injection outlet in the working conditions below and use
angle valve to control the flow rate to the evaporator.
1.Low compression ratio: Working condition is CT-ET<15℃

2.VFD system：Operational frequency is lower than 60%~80%of rated frequency
3. Heat pump system
Single-stage compression system (Without Economizer):
In single-stage compression system, the outlet of motor injection port is connected with
evaporator. The pressure in motor casing is similar to evaporating pressure and this will
cause condensation on the surface and deteriorate the insulation of main power terminals.
In addition, when the motor casing pressure is lower than bearing housing pressure, the
lubricant will flow into the motor casing and then enter the evaporator. Therefore, it is a
must to install MPV (Minimum Pressure Valve) in the main motor injection outlet pipes and
make sure to keep the standard below:
1kgf/cm2≦Motor Pressure(Pmotor)–Evaporating pressure(Ps)≦ 1.5kgf/cm2。
Temp. Sensors Pt100 or Pt1000 – for motor coil temp. monitoring
There are 4sets of Pt100 or Pt1000 temperature sensors mounted in the motor coil.
Adjust flow of liquid injection to motor by temperature feedback of these sensors. Choose
the highest temperature among these four sensors for controlling the motor coil
temperature between30~90℃.
Note: When temperature in any set of Pt100 or Pt1000 temp sensor reaches 90℃, the
controller should raise the alarm. When the temperature reaches 95℃, the
compressor should stop until the cause of high temperature has been eliminated.
℃alarm
Tmo> 90℃
℃
Tmo> 95℃ shut down
Warning：Motor temperature after cooling should be higher than ambient temperature to

prevent condensing water which might cause insulation failure of wiring
terminals.
Protector connect method: 1 & 2 are PTC protector contact, A & B are concurrent, O1 is
contact for 2 pairs of Pt100, C& D are concurrent, O2 is contact for the other 2 pairs of
Pt100.
68
Figure 5.3 Protection terminal plates.
Specifications: Pt100 sensor

 Recommended max. meas. Current for heat coefficient <0.1K – DC1 ~ 3 mA
 Heating coefficient - 10mΩ/K
 Sensor resistance at 0℃ - 100Ω±0.12Ω
 Change of resistance 0 ~ 100℃ - 0.385Ω/K
 Insulation test voltage U is – AC 1.5kV
Figure 5.4Pt100 sensor
Specifications: Pt1000 sensor

 Recommended max. meas. Current for heat coefficient < 0.1K –DC0.2 ~ 2mA
 Sensor resistance at 0℃ - 1000Ω±1.20Ω
 Change of resistance 0 ~ 100℃ - 3.85Ω/K
 Insulation test voltage U is – AC 1.5kV
Figure 5.5 Pt1000 sensor
1. Please specify Pt100 or Pt1000 sensors when placing orders to Hanbell. In

addition, all models can be equipped with Pt100 or Pt1000 sensors to precisely
measure motor coil temperatures for control of motor cooling.
69
2. If the compressor is for high voltage or VFD application, the shielded wire need to
be used in signal wire to avoid signal interferences.
5.2 Motor protector

In order to protect the compressors, the RT series compressors have been equipped with three
PTC temperature sensors on the motor coil. The temperature sensors can be connected to the
INT69HBY temperature control module to monitor the temperature change of the motor coil. When
the coil temperature exceeds the set temperature causes PTC thermostat resistance increase and
leads the INT69HBY temperature control to module trip in order to achieve protection. For the first
trip, the protector will recover in five minutes, for the second trip, the protector will recover in sixty
minutes. Force lock will take place if three trips occur and reset after 24 hours.
Technical data of INT69HBY

INT69HBY motor protector monitors phase loss, phase sequence, motor temperatures, and
discharge temperatures with manual reset.
● Supply voltage
AC 50/60 Hz 115/120V-15.....+10% 3VA
AC 50/60 Hz 230/240V-15.....+10% 3VA
● Relay output
Max. AC 240V, Max. 2.5A, C300
min. ＞ 24V AC/DC, >20 mA
● Ambient temperatures
-30 ~ +70 ℃
● Phase sensor
3 AC, 50/60Hz, 200 ~ 575 V±10%
Error Blink C odes

P TC Tem perature Error
Tim er delay active (PTC < R reset)
Auto reset for INT69HBY

,but not for M -PI-S28
1st: 5m in tim e delay after PTC < R reset
2nd: 60m in tim e delay after PTC < R reset
3rd: Lockout after three consecutive PTC
tem p errors within 24hrs
P hase sequence
P hase failure
Internal error
S hort Long
interruption interruption
Figure 5.6Blink code of INT69HBY
70
Figure 5.7 INT69HBY & PTC thermostats connection diagram
Phase loss and phase sequence

1. The phase monitoring of phase loss & phase sequence works after the motor starts 1
second (power on L1-L2-L3), and lasts 10 seconds (t0 + 1sec to t0 + 11sec)
2. If one of these parameters is incorrect, the relay locks out (M1-M2 is open).
3. The lockout can be cancelled by main reset of approx. 5 seconds (disconnect L-N)
Note: In order to make sure phase loss and phase sequence protection function well,
please connect L1, L2, and L3 to the motor side as Figure5.6 shown.
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Motor temperature
The motor temperature is constantly measured by thermostat (PTC) loop connected on
S1-S2. If detected temperature exceeds setting its resistance will increase above the trip
point then the output relay trips (M1-M2 is open). After cooling down below the response
temperature, 5-minute delay is activated. After delay has elapsed, the relay pulls in again
(M1-M2 is closed).The time delay can be cancelled by main reset of approx. 5 seconds
(disconnect L-N).
Other major functional descriptions are as below:

1. After the supply voltage has been connected, a three second initialization period follows.
Provide the PTC chain resistance is below the reset threshold (2.75kΩ), the relay trips
after these 3 seconds have expired.
2. 1 to 9 PTC thermostats with different nominal response temperature may be connected
serially to the PTC input.
3. If any thermostat resistance increases above trip level the relay drops out. This failure
results in a lockout. (5 minutes delay for 1st PTC failure, 60 minutes delay for 2nd failure,
lockout for 3rd failure.)
4. If a rapid temperature increase is detected (locked rotor condition), the output relay
drops out. This failure results in a lockout.
5. The phase monitoring of the three phase motor voltage becomes active 1 second after
motor has started, for duration of 10 seconds. In case of a wrong phase sequence or a
phase failure, the relay switches of and locks.
6. The Lock-out and delay time may be lifted by cycling the power off for approx. 5
seconds.
7. To avoid nuisance tripping due to reverse running after shutdown (pressure
equalization), the phase monitoring function is only re-enabled approx. 20 seconds after
motor stop.
8. A dual LED (red / green) provides additional information about the motor protector and
compressor status.
9. The relay is fed out as an N/O dry contact, which is closed under good conditions.
10. Sensor and supply circuits are galvanic isolated.
11. The motor protector is not suitable for application of frequency converters.
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5.3 Electrical data and design

