SCREW REFRIGERATION COMPRESSORS

Transcription

1 SCREW REFRIGERATION COMPRESSORS STANDARD Safety Precautions 1. Before operation, make sure to read the instruction manual carefully for your safety and the equipment safety as well. 2. Never attempt to perform unauthorized equipment modifications. Unauthorized modifications could lead to damage or injury. 3. The compressors are designed to compress specified refrigerant. Never use them with other gases. Doing so could result in accidents or break downs. Overseas Locations KOBELCO COMPRESSORS VIETNAM CO., LTDKCV #3 Dang Huu Pho, Quarter 2, Thao Dien, Dist. 2, HCMC, Vietnam Tel : Fax : KOBELCO COMPRESSORS (SHANGHAI) CORPORATIONKCS 1/D,B/Unit,Tower 3,No.168 TianShan West Rd.Shanghai,China Tel : Fax : , KOBELCO COMPRESSORS INDIA PVT. LTD.KCIN 249G,3rd Floor, AIHP Tower, Udyog Vihar, Phase-4, Near India Bulls Building Gurgaon 12215, Haryana, INDIA Tel : Fax : International Marketing Refrigeration System & Energy Department Compressor Division Machinery Business 9-12, Kita-Shinagawa 5-chome, Shinagawa-ku, Tokyo, , JAPAN Tel : Fax : URL : ThPRIZE e Japan Machinery Federation PRIZE Japan Society of Refrigerating and Air Conditioning Engineers KOBELCO iz Series was granted awards for outstanding energy-saving equipment. Work Instructions (Specifications and descriptions herein may change without notice.) 1791E

2 PRIZE o ciety era tion o Japan S Jap The PRIZE ing E ngineer s SCREW REFRIGERATION COMPRESSORS f Ref n rigeratin Air Conditio g and an d Machinery Fe KOBELCO iz Series was granted awards for outstanding energy-saving equipment. Screw Refrigeratinon com pressors STANDARD Two stage screw com pressor / drive Receiver unit Two stage screw com pressor / Fixed speed drive Nominal output kw SHα BASIC Quiet Quiet operation achieved by Kobelco s low-noise technology in every possible aspect Operation efficiency maximized by Kobelco s original profile super rotors Water cooled unit Receiver unit It always started with KOBELCO Since Kobe Steel perfected Japan's first domestically produced compressor in 1915, KOBELCO has been at the forefront of Japanese innovation in compressor technology, responding with dedication to each new challenge and need. As evidenced by its success at marketing Japan's first screw compressor in 1956, KOBELCO continues today to reaffirm its coitment to developing the most innovative technology, proven quality, and industry leadership. Compact in size Reliability High Performance 15 Continuous operation for 24, hours ensured Labor saving Labor-saved routine inspections available Nominal output kw izs Water cooled unit 3 37 Space saving ensured by downsized unit design Features P. 3-4 Ⅱ Water cooled unit Standard Specitications P. 5-6 Ⅲ Receiver unit Standard Specitications P. 7-8 STANDARD Water cooled unit / Receiver unit Standard Specitications Water cooled unit Standard Specitications About Maintenance 1 Single stage screw com pressor / drive INDEX Two stage izα Water cooled unit 24 Single stage Nominal output kw 18 P. 9-1 P. 11 P

3 KOBELCO s four Big Features 1 Outstanding energy saving performance by Kobelco inverter drive compressor. 3 New iz monitor with various function for quick and proactive trouble shooting. SCREWREFRIGERATION COMPRESSORS izα series can control its cooling capacity with its inverter drive linear speed control to avoid excessive cooling, thereby permitting outstanding energy saving performance. Piston valve used for capacity control has been replaced to inverter drive capacity control to ensure optimum operation in accordance with cooling capacity fluctuation SHα37F 2units (Fixed speed model / 37kW motor 2) izα11w ( drive model / 65kW motor 1) 17 1 Saving merit per one year run drive Conventional model Power consumption ratio () Example of energy-saving effect when the suction-pressure saturated is Max. energy-saving effect CO2 reduced 27tons Cooling capacity () Electric cost saved by US$9, <Conditions> Yearly average loading ratio: 7, Running hrs: 6, hrs, Electric cost: US$.136/kWh ET/CT = -/+ ( area) Maximum increasable cooling capacity by accelerating rotating speed by inverter drive (compared with Kobelco conventional model in area) increasable2 approx in Outstanding energy saving performance according to partial loading Partial load Conventional refrigeration compressor has been unavoidable to reduce cooling capacity significantly accompany with evaporating drops. Accelerating motor speed technology with inverter drive (Patent registered) enable izα series increase its cooling capacity at lower than izα series can perform equally in both of and 6Hz area, which is a big merit for area users where 2 less performance than 6Hz area has been unavoidable. Those functions enable to select smaller compressor than before. When suction pressure saturation is - cooling capacity is 6 Hz area Energy save Conventional Patent Registered No US Patent #64822 Series motor speed accelerates accompany with evaporative drop. speed increasesas the evaporating lowers speed is constant on conventional models. New iz monitor indicates compressor running conditions, various alarms and those histories. Also stops compressor automatically against emergency waning. iz monitor Suction pressure / Remote capacity control 4 Alternative running applications Additional indication E/C/M lamp E: Emergency stop C: Caution M: Maintenance Merits of motor start up by inverter drive Smooth motor startup by inveter drive eliminates inrush current and hot start Alternative linear capacity control or step capacity control can be selected due to clients demands. Linear capacity control with originally equipped suction pressure sensor and also optionally installed sensor (requested users to supply) at freezing site are available. Super heat is added to monitor compressor situation more clearly. Compressor protective functions The effect of equipped inverter drive can be found when to startup compressor. Since conventional star-delta startup induces inrush current and requires approx 1 minutes interval before restarting. Thanks to the equipped inverter that allows smooth starting, izα series can restart quickly without any interval. The smooth starting mechanism permits compressor to stop even in the conventional condition of interruption is not allowed. This mechanism enables more effective energy saving and down sizing of the power facility. Liquid crystal display (LCD) Translucent screen (with blacklight) for a clear view even in the dark. Current Since this series is single stage compressor, intermediate pressure sensor is not installed..mpa appears on a monitor. Linear capacity control fixes its rotating speed sensing with originally equipped suction pressure sensor otherwise optionally equipped sensor (the sensor and 4-2mA DC signal are requested users to supply) at freezing site. Controlling factor of suction pressure at the freezing site is requested to preset. Step control Conventional machines (Star-delta starting) E/C/M lamp E: Emergency stop C: Caution M: Maintenance Capacity step control function is also equipped with iz monitor, its setting value is available to change flexibly increasable approx in 5 Hz area Evaporating () Time 3 4

4 TWO STAGE Water cooled unit Standard Specifications ( to ) Number of compressor Nominal output 123 kw R4A Main:3 phase 2,22,38,,415,4,46,48 () Control circuit:1 phase 223V () 1 unit Continuous control mode or step control mode (3 steps: 5,, and 1) Water-cooled semi-hermetic; 4-pole; 3-phase induction type Horizontal shell and tube (serving also as a receiver) WATER COOLED Condenser Receiver capacity Lubricating oil IDEMITSU Daphne Hermetic Oil FVC32D spatial volume gas inlet liquid outlet Condenser Cooling water inlet/outlet Oil cooler 4 5 db(a) Rc x111 x Rc 2 Oil coolerless specification x111 x Rc x115x x12x x1265 x x126x A x129x R4A Number of compressors 123 Nominal output kw Condenser Receiver capacity spatial volume 4 gas inlet liquid outlet Condenser Cooling water inlet/outlet Oil cooler Lubricating oil IDEMITSU Daphne Hermetic Oil FVC32D 5 db(a) R4A Main:3 phase 2,22,38,,415,4,46,48 () Control circuit:1 phase 223V () 1 unit 2 units Continuous control mode or step control mode (3 steps: 5,, and 1) 9 x2 65x2 x2 9x2 Water-cooled semi-hermetic; 4-pole; 3-phase induction type Horizontal shell and tube (serving also as a receiver) A x132x A x142x x2 A Rc x197x Ax2 A Rc x2x Ax x 21x Ax x 21x *1: The minimum capacity depends on production range and operation conditions (25) *2: Requested to enter proper signal due to selected running mode. *3: Partial loading value for step control is changeable flexibly. *4. Condenser spatial volume for refrigerant is calculated by subtracting the volume of the heat exchanger tube from the inside volume of the condenser. *5: Oil quantity is minimum charge only for condensing unit. Actual oil quantity for whole of the plant (system) should be determined at the site referring the oil level of sight glasses during compressor running. Charge oil on site and replenish when the level gets lower than requested. Use specified refrigerant machine oil (Oil is requested users to supply) *6: level (scale A) indicates the values measured at 1meter away from the compressor and 1meter above from the floor level when the suction pressure saturated is - without any echo influence. In the actual installed conditions the noise level maybe different from indicated value because of the influence of surrounding noise and echo. * : Hot gas defrost model is available optionally. * : When suction pressure saturated is required below modification for ultra low with cost up is needed. * : control and harmonic suppression measurement should be taken as necessary according to respective guidelines. * : Electric power for control circuit is requested users to supply * : This is a case for superheat and economizer middle stage evaporative +1 (izα3w, W, 5Wcase is+5) * : Please contact Kobelco in case of using suction pressure saturating is less than

5 TWO STAGE Receiver unit Standard Specifications ( to ) Number of compressor Receiver capacity Nominal output R4A Main:3 phase 2,22,38,,415,4,46,48 () Control circuit:1 phase 223V () Continuous control mode or step control mode (3 steps: 5,, and 1) kw x2 x2 db(a) 5 1 unit 2 units semi-hermetic; 4-pole; 3-phase induction type gas inlet (suction) 1A x2 1Ax2 gas outlet (discharge) liquid inlet (return) 25A 25A 32A 32A A 65A A liquid outlet A Lubricating oil IDEMITSU Daphne Hermetic Oil FVC32D x185x117 22x11x12 22x1165x12 295x135x x135x x133x x198x16 33x215x *1: The minimum capacity depends on production range and operation conditions (25) *2: Requested to enter proper signal due to selected running mode. *3: Partial loading value for step control is changeable flexibly. *4: Oil quantity is minimum charge only for condensing unit. Actual oil quantity for whole of the plant (system) should be determined at the site referring the oil level of sight glasses during compressor running. Charge oil on site and replenish when the level gets lower than requested. Use specified refrigerant machine oil (Oil is requested users to supply) *5: (scale A) indicates the values measured at 1 meter away from the compressor and 1 meter above from the floor level when the suction pressure saturated is - without any echo influence. In the actual installed conditions the noise level maybe different from indicated value because of the influence of surrounding noise and echo. * : When suction pressure saturated is required below modification for ultra low with cost up is needed. * : control and harmonic suppression measurement should be taken as necessary according to respective guidelines. * : Electric power for control circuit is requested users to supply * : This is a case for superheat and economizer middle stage evaporative +1 (izα3ar, AR, R case is +5) * : Please contact Kobelco in case of using suction pressure saturating is less than R4A

6 TWO STAGESTANDARD Water cooled unit TWO STAGESTANDARD Receiver unit Standard Specifications( to ) Number of compressor Nominal output kw Condenser Receiver capacity spatial volume 1 gas inlet liquid outlet Condenser Cooling water Oil cooler inlet/outlet Lubricating oilidemitsu Daphne Hermetic Oil FVC32D) 2 db(a) 3 R4A Hz 6Hz 6Hz * : This is a case for superheat and economizer middle stage evaporative R4A Main: 3 phase 2/222,38,/4() Control circuit:1 phase 223V () 1 unit Water-cooled semi-hermetic; 2-pole; 3-phase induction type Star-delta Horizontal shell and tube (serving also as a receiver) A 19.5 Rc x8x x985x A x15x x117x *1: Water cooled condenser spatial volume is calculated by subtracting the volume of the heat exchanger tube from the inside volume of the condenser. *2: Oil quantity is minimum charge only for condensing unit. Actual oil quantity for whole of the plant (system) should be determined at the site referring the oil level of sight glasses during compressor running. Charge oil on site and replenish when the level gets lower than requested. Use specified refrigerant machine oil (Oil is requested users to supply) *3: Water cooled type noise (scale A) indicates the values measured at 1 meter away from the compressor and 1 meter above from the floor level when the suction pressure saturated is - without any echo influence. In the actual installed conditions the noise level maybe different from indicated value because of the influence of surrounding noise and echo. * : Hot gas defrost model is available optionally. * : When suction pressure saturated is required below modification for ultra low with cost up is needed. * : control and harmonic suppression measurement should be taken as necessary according to respective guidelines. * : Electric power for control circuit is requested users to supply. * : Gauges for suction and discharge gas are optional Hz 6Hz 6Hz Hz Hz Standard Specifications( to ) Number of compressor Nominal output kw Receiver capacity gas inlet (suction) gas outlet (discharge) liquid inlet (return) liquid outlet Lubricating oil (IDEMITSU Daphne Hermetic Oil FVC32D) 1 db(a) A 25A x8x *1: Oil quantity is minimum charge only for condensing unit. Actual oil quantity for whole of the plant (system) should be determined at the site referring the oil level of sight glasses during compressor running. Charge oil on site and replenish when the level gets lower than requested. Use specified refrigerant machine oil (Oil is requested users to supply) *2: Receiver unit cooled type noise (scale A) indicates the values measured at 1 meter away from the compressor and 1 meter above from the floor level when the suction pressure saturated is - without any echo influence. In the actual installed conditions the noise level maybe different from indicated value because of the influence of surrounding noise and echo R4A Main: 3 phase 2/222,38,/4() Control circuit:1 phase 223V () 1 unit Semi-hermetic; 2-pole; 3-phase induction type Star-delta A 32A A x9x x11x x11x * : When suction pressure saturated is required below modification for ultra low with cost up is needed. * : control and harmonic suppression measurement should be taken as necessary according to respective guidelines. * : Electric power for control circuit is requested users to supply. * : Gauges for suction and discharge gas are optional. 6Hz 6Hz 6Hz * : This is a case for superheat and economizer middle stage evaporative Hz 6Hz 6Hz Hz Hz

7 SINGLE STAGE Water cooled unit Standard Specifications ( to -) 123 Nominal output kw Condenser Receiver capacity spatial volume 4 gas inlet 65A 65A liquid outlet A A Cooling water inlet/outlet (Condenser) - Lubricating oil IDEMITSU Daphne Hermetic Oil FVC32D db(a) x915x15 225x96x x1x155 27x1165x *1: The minimum capacity depends on production range and operation conditions specified refrigerant machine oil (Oil is requested users to supply) *2: Requested to enter proper signal due to selected running mode. *6: level (scale A) indicates the values measured at 1meter away from the compressor *3: Partial loading value for step control is changeable flexibly. and 1meter above from the floor level when the suction pressure saturated is *4. Condenser spatial volume for refrigerant is calculated by subtracting the volume of the heat exchanger -15 without any echo influence. In the actual installed conditions the noise level maybe tube from the inside volume of the condenser. different from indicated value because of the influence of surrounding noise and echo. *5: Oil quantity is minimum charge only for condensing unit. Actual oil quantity for whole of the plant * : Hot gas defrost model is available optionally. (system) should be determined at the site referring the oil level of sight glasses during * : control and harmonic suppression measurement should be taken as necessary compressor running. Charge oil on site and replenish when the level gets lower than requested. Use according to respective guidelines R4A Main:3 phase 2,22,38,,415,4,46,48 () Control circuit:1 phase 223V () Continuous control mode or step control mode (3 steps: 5,, and 1) 3 37 Semi-hermetic; 4-pole; 3-phase induction type Horizontal shell and tube (serving also as a receiver) * : This is a case for superheat and economizer middle stage evaporative The Importance of Preventative Maintenance and Operating check Element Refrigiration Oil Dryer Regular maintenance can keep your compressor safe and trouble-free, and will provide you peace of mind throughout your ownership. Neglecting regular maintenance can increase running cost and degrade the cooling performance. It might also cause failure and damage, eventually it might increase the cost of replacing defective parts. Please refer this booklet for your future ownership Maintenance Checklist Maintenance plan is scheduled according to the actual operation time or the time mesured from the delivered date, whichever comes first. Warranties do not cover regular maintenance. Compressor Overhaul Main Monitor Cooling Tube Parts Pressure sensor Temperature sensor Controller monitor Safety valve High pressure limit switch Pressure gauge Temperature gauge Oil pressure relay Dis. monitoring relay Suction filter element Oil filter element Bearing O-ring Rotor Cooling Fan Battery Water Cooled Unit Parts Condencer Oil Cooling Unit * * * * * * * * every 3, hrs / 6 months / Cleaning / / every 3, hrs / 6 months every 6, hrs / 1 year / / / / every 6, hrs / 1 year Cleaning Cleaning every 12, hrs / 2 years every 12, hrs / 2 years *1: Safety valve and high pressure limit switch are required annual operating check. *2: The defective suction filter element should be replaced or cleaned up after inspection. *3: Oil filter element should be replaced in advance in case that pressure drop (discharge pres. minus supplied oil pres.) gets higher than.25mpa. *4: Refrigeration oil needs to be checked regularly and changed frequently according to the safety guideline. *5: If any irregularities are found during inspection, they should be replaced. *6: We suggest to analyze the cooling water quality every year. every 24, hrs / 4 years every 24, hrs / 4 years Remarks Coon Coon Fixed Speed Drive Fixed Speed Drive Fixed Speed Drive Fixed Speed Drive Remarks 11 12

8 The Importance of the Oil Compressor Overhauling Oil is injected to screw compressor for the compression process. Three Key Functions of Lubricant Oil. The screw compressor unit is the heart of the whole refrigeration compressor unit. Recoend regular overhaul performed by KOBELCO professional staff. Kobelco compressor unit is constructed with major components such as screw rotors, bearings, motor and casings. The overhaul work includes replacement of bearings, o-rings and other deteriorated items, check-out rotors and casings and refresh them. Lubricating Bearing In order to prevent serious trouble such as making abnormal sounds and vibration or fatal damage, preventative maintenance should be performed. In addition, it helps to reduce its cost and to maintain the original performance of compressor. roller Screw Rotor Overhaul Screw rotors are rotating at high speed in clearance of less than.3 to each other. Therefore foreign materials contained in the lubricant would cause damage on surface of the rotors. Major services of the overhaul are polishing the surface of rotor and adjust clearance value to make sure them rotate with good condition. New Cooling Sealing Damaged rollers of bearing due to insufficient lubricant. Before Suction Element Cover After Suction Filter Element Two stage Compressor Inlet port Oil and Oil Filter Element should be changed regularly Old New Bearings of 2nd dis. Bearing of 2nd suc. Bearing of 1st suc. side Bearings of 1st dis. Jacket for refrigerant Oil repeats the procedure of being injected in the screw compressor, where it is mixed with refrigerant then comes out together to oil separator, where they are separated into oil and refrigerant again and come back to compressor. While repeating this cycle, oil keeps itself at high for a long period and it would cause failures and problems such as starts damaging, clogging oil filter and making sludge, eventually losing its original functions. DO NOT MIX other brands/greads oil. It would cause serious damages. Only use KOBELCO specified lubricants, and Kobelco genuine oil filter element. Deteriorated oil Clogged Oil Filter Element New Discharge Port 2nd stage Male Rotor 2nd stage Female Rotor 2nd stage 1st stage Male Rotor 1st stage Female Rotor 1st stage Stator Rotor