Rev. M 5.9.

1
Rev.-11-15-2022

HANBELL COMPRESSOR
INSTALLATION & START-UP GUIDE

RC2 Series

WARNING!
NO OIL is shipped in compressor.
Compressor must NEVER be run backwards.
Oxygen is never to be used to pressure test any refrigerant system.

These Safeties ARE Required at Startup to Maintain Hanbell Warranty

a) Motor Module Trip (INT69HBY): Open for 1 second
b) Low Oil Level Float Trip: Open for 60 seconds +30 seconds extension
c) Unsafe Suction: Less than 5 psi for 3 seconds +25 seconds extension
d) High Discharge Temperature: Greater than 230°F for 2 seconds
e) Low Differential Pressure: Less than 65 psi for 60 seconds (Oil-Suction) +60 seconds extension
f) Unsafe Differential Pressure: Less than 35 psi for 5 seconds (Oil-Suction) +25 seconds extension
g) Dirty Filter (Discharge Pressure - Oil Pressure): Greater than 20 psi for 60 seconds
h) Low Discharge Superheat: Less than 20°F for 300 seconds

+ Indicates allowable time extension added to the trip delay during the first 5 minutes of
compressor operation while starting.

Please read pages 36 ~ 40 for Warranty Information

5580 Enterprise Pkwy., Fort Myers, FL 33905 Office (239) 694-0089 Fax: (239) 694-0031

www.mcscontrols.com
COMPRESSOR INSTALLATION & START-UP GUIDE REVISION M

The MCS Commitment is to provide practical solutions for the industries

needs and to be both a leader and partner in the effective use of
microprocessor controls.

Micro Control Systems, Inc.

5580 Enterprise Parkway
Fort Myers, Florida 33905
PH:(239) 694-0089 FAX:(239) 694-0031
www.mcscontrols.com

All information contained within this document is considered to be proprietary information of Micro Control Systems, Inc.
No information or data from this document shall be published, used, reproduced, transmitted, or disclosed to others outside
your organization without the prior expressed written consent of Micro Control Systems, Inc. This document and the information
contained herein shall be treated as proprietary. Reasonable provisions shall be provided to ensure that this information remains
proprietary by your employees, agents, and other personnel that may have access to this document.
Copyright ©2022
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COMPRESSOR INSTALLATION & START-UP GUIDE REVISION M

Table of Contents

Chapter - 1. Compressor Crate Unpacking & Inspection........................................................... 4

Chapter - 2. Safety and Installation Procedures............................................................................. 5
2.1. Compressor Safety Instructions...................................................................................................................5
2.2. Installation Procedures.................................................................................................................................5
Chapter - 3. Recommended Liquid Injection Piping...................................................................... 6
Chapter - 4. Electrical Wiring.................................................................................................................... 7
Chapter - 5. Wiring Procedures - Y-Delta / Part Winding............................................................. 8
5.1. Electrical Power Terminals.........................................................................................................................11
Chapter - 6. Across the Line Jumper Bar Installation................................................................12
Chapter - 7. INT69HBY MOTOR PROTECTION................................................................................13
7.1. Description - INT69HBY DIAGNOSE ........................................................................................................13
7.2. Flash Codes...............................................................................................................................................13
7.5. Flash Code Overview.................................................................................................................................14
7.6. How to Wire INT69HBY Diagnose..............................................................................................................15
Chapter - 8. RC2-100, 140 Installation Guide.................................................................................16
Chapter - 9. RC2-170 ~ 580 Installation Guide...............................................................................17
Chapter - 10. RC2-710 ~ 930 Installation Guide...............................................................................18
Chapter - 11. Maintenance Area Requirement.................................................................................19
Chapter - 12. Compressor Piping.............................................................................................................20
Chapter - 13. Pre-Start-Up Procedure...................................................................................................21
13.1. Oil Types.....................................................................................................................................................22
7.3. HANBELL FLOODED TYPE WITH OIL SEPARATOR...............................................................................23
7.4. HANBELL FLOODED TYPE WITH OIL SEPARATOR & OIL COOLER.....................................................24
Chapter - 14. Start-up Procedure............................................................................................................25
14.1. Recommended Safety Settings..................................................................................................................25
Chapter - 15. Hanbell with VFD................................................................................................................26
15.1. Wiring & Controls Set Up............................................................................................................................26
15.2. Compressor Set Up....................................................................................................................................26
15.3. Solenoids....................................................................................................................................................27
15.3.1 Solenoid Identification (Normally Open / Normally Closed)..............................................................27
15.3.2 Infinite Capacity (Stepless) Minimum (50-100%)..............................................................................28
15.3.3 Step Load 50%, 75%, 100%.............................................................................................................29
15.3.4 Step Load 25% 50%, 75% & 100% (Only 25% at Start-Up and Shut-Down)...................................29
15.3.5 Solenoid Alignment...........................................................................................................................30
Chapter - 16. Slide Amp Calculation......................................................................................................34
16.1. Slide Amp Calculation through MCS-Connect............................................................................................34
Chapter - 17. Compressor Warranty Information............................................................................36
Chapter - 18. Handling POE Oils..............................................................................................................38
Chapter - 19. Hanbell Maintenance Forms.........................................................................................39
19.1. Hanbell Warranty Startup Form..................................................................................................................40

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COMPRESSOR INSTALLATION & START-UP GUIDE REVISION M

Chapter - 1. Compressor Crate Unpacking & Inspection

1. Inspect crate and compressor for any shipping damage.
2. The compressor is in an easy open crate, cut straps and lift off crate top
from base.
3. Use either steel cable or safety ropes to lift the compressor, see Figure
1. The cable should be capable of holding up to a minimum of 2 tons.

Use caution while lifting the compressor

Figure 1
Lifting Compressor with Steel Cable

► Make sure that the steel cable does not touch the Solenoid Valves, Capillary, Oil Heater, Discharge Temperature
Sensor and or Power Terminals, etc. to prevent damage.
► Use only steel cable or safety ropes to lift the compressor; make sure that the cable/rope has the proper strength to
lift the compressor.
► Keep the compressor horizontal while lifting.
4. Check compressor nameplate for correct model and voltage designation.
5. To facilitate customer installation requirements, the parts listed in Table 1 are factory supplied in separate boxes located
in the compressor terminal box or packed in the compressor shipping container. Please verify that you have received all
accessory parts.

Table 1: Compressor Accessories & Service Valve Parts

Qty Description
1 Stop Valve Assembly
1 stop valve, 2 gaskets, 1 charging valve, 4 bolts, 1 half union connector, 1 flare nut, 1 flare seal
bonnet
1 Discharge bushing connector
1 Suction bushing connector
1 Motor Terminal Junction Box Assembly
1 terminal box, 1 motor protection, 2 plastic terminal plugs, 1 reset button, 4 wires

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COMPRESSOR INSTALLATION & START-UP GUIDE REVISION M

Chapter - 2. Safety and Installation Procedures

2.1. Compressor Safety Instructions

1. Follow recognized safety procedures and practices.
2. In order to prevent the penetration of moisture, air or impurities, the compressor has been charged with Nitrogen
gas. Do not remove any compressor bolts or fittings until the factory supplied holding charge has been relieved.
3. Do not apply any power to the compressor unless all valves are open and solenoids are energized (suction / discharge,
service valves, economizer and oil shut off valves).
4. Do not operate or provide any electrical power to the compressor unless the terminal box cover is in place and
secured. Measurements of the current and voltage during running conditions must be taken at other points in the
power supply.
5. Do not remove terminal box cover until all electrical sources have been disconnected.

WARNING: Failure to follow these instructions could result in serious personal injury.
2.2. Installation Procedures
1. Holding Charge: The screw compressor is factory supplied with 15 psig (0.5 bar) holding charge of nitrogen gas.
The internal pressure must be relieved before attempting to remove any compressor fittings or parts. Relieve the
holding charge by removing the threaded cap on the low pressure Schrader connection fitting and depressing the
internal Schrader stem.

CAUTION: This compressor may contain trace amounts of oil. Do not relieve the holding
charge or open the compressor ports until it is ready to be connected to a closed dry
system. Excessive moisture will shorten compressor life.
2. Installation of the Compressor Electrical Terminal Box: Four bolts located on the top of the electrical terminal
box cover mount the electrical terminal box; it is adjustable to the cable hole direction to meet the power cables’
optional connection direction from the chiller.
3. Oils: Adding and removing oil is done through the Drain valve located on the solenoid side of compressor.
The compressor has no oil and is not charged with oil. When adding or doing a complete change, use only the
listed Hanbell approved oils. POE oils readily absorb moisture and cause acid formation in the system. Keep oil
exposure to the atmosphere to a minimum.
4. Installation of the Service/Stop Valve: Unpack the service/stop valve’s box then check against the list on the out-
side of the box to ensure correct parts. Be sure that all parts inside the carton are clean. Use the four bolts to secure
the service/stop valve. Use PTFE sealer to seal the adapter while tightening it. Please refer to page 19, ‘Maintenance
Area Requirement’ for space that is required for future service and maintenance needs.
5. Service/stop Valve Recommended Connection

Figure 3-A RC2-100, 140 & 180 Figure 3-B RC2-170, 200~580 & 620 Figure 3-C RC2-610, 710~930

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COMPRESSOR INSTALLATION & START-UP GUIDE REVISION M

Chapter - 3. Recommended Liquid Injection Piping

1. Liquid Injection Solenoid