：Y-Δ
5.3.1 Motor design： ΔStarting
The Y-Δmotor connects the motor coil by Y connection during starting therefore
reducing voltage on coils to 1/√3 of input voltage and reconnects the motor coil by Δ
connection after starting. In doing so, starting current can be thoroughly decreased. It is
called voltage-drop starting.
The Y-Δ motor connection method is shown in the following motor wiring diagram: In Y
connection, MCM, MCS are inductive while the motor leads Z, X, Y are tied together as
neutral connecting as letter Y. After timer set period (till peak value decreases), MCM,
MCS become deductive. Around 0.25 sec later, MCM, MCD are inductive, they turn out Δ
connection.
I (AMP)
Starting
Current
Full load Amper
Time
Y- shift time 0.25~0.5sec
Figure 5.8Y-Δ starting diagram
Attention : After Y start, MCM & MCS are deductive for 0.25sec and then MCM & MCD
are inductive forΔ run. Within transient 0.25sec, a pseudo short circuit might occur due to
inappropriate action of contactors then causing compressor trip. When it occurs, we
recommend you use adjustable Y-Δ timer to lengthen the time span for MCM, MCS
deduction - MCM, MCD re-induct from 0.25sec to 0.5sec directly in the micro controller or
the PLC program. Please refer to Y-Δshift time diagram for details. Because the motor is
not powered during Y-Δ shift. A shorter Y-Δshift span is suggested to prevent the second
start due to decreasing rotation speed. However, if the Y-Δshift span is too short, the
aforementioned pseudo short circuit might occur.
5.3.2 Characteristics of Starting

●Y-Δ
1. Starting current in Y connection is 1/3 of lock rotor ampere.
2. Starting torque in Y connection is 1/3 of lock rotor torque.
3. Acceleration of the motor rotor becomes smaller at full-load starting. Therefore
compressors require starting at partial load (=Actuator 0％).
● Soft-start features
1. Starting current is 3 times higher of rated current ampere.
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2. Soft-starter could set up the starting time, longer the starting time, less the ampere it has.
For more details, please refer to technical documents of each manufacturer.
●Direct start
1. When the high voltage motor adopts full voltage starting, the starting current is about 6~7
times of the motor rated current.
●Step-down start
1. High voltage motor could operate with high voltage step-down transformer. Any technical
advice, please contact Hanbell.
：Direct on line start/soft start/inverter start

5.3.3 Motor design：
RT series compressors with high voltage motors can start by direct start as below
shown.
Figure 5.9 Wiring for high voltage
RT series compressors with low voltage motors can start by Y-Δ start, soft start and
inverter start as below shown.
Figure 5.10 Wiring for low voltage
Note: In case of soft start and inverter start, bridges must be installed for wring of the same
phase to prevent current imbalance.
74
High Low
voltage Motor voltage Motor
cable entry
cable entry
Figure5.11Cable inline location diagram
Warning ：High voltage wiring entry should not take the entry of low voltage cable wiring.
When taking the low voltage cable entry, the magnetic induction produced
among phases will cause heat to the wiring box. Both entrances are applicable
for low voltage wiring.
75
5.3.4 MCC & LRA

Low voltage(Y-△)
50Hz 60Hz
Modle Power Voltage Rated MCC LRA Power Voltage Rated MCC LRA
Motor Motor
( kW) (V) current(A) (A) (A) ( kW) (V) current(A) (A) (A)
380 543 760 3,320 380 540 757 3,450
310
A 310 400 511 716 2,870 575 356 499 2,090
415 493 690 3,005 A 440 467 654 2,785
RT-120(E,T) 312 460 448 627 2,945
RT-130(E,T) 480 429 601 2,615
RT-140(E,T) 380 626 876 3,780 380 625 876 4,195
360
RT-111 B 360 400 597 836 3,330 575 413 578 2,445
415 576 807 3,510 B 440 557 780 3,555
372 460 535 749 3,760
480 510 714 2,935
380 720 936 4,680 380 721 938 4,665
A 410 400 687 894 4,130 575 479 623 3,165
415 667 868 4,355 A 410 440 621 808 3,925
460 600 780 4,185
480 564 734 3,560
RT-160(E,T)
380 903 1,174 5,940 380 907 1,180 6,005
520
B 520 400 861 1,119 4,825 575 596 775 3,915
415 830 1,080 5,085 B 440 856 1,113 5,355
570 460 823 1,070 5,680
480 785 1,021 4,795
380 1,078 1,401 6,665 380 1,079 1,403 7,290
620
A 620 400 1,030 1,339 5,710 575 717 933 4,375
RT-240(E)
415 998 1,298 6,035 A 440 934 1,214 5,805
RT-221
624 460 895 1,163 6,160
480 860 1,118 4,930
50Hz 60Hz
Motor Motor
380 829 1,078 5,485 380 828 1,077 5,465
475
A 475 400 787 1,023 4,685 575 550 715 3,505
415 760 988 4,920 A 440 742 965 4,565
492 460 714 929 4,835
RT-180(E,T) 480 686 893 4,225
RT-161 380 1,078 1,401 6,665 380 1,079 1,403 7,290
624
B 620 400 1,030 1,339 5,710 575 717 933 4,375
415 998 1,298 6,035 B 440 934 1,214 5,805
624 460 895 1,163 6,160
480 860 1,118 4,930
380 903 1,174 5,940 380 907 1,180 6,005
520
A 520 400 861 1,119 4,825 575 596 775 3,915
415 830 1,080 5,085 A 440 856 1,113 5,355
570 460 823 1,070 5,680
480 785 1,021 4,795
RT-200(E,T)
380 1,255 1,632 6,985 380 1,251 1,626 7,960
720
B 720 400 1,189 1,546 6,845 575 826 1,074 4,610
415 1,151 1,496 7,185 B 440 1,112 1,446 6,455
744 460 1,069 1,390 6,850
480 1,029 1,337 5,805
380 1,255 1,632 6,985 380 1,251 1,626 7,960
720
A 720 400 1,189 1,546 6,845 575 826 1,074 4,610
RT-260(E)
415 1,151 1,496 7,185 A 440 1,112 1,446 6,455
RT-280(E)
744 460 1,069 1,390 6,850
480 1,029 1,337 5,805
Table 5.1 MCC&LRA of low voltage models
Note：Cooler standard equipment Motor A, able to operate the maximum load condition is about
CT / ET = 40/13 ℃, the heating machine operating condition is about CT / ET = 52/14 ℃,
a slightly different from the actual horsepower during the motor design. The actual
76
maximum continuous operation current (MCC) should be in accordance with the above
table. When the actual operating conditions of the unit exceeds the MCC value, please
use Motor B and state for Motor B on the purchasing order instead.
Caution1.This table stated rated current and LRA for Motor design performance are not referring to
the compressor operating rated current.
Caution2.The value of MCC in this table is related to the maximum temperature rise (90 ° C) of the
Motor and is irrelevant to motor power (size). Therefore, a voltage drop in the power
supply will cause motor temperature rise (refer to 4 Motor Coil Temperature Sensor
Pt100 or Pt100 Description).
High Voltage (Direct)

50Hz 60Hz
Motor Motor
6kV 38 45 215 3.3kV 69 83 443
A 330
10kV 23 27 154 4.16kV 54 65 381
A 330
6.6kV 34 41 231
11kV 20 24 140
RT-120(E,T)
6kV 50 60 322 3.3kV 91 109 636
B 440
10kV 30 36 217 4.16kV 71 86 485
B 440
6.6kV 45 54 303
11kV 27 32 199
6kV 41 49 254 3.3kV 75 90 526
A 360
10kV 25 30 177 4.16kV 59 71 446
A 360
RT-130(E,T) 6.6kV 37 45 256
11kV 22 27 160
RT-140(E,T)
6kV 50 60 322 3.3kV 91 109 636
RT-111 B 440
10kV 30 36 217 4.16kV 71 86 485
B 440
6.6kV 45 54 303
11kV 27 32 199
6kV 50 60 322 3.3kV 91 109 636
A 440
10kV 30 36 217 4.16kV 71 86 485
A 440
6.6kV 45 54 303
11kV 27 32 199
RT-160(E,T)
6kV 58 70 362 3.3kV 107 128 722
B 520
10kV 35 42 249 4.16kV 84 101 595
B 520
6.6kV 53 63 341
11kV 31 38 228
6kV 58 70 362 3.3kV 107 128 722
A 520
10kV 35 42 249 4.16kV 84 101 595
A 520
6.6kV 53 63 341
RT-180(E,T) 11kV 31 38 228
RT-161 6kV 69 83 417 3.3kV 126 152 812
B 620
10kV 41 50 256 4.16kV 100 120 650
B 620
6.6kV 63 75 394
11kV 37 45 233
6kV 63 76 430 3.3kV 115 138 418
A 560
10kV 38 46 263 4.16kV 91 109 628
A 560
6.6kV 57 68 365
11kV 34 41 240
RT-200(E,T)
6kV 80 97 473 3.3kV 146 175 924
B 720
10kV 48 58 296 4.16kV 116 139 764
B 720
6.6kV 73 87 470
11kV 43 52 273
77
50Hz 60Hz
Motor Motor
6kV 73 88 440 3.3kV 136 163 917
A 660
10kV 44 53 253 4.16kV 106 127 675
A 660
6.6kV 67 81 445
11kV 40 48 230
RT-240(E)
6kV 92 110 668 3.3kV 168 202 1,235
B 820
10kV 54 65 342 4.16kV 132 158 952
B 820
6.6kV 83 99 591
11kV 49 59 314
6kV 80 97 473 3.3kV 146 175 924
A 720
10kV 48 58 296 4.16kV 116 139 764
A 720
6.6kV 73 87 470
RT-260(E) 11kV 43 52 273
RT-280(E) 6kV 100 121 681 3.3kV 182 218 1,269
B 900
10kV 60 72 369 4.16kV 145 174 1,016
B 900
6.6kV 91 109 629
11kV 54 65 338
6kV 80 97 473 3.3kV 146 175 924
A 720
10kV 48 58 296 4.16kV 116 139 764
A 720
6.6kV 73 87 470
11kV 43 52 273
RT-221
6kV 92 110 668 3.3kV 168 202 1,235
B 820
10kV 54 65 342 4.16kV 132 158 952
B 820
6.6kV 83 99 591
11kV 49 59 314
6kV 107 129 748 3.3kV 194 233 1,348
A 960
10kV 63 76 407 4.16kV 154 184 1,096
A 960
6.6kV 97 116 692
11kV 57 69 373
RT-301
6kV 123 147 802 3.3kV 222 267 1,547
B 1,100
10kV 74 89 502 4.16kV 176 212 1,178
B 1,100
6.6kV 111 133 743
11kV 66 79 456
Table 5.2 MCC&LRA of low voltage models
Note：Cooler standard equipment Motor A, able to operate the maximum load condition is about CT / ET
= 40/13 ℃, the heating machine operating condition is about CT / ET = 52/14 ℃, a slightly different
from the actual horsepower during the motor design. The actual maximum continuous operation
current (MCC) should be in accordance with the above table. When the actual operating conditions
of the unit exceeds the MCC value, please use Motor B and state for Motor B on the purchasing
order instead.
Caution：1. This table stated rated current and LRA for Motor design performance are not referring to the
compressor operating rated current.
Caution：2. The value of MCC in this table is related to the maximum temperature rise (90 °C) of the Motor
and is irrelevant to motor power (size). Therefore, a voltage drop in the power supply will cause
motor temperature rise (refer to Motor Coil Temperature Sensor Pt100 or Pt100 Description).
5.3.5 Grounding
Grounding point in electric system normally is a neutral point. Exposed compressor
conductor should not be electrified in normal use. But there is possibility that the
compressor is electrified under malfunction condition. For security purpose, HANBELL
strongly recommends to ensure the grounding during installation.
Suggestion:
a. Dedicated M12 grounding screw (instructed in terminal box) should be reliably
connected with grounding wire.
78
b. Metal sheath of power cable, palpable threading pipe, cable metal trucking, and
cable trays should be grounded.
c. Metal sheath of armored control cable, non-armored or non-metallic sheathed cable
should be grounded.
d. Power cable grounding wire should use copper wire or tinned copper braided wire,
and the cross-sectional area should follow below table:
Power cable (mm2) Grounding wire(mm2)
120 and lower 16
150 and higher 25
Note：Resistance of grounding should not be higher than 8Ω.
5.3.6 Insulation for high voltage main terminals

5.3.6.1 Method 1:
After checking the phase sequence and the rotation direction of the motor, insulation
work must be done on main terminals for voltage higher than 6000V.
MATERIALS:
1. LOCKTITE Cleaning liquid
2. 3MSCOTCHFIL gray electrical insulation materials
3. 3MSCOTCHKOTE paints
4. Plastic insulation tapes
HANBELL will not provide the materials above because all of them can be sourced
locally.
Steps：
1. Shut down the power of the compressor.
2. Clean the dust, water, and oil on terminals by cleaning liquid.
3. Apply 3MSCOTCHFIL gray electrical insulation materials on the joint parts to make it
smooth.
4. Apply 3MSCOTCHKOTE paints on the ceramic parts of power bolts up to 1/2”position.
Apply 3MSCOTCHKOTE on the power bolts where gray electrical insulation materials had
been applied and the on cable for 10”long from power bolts. Then, apply SCOTCHFIL gray
electrical insulation materials on the surface again.
5. Use plastic insulation tapes to stick the whole painting layers.
6. Use 3MSCOTCHKOTE paints again for moisture prevention
5.3.6.2 Method2:
Use Hanbell RITA- CBTM 2050 Heat shrinkable tube and insulate the wiring terminals
with for voltage higher than 6000V.
Materials：
1. High voltage insulation tapes
2. RITA- CBTM 2050 Heat shrinkable tube
3. Heating by blowlamp
Steps:
1. Put heat shrinkable tube into high voltage cable and tighten R type clip based on
regulation.
2. Move pre-inserted heat shrinkable tube to proper position (The heat shrinkable tube
should cover more than 30mm of white ceramic part of the terminal, and the cable and
terminal joint part is not allowed to be exposed.)
3. Use blowlamp to heat up heat shrinkable tube to make the surface becomes tight.
(Heating temperature is above 110°C) 。
79
4. Use high voltage insulation tapes to wrap both side of heat shrinkable tube to prevent
it from moisture (As figure 35 below) 。
Insulation Tape Sealing

Place
Figure 5.11Heat-Shrink Tube Diagrammatic Sketch for Covering
5.3.7Protective measures of electric shock

To prevent electric shock accident, compressor operating under electrified condition or
electrified while shutting down, please follow the protective measure:
1. Around electrified part should place mark of awareness like “HIGH-VOLTAGE,
DANGER”.
2. Using railing and partition to prevent unconscious personnel get close to electrified
area. Barriers do not required to be locked, but need to be set and cannot be
moved unconsciously.
3. Establishing protective fence surrounding the compressors and the units with 1.5m
safe distance to prevent direct contact of electrified device.
Suggestion:
1. Regular setting of leakage protection should higher than 50mA, in humid region,
25mA will be more proper.
2. Terminal connecting voltage should not larger than 50V, in humid region: 25V.
3. Grounding resistance should not larger than 500Ohm.
4. Air cut board (ACB) normally placed with leakage breaker; please refer to relative
operating setting.
5. Once leakage breaker launched, please check if the insulation of every device and
wiring setting are correct, Please launch the system after check. Please contact
device supplier of there is any problems.
Note:
1. Between motor casing and ground, resistance = 0Ω, potential difference = 0V.
2. Between device casing and ground, resistance = 0Ω, potential difference = 0V.
3. Between drive and device casing, resistance = 0Ω, potential difference = 0V.
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5.4 Compressor Electrical and Safety Practices

5.4.1 Electrical Safety Precautions:
1. Once connected to the compressor, the power supply of the voltage would get
very dangerous. Only qualified electricians and electrical engineers are allowed to
the work installation. It shall be in strict accordance with the manual operation of
the program as well as national regulations and safety codes before installation.
2. Users and installers shall be in accordance with the National Electrical Code as
standard to provide grounding and install a protective circuit.
3. Before performing any maintenance operation, make sure the power switch is
turned off to avoid accidents.
4. Before normal operation of the compressor or unacknowledged power is off, do
not open the compressor terminal box to avoid danger.
5. After confirming the direction of rotation of the motor while the terminal without
insulation protection, make sure to stay away from the compressor and
assembling unit, to avoid the risk of electric shock.
6. When doing compressor maintenance work, inspection or parts replacement, it is
a must to cut off the main power supply to the terminal discharge in order to avoid
the risk of electric shock.
5.4.2 The Inspection and Preparation before Electrical Wiring

5.4.2.1 Inspection of Unpacking
1. All compressors have been passed the strict test by Hanbell. Users are
unauthorized to disassemble to inspection, if necessary, please contact Hanbell
Company.
2. Check the motor terminal box of compressor firstly when unpacking if there is
damage, collision or deformation.
3. After first or a long time running, when compress start-up, it must uses DC2500V
meg - ohmmeter to measure motor terminal box of the main terminal and the chamber
cold insulation resistance test, the insulation value shall not less than the value
determined by the formula as followed.
In the formula: R ― Motor Winding Insulation of Resistance (MΩ)

UN ― Rated Insulation Voltage (V)
PN― Motor Power Rating (KW)
When the motor is damp or the insulation resistance is lower than the calculated values, it
shall take action of drying motor stator, drying temperature must not exceed 120 ℃.
NOTE: Hanbell compressor has been test passed by national standards withstanding
voltage testing. Users and installation contactor are not allowed to do the testing. If
necessary, please contact with Hanbell Company.
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5.4.2.2 Cable Selection:
1. Selection of high-voltage cables shall comply with IEC183 and DL401 "high
voltage cable guide for the selection" standard.
2. Low voltage cable should meet the IECA S-19-81standard, 600V insulated wire,
insulation-Haipa Dragon (Hypalon).
3. All on-site supply of cables and wires, equipment and field wiring, cable wire
terminals and equipment are necessary to comply with various regulations and
engineering requirements for use.
4. Location-site installation wiring and cable wires on-site installation of each device
must be without prejudice to the vicinity of the device readings, adjustor repair any
part of the operation.
5. Any damage to the installation were to incorrect wiring between the starter and the
compressor caused responsible.
5.4.3 Power Wiring Detail:
5.4.3.1 Caution for wiring

a. Verify the nameplate ratings are compatible with the power supply characteristics
and the electrical data on the nameplate. Use copper conductors to connect to
power supply.
b. High voltage cable must fulfill national regular and standard.
c. User and contractor are not allowed to change the shape and dimension of cable
box.
d. The material of armature terminal is brass; therefore armature terminal cannot
stand the weight of high voltage cable. Installer must apply external cable shelve
or tension-ease device to stand the high voltage cable. HANBELL will not provide
wiring terminals.
e. Please choose wiring size of power supply under 1.25 safety margin of maximum
load. Wire diameter, cross-sectional area, and current can refer to table 5.2. And
elastic wire is required to make the maintenance easier and decrease
transmission of vibration.
f. When tightening the cable connector of armature terminal (tighten bolt A&B), use
torque wrench with the torque lower than 700kgf-cm (5/8” & 9/16” copper nut).
Please refer to the figure 5.12.
g. Cable wiring and construction inspection rules must follow GB50168-92.
600V Hypalon cable (*1C)

Area of section Maximum Area of section Maximum
(mm2) permissible (mm2) permissible
current (A) current (A)
50 200 150 410
60 230 200 500
80 280 250 570
100 330 325 670
125 370 400 760
Table 5.2
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Figure 5.12 Connection of power bolts and terminals
5.4.3.2 Making of cable end and the connector

The making of cable end and the connector must be conducted by experienced personnel
and follow working rules.
When making cable end and connector with the voltage higher than 6Kv outside, the
Relative Humidity (RH %) must be around 70%. When relative humidity is high, heathen
ambient temperature or cable.
When making plastic insulation cable end and connector, avoid the dust falling into the
insulation and do not process during the fog or raining days.
Please follow the requirements below:

1. Type and specification must follow the cable type e.g. voltage, core numbers,
protection layers, and environment.
2. The structure must be easy, compact for installation.
3. Materials and parts must meet the technical requirement.
4. Performance must follow current national standard.
The insulation materials should be not only aligned with demands, but also compatible with
cable insulation. Hardness, expansion coefficient, tensile strength, and breaking extension
of these two materials must be similar. Rubber insulation cable must apply high viscosity
and elasticity materials as additional insulation.
When connecting core and amour clamp, must apply standard connecting tube and wiring,
the inner diameter must be compatible with core and the intersecting surface must be
1.2~1.5 bigger than the intersecting surface of core. When press bond, coaxial cable press
pliers and mold must meet the specification requirement.
Working Inspection：
Before making the end of cable and connector, must be familiar with working information
for installation, ensure the inspection procedure, and meet the demands below:
1. Ensure the insulation of cable is in good condition without damping, and no moisture is
allowed inside the plastic cable. Test the electronic performance which must be aligned
with the standard.
2. The specification of accessories must be the same with cable, no injury parts, no
damping of insulation materials, and sealing materials must work. Assemble
83
accessories of casing structure firstly, and the cleaning of inner tube, testing for the
sealing, and dimension of structure must align with the requirement.
3. Working machine must be well prepared, easy to be operated, in clean condition, spare
part are well prepared, and the solvent to clean the plastic insulation on the surface
must follow working rules.
4. Testing the assembling if necessary
Requirement for cable processing:

When making wiring terminal and connector with starting from cutting the cable until
finishing, shortening the insulation exposure lead-time is the must. When cutting the cable,
do not injure core of conductor and preserved insulation layer.
When the fueling cable is inserted with cable, make the connector firstly, and if there are
position difference, make the lower byte connector firstly.
The end of cable and connector must be insulated properly, sealed for damp-proof, and
mechanical protection.
For the cable with the power higher than 6kV, the positive procedure to improve screened
part of cable for central integration is the must and ensures the distance between terminals
insulation and grounding insulation.
Wire terminal lugs

a. Use and size proper crimp type wire terminal lugs in the jobsite.
b. The main power bolt specification is M16. Electricity distribution should be performed by
professional electrician to select the appropriate terminal diameter.
c. Use copper washers on power bolt connections.
d. Tighten each bolt by 300kgf-cm torque force
e. These connections should be under supervision of a qualified electrical engineer in
compliance with NEC or local guidelines
AWG mm2 N AWG mm2 N

30 0.05 6.7 3 26.670 712
28 0.08 8.9 2 33.620 801
26 0.13 13.4 1 42.410 890
24 0.2 22.3 1/0 53.49 1112.5
22 0.324 35.6 2/0 67.43 1235
20 0.519 57.9 3/0 85.01 1557.5
18 0.823 89 4/0 107.2 2002.5
16 1.310 133.5 250 127 2225
14 2.080 222.5 300 156 2447.5
12 3.310 311.5 350 177 2670
10 5.261 356 400 203 2892.5
8 8.367 400.5 500 253 3560
6 13.300 445 600 304 4005
4 21.150 623 700~2000 355~1016 4450
Table 5.2 Pull-out force of crimped connections
Note:
1. Refer to UL-486A for pull-out force standard of crimped connections.
84
2. Ensure power supply wiring and output motor wiring are connected to the proper
terminals. Failure to do so will cause catastrophic failure of the motor.
5.4.4 Limitation of power supply
a. Voltage limitation b. Frequency:

1. Long term running: Low voltage±5%; High voltage±2%1. Rated frequency±2%
2. Instant running: Low voltage±10%; High voltage±4%
3. Unbalanced: Low voltage±3%; High voltage±2%
Power of some areas is unstable. Install an additional voltage protector with mentioned
voltage limitation above to ensure safe operation of the compressor.
1. Unbalanced voltages :
Unbalanced voltages occur because of variations in load. When load on one or more of
the phases are different from the other(s), unbalanced voltages will appear. This can be
due to different impedances, type, and value of load on each phase. Unbalanced voltages
can cause serious problems, particularly for the motor.
National Electrical Manufacture Association (NEMA) defines voltage unbalance as below:
maximum voltage deviation from average voltage

Percentage of unbalanced voltage = 100 ×
average voltage
NEMA states that poly-phase motors shall operate successfully under running
conditions at rated load when unbalanced voltage at the motor terminals does not exceed
1%. Furthermore, operation of a motor under above 5% unbalanced condition is not
recommended. It probably results in motor damage.
Unbalanced voltages at motor terminals cause unbalanced phase current. This causes
excessive heat to shorten motor life. If unbalanced voltage is too high, thereduced torque
capability might not be adequate for the application and the motor will not attain rated
speed and.
Some more common causes of unbalanced voltages are:

●Unbalanced utility supply
●Unequal transformer tap settings
●Transformer failure
●Open delta connected transformer banks
●Large single phase distribution transformer in the system
●Heavy reactive single phase loads such as welding machine
●Open phase on the primary of a 3-phase transformer in the distribution system
●Blowout fuse on the 3-phase bank of power factor improvement capacitors
●Unequal impedance in conductors of power supply wiring
●Unbalanced distribution of single phase load, such as lighting
A 3-phase unbalanced voltage protector is an optional accessory. Please contact Hanbell

for more details.
85
Chapter 6 Compressor lifting and installation

6.1 Compressor lifting
After the compressor arrives at the warehouse, check the crate if it is in good condition
and check all compressor accessories with shipping documents to see if there is any
discrepancy.
Each HANBELL centrifugal compressor has been fully tested at the factory and all
precautionary measures have been taken to make sure the compressor is in perfect
condition during working. When lifting the compressor, it is recommended to use a steel
chain, a steel cables as shown in the Figure 6.1as below, or a safety rope, which have
loading capacity of 5,000kgf.
Figure 6.1 lifting the compressor with a steel chain or a steel cable
Make sure that the steel chain, steel cable, safety rope or other lifting equipment is
properly positioned to avoid damage to the compressor and its accessories. Keep the
compressor in a horizontal position when lifting to avoid crashing on the ground, hitting on
the wall or any situation that may damage it and its accessories.
6.2 Compressor mounting

The position of the compressor in the refrigeration system should be accessible and
makes sure that the chiller base or site is far enough from any heat source to prevent heat
radiation. The compressor should also be installed as closer as possible to the power
supply for easier connection. It is a must to keep good ventilation and low humidity
condition in the site. Make sure that the supporter is strong enough to prevent vibration
and noise while the compressor is operating.
The compressor must be installed horizontally. In order to prevent vibration when

operating, cushions or mounting pads should be installed. The installation of mounting
pads is shown in the Figure 6.2below. The tightening of bolt should still keep certain
deformation tolerance on rubber pad.
※It is strongly recommended the position of the compressor is higher than the evaporator,
and the compressor mounting pad is higher than the economizer refrigerant level (Figure
6.3).
※Please make sure to lock the mounting of the front side and back side, and it is no need
to lock the mount in the middle shown in figure 6.2 below.
86
Figure 6.2 Installation of mounting pads
Figure 6.3 Installation of Economizer
Note1: It is suggested position of compressor should be higher than evaporator, and the
compressor foot base should be higher than economizer liquid level (as figure 6.3) to
prevent pressure loss of liquid return,
Note2: Compressor fixed bolts are required for 2 side of compressor. The middle one is not
necessary.
87
6.3 Compressor protection device

Protection devices as below table are basic configuration (depends on the order). Must
build up protection setting as this security requirement. You shall take their own risk if
changes the setting without our permission.
Compressor device Setting point Note.

Compressor motor protector
Trip temp.:110℃, Return temp.:100℃ Standard
( PTC sensor)
Reverse phase protection
Standard
(protector INT69HBY)
phase failure protection
Standard
(protector INT69HBY)
Oil filter pressure difference
Trip pressure: 1.5kg/cm2 Optional
switch
Motor temp. sensor
Pt10/Pt1000(motor liquid Temp. control 30~90℃ Standard
injection usage)
˙Manual reverse setting(recommended):
As compressor protection device. Compressor motor coil protection and compressor
discharge temperature must connect with INT69HBY connector. In case it can react
immediately when the temperature tripped. And set up the guiding light on control box.
Turning on the compressor at shorted circuit to bypass protection module is not allowed,
and Hanbell is not responsible for the damage.
88
6.4 Compressor accessories

Hanbell designs complete standard and optional accessories according to various
application requirements for safe and steady operations well as the best performance.
● ：Standard, ∆：
：Optional
Accessory RT
Suction/Discharge flange ●
Economizer flange ●
INT69HBYmotor protector ●
IP54 terminal box ●
Refrigerant heater(300W*2) ●
Oil heater(500W*2) ●
Oil drain valve ●
Motor PTC ●
Motor temperature sensor(Pt100 or Pt1000) ●
Oil tank temperature sensor(Pt100 or Pt1000) ●
Discharge temperature sensor(Pt100 or Pt1000) ●
Lubricant ●
External oil filter △
Oil cooler(5RT) △
Oil pressure differential switch △
Mounting pad △
Actuator heater △
Ejector △
Discharge valve △
Table 6.1 Spare parts (Standard/Optional)
Note: The accessory chart is for purpose only. Actual specification and accessories
enclosed might vary with different quotation and agreement respectively. If any
optional accessory is required and out of above mentioned standard accessories,
please contact Hanbell for detailed specification and quotation.
89
6.5 Operation and maintenance

6.5.1 Compressor start-up
The table below shows the required procedures and points before commissioning the
compressor.
Items Check Points Remarks

1. Inject 13.5 bar of nitrogen. 1. Close the service valve on the
2. No leakage within 12 hours. evaporator
Leakage test 3. Mark the confirmed pressure on the pressure gauge.
1. Vacuum pressure should below 750mmHg. 1. High pressure gauge must be

2. Maintain the vacuum state for 12 hours and confirm closed (no vacuum scale).
Vacuum test whether the degree of vacuum has changed or not. 2. Do not conduct electrical testing
under vacuum state.
1.Use vacuum method and the angle valve on the 1. The oil level should not be higher
return flange of compressor for filling lubricant oil than the H scale on the oil display
2. Fill the oil until oil display at H scale. Verify the oil to avoid agitating the oil when the
level and refill (if necessary) after commissioning gear rotates.
Lubricant oil 3.Remove the wiring of the built-in oil pump to avoid 2. Determine the lubricating oil
refilling malfunction of the oil pump due to insufficient oil heating time on condition like
which will result in damage to the oil pump under high latitude or cold area.
4.The oil heater should be powered on 24 ~ 48 hours
before compressor started to ensure oil temperature
is above "evaporation temperature " + 20 ℃"
1. Confirm whether the chilling water pump and the 1. Record the amount of refrigerant
cooling water pump are running before refrigerant filled.
filling.
2. Firstly add the gaseous refrigerant to above
Refrigerant refilling saturation temperature 0 ℃.
3. Fill the gaseous refrigerant to 2bar (g) after
connecting the oil pump power.
4. Then charge the liquid refrigerant to 80% of the
standard amount.
1. Adjust firstly the angle valve opening of the motor 1. Please adjust the opening of the
housing to 2 cycles, and then open fully the outlet valve according to the actual
valve at the bottom of the motor housing. maximum load condition of the
model and control the motor
Motor fluid spray temperature at <90℃.
volume 2. The present specifications are
Pt100 (or Pt1000) a total of 4
groups, need to be connected to
the control system to monitor
motor temperature.
1. Verify if the electrical specifications of the Actuator 1. Make sure the Actuator is
and hot gas bypass valve are correct. working properly.
2. Actuator: Control signal of 5% ~ 100% is 4.8 ~ 20mA
(or 0.5 ~ 10V), check if the actuator indicator
Control setting steering is rotating.
3. Actuator starting point is set to be 5% (for start-up
program).
4. Hot gas bypass valve: check if movement from 0% ~
100% is normal.
90
1. Oil pump steering test: Use motor rear cap oil sight 1. Motor fluid spray volume can be
glass to observe whether there is intake of observed from the display under
lubricating oil. the motor rear cap. The
2. Motor Steering Test: After starting the push button, refrigerant level should not be
observe the motor rear cap oil sight glass. The higher than the coil to avoid oil
steering direction should be in counterclockwise. agitating and spilling, and further
Confirmation 3.Check the following before starting the compressor : cause damage of the motor coils.
before start-up a. Actuator=5%. 2. During compressor stable
b. Hot gas bypass valve (HGBP)=100% operation, the oil level should be
c. Medium pressure valve =0% controlled between M ~ H scale
on the oil display.
1.Load test: 1. The maximum liquid level of the

a. After the previous start-up process is completed, liquid refrigerant in the
actuator opening should be from 5 → 10%, medium economizer should not be
pressure valve should be 0 → 100%, hot gas bypass exceeding 1/2 of the economizer
valve will still maintain at 100%. muffler to avoid liquid
b. Adjust the capacity according to the normal loading compression (or to install addition
and unloading control logic. Then the hot gas bypass liquid level protection switch or
valve can be closed. delay pressure valve turning on).
c. Ensure that the lubricant oil temperature of the 2. Medium pressure sensor (or
cooler outlet is 30 to 45 °C. Check the cooling external pressure gauge) and
medium flow if the temperature is not within the medium pressure inlet gas
range. temperature sensor shall be
d. Make sure feedback motor temperature of Pt100 (or provided to calculate super heat
Pt1000) is at 30 ~ 90 ℃to avoid condensation at the temperature of medium pressure
outer side of the motor. inlet. It is recommended to be
Start-up process e. After flooded chiller is fully loaded, observe the between 0 and 0.5 ℃ and
test and check condition of the refrigerant in the evaporator, the observe the state of refrigerant in
copper tubes must be slightly visible, and the the gas inlet sight glass.
bubbles created by evaporation of the refrigerant 3. If the operating current is greater
can be seen. than the maximum continuous
f. Super heat temperature of discharge is appropriate operating current during loading,
and should be at Tc +5 ~ 10 ℃. the compressor should be
g. Measurement and recording on vibration and noise unloaded (IGV ↓) to avoid
h. Unloading test: Testing the load change is to test the overloading the compressor
relationship between hot gas bypass valve opening (over current protection).
and safety margin line (or the inverter surge line). 4.Vibration measurement (new
machine overall capacity) :
Motor end：≦1.8 mm/s
Gear end：≦0.8 mm/s
Noise level：＜88 dB(A)
＊＊Please refer to 6.7Compressor
vibration measuring point
1. Increase the temperature of chilling water and lower 1. Time interval between re-start
the temperature of the cooling water (can be and shutdown should not be less
determined and adjusted through pressure ratio than 20 minutes and ensure
change trends). motor temperature should not
a. Firstly turn on the hot gas bypass valve: 0% → exceed 70℃.
100%
b. The Actuator is adjusted downward according to the
Shut down process
capable operation pressure ratio Pr (max) obtained
test and check
from safety margin equation.
c. The oil pump will delay 3 seconds to turn off after
shutdown of compressor.
2.Verify if the compressor motor stops rotating within
30 seconds; if not, please check whether pressure
ratio is a little higher and adjust opening of the hot
gas bypass valve as reference.
91
3. Make sure Actuator opening is 5% and hot gas

bypass is 100% after shut down, and record the oil
level.
4. Re-confirm the oil level change and oil heater
heating status after 2 hours shutdown.
Table 6.1 Compressor unit first run check table
Some important issues as below before starting the compressor:
1. Before the initial start at the job site, check all auxiliary facilities which should be fixed
firmly.
2. In the low ambient temperature, oil viscosity should be considered. Refrigerant and oil
heaters are supposed to turn on if necessary.
3. Check all electronic equipment match the controller.
4. Check all stop valves in the system which should be opened.
5. The operating condition of the compressor after commissioning at the job-site should be
adjusted; discharge temperature will be at least 5℃abovesaturated condensing
temperature and suction vapor superheat should be within 1℃ comparing to saturated
evaporating temperature.
6. Contact HANBELL or the local distributor if any abnormal vibration or noise is found at
pipeline while the compressor is running.
7. Regularly check the chiller according to national regulations and the following items
should also be checked:
-Operating data
-Oil level
-All compressor monitoring parts
-Check electrical cable connections and tightness
Note: During shipment of the compressor, all valves have been closed. After layout of all
components in the system, make sure these valves are open.
6.5.2 Compressor control logic
92
Procedure of start Procedure of stop
3S 20S 3S
IGV1 10% 10%

5% 5%
5%
IGV2
5%
5% 5%
HGBP
Mid-pressure
proportional
valve
Oil Pump
Compressor
1 2 3 4 5 6 7 8 9 10 11 12
Figure 6.4 Control logic diagram of the start-stop
1. Time Zone 1-4: Actuator (IGV1 & IGV2), Hot Gas Bypass Valve (HGBP), and Medium Pressure
Valve Self-test time zone require self-test procedure prior to each startup to prevent abnormal
shut down or valve un-recovery failure.
2. Time zone 4-5: oil pump pre-open time 3 seconds; Actuator IGV2 pre-open to IGV1 = 10% of
the corresponding position.
3. Time Zone 5-6: Number of seconds during compressor start-up process
Note1：Time Table 6 Compressor Startup Completion Point, Actuator (IGV1) will immediately
open to 10% position.
4. Time zone 6-7-8: The unit is free to load and unload according to the capacity control logic.
5. Time Zone 8-9: Time point 8 the shutdown command is issued and the heater bypass valve hits
to fully open position.
6. Time Zone 9-10: The Actuator (IGV1) is still unloaded according to the safety margin equation;
the medium pressure valve begins to close to fully close position.
Note2：When the pressure ratio is high, IGV1 may not close to 10% position
Note3：After the heater bypass valve is fully open, it will start to count about 20 ~ 30seconds. If
the IGV1 still cannot be closed to 10% when the time is up, the compressor will need to
be stopped (shutdown)
7. Time Zone 10-11: Pump Delay 3seconds shutdown area
8. Time Zone 11-12: Lower the Actuator (IGV1) opening to 5% while IGV2 is closed to 5% position
93
6.6 Troubleshooting
The table below shows some problems that might occur at the jobsite. This table will
only be served as a guide for engineers to understand the situation once the problem
occurs.
Problem Possible cause Action

Refrigerant shortage Charge refrigerant
Sudden trip
of the motor Unstable electricity system or power failure Check power supply
thermostat Motor overloaded Check motor condition.
/sensor Bad motor coil causing temperature rising
Check the coil or the motor stator.
rapidly.
Bad motor coil. Check the coil or the motor stator.
Motor power terminal or bolts are wet or frosty. Check power bolt.
Poor insulation Motor power terminal or bolts are bad or dusty. Check power bolt.
of the motor Acidified internal refrigeration system. Clean the system.
Motor coil running long time continuously
Check liquid injection condition.
under high temperature.
Voltage incorrect. Check power supply
Compressor Motor failure Replace the motor

starting failure or Incorrect power supply connection. Check and reconnect it
Y-Δ shifting
Y-Δtimer failure. Check or replace it
failure
Rotor jam Check and repair it
Protection device trip Check devices
Damaged bearings. Replace bearings.
Check oil level of the compressor if

Abnormal Insufficient lubricant.
enough, or add some oil if necessary.
vibration and
noise of the
Working out of the operating limit (surge) Check the operating range.
compressor
Improper pipe system. Check the system piping.
Unbalanced motor rotor Check and balance the rotor.
Check leakage. Charge additional
Insufficient refrigerant. refrigerant and adjust suction superheat
less than 1℃
Condenser problem due to low efficiency. Check and clean the condenser.
High
discharge Refrigerant is overcharge. Reduce refrigerant
temperature Recover and purify refrigerant and
Air/moisture in the refrigerant system
vacuum system.
Replace and adjust proper suction
Improper expansion valve using super-
heat
Oil loss Improper system piping Check the oil pump
Check leakage. Charge additional

Low suction Lack of refrigerant
refrigerant.
pressure
malfunction of the expansion valve Check and reset for proper superheat
Note:
94
1. The replacement of compressor internal parts should be performed by qualified service

technicians only.
2.When reclaiming liquid refrigerant, chilled water pump and cooling water pump can be off;
when reclaiming , make sure chilled water pump and cooling water pump are running (or
drain out chilled water or cooling water); when reclaiming refrigerant(liquid or gas), make
sure start circuit of the compressor is open and oil heater must be powered. When
reclaiming refrigerant till 1~2psi, it’s recommended to drain out refrigerant and charge
nitrogen to establish positive pressure and during repair keep purging some amount of
nitrogen; if the job of greater opening is done(dismantle gas return pipe of motor cover), it’s
recommended to reclaim refrigerant and charge nitrogen to positive pressure, vacuum
again (below 5 torr) and then charge nitrogen to positive pressure (within 8 hours, it cannot
increase above 1.33torr ) to ensure remain of refrigerant in the system to the minimum.
95
6.7Compressor vibration measuring point
1. Simple vibration measurement

Motor rear parts：MV、MH & MA
MH
MV
MH
MA
MV
MA
96
Gear Proximal parts：CIV、CIH、CIA
CIV
CIA
CIH CIH
CIA
CIV
97
2.Spectrum measurement：Please contact service technicians for spectrum measurement

settings.
Besides simple vibration meter point 6, additional measurement of the gear part distal:
COV, COH, COA is necessary.
COH
COH
COA
COV
COV COA
98

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All manuals and user guides at all-guides.

5.2 MOTOR PROTECTOR .................................................................................................70

Storage: -10℃ to 70℃ (14℉ to 158℉)

Chapter 2. Basic design

2.2 Application limits

Figure 2.1 RT series application limits

2.3 Compressor specifications

1. Under CT/ET=36℃/6℃(refer to ASHRAE 90.1-2015)

RT-160 RT-180 RT-200

1. Under CT/ET=36℃/6℃(refer to ASHRAE 90.1-2015)

RT-240 RT-260 RT-280

1. Under CT/ET=36℃/6℃(refer to ASHRAE 90.1-2015)

Model RT-111 RT-161 RT-221

1. Under CT/ET=36℃/6℃(refer to ASHRAE 90.1-2015)

Voltage RT-111 ~ 161 RT-221

2.4 Compressor outline

High voltage compressor outline RT-120~140(E,T)/RT-111 (motor A)

High voltage compressor outline RT-120~140(E,T)/RT-111 (motor B)

Low voltage compressor outline RT-160~200(E,T)/RT-221 (motor A)

High voltage compressor outline RT-160(T)(motor B)

Low voltage compressor outline RT-160(T)(motor B)

Low voltage compressor outline RT-180(T),RT-161(60Hz) (motor B)

Low voltage compressor outline RT-180~200(T),RT-161(50Hz) (motor B)

High voltage compressor outline RT-180~200(T),RT-161(50/60Hz)

Low voltage compressor outline RT-200(T) (60Hz) (motor B)

High voltage compressor outline RT-202,RT-221 (50/60Hz) (motor A)

High voltage compressor outline RT-202,RT-221 (50/60Hz) (motor B)

Low voltage compressor outline RT-221 (50Hz) (motor A)

Low voltage compressor outline RT-221 (60Hz) (motor A)

Low voltage compressor outline RT-240~280 (50Hz) (motor A)

High voltage compressor outline RT-240~280 (50/60Hz) (motor A)

High voltage compressor outline RT-240~280 (50/60Hz) (motor B)

Low voltage compressor outline RT-240 (60Hz) (motor A)

Low voltage compressor outline RT-260~280 (60Hz) (motor A)

Figure 2.2 Flange size

Table 2.5 Flange dimensions

Flow Flow Pressure

Figure 2.2.1 Outline of butterfly valve

Figure 2.3 Discharge and suction piping

Caution: Residue from welding might damage the compressor seriously.

Figure 2.4 Enclosure of piping connection

2.5.2 Size of bushings for motor liquid injection

Figure 2.5 Size of bushings

Liquid injection inlet 3/4" Flare

Table 2.6 Dimensions of bushings

2.6 Compressor structure

Figure 2.6 Compressor structure

NO. Description NO. Description

Chapter 3. Capacity control system

Inlet guide vane

Figure 3.1 Compressor inlet

Double guide vane performance

Figure 3.2 System with an economizer

3.1.1 Control of inlet

Min. mass flow

3.2 Vane Actuator control

Table 3.2.1 Actuator data

3.2.2 Proportional control board setting

Figure 3.5 Control board of the Actuator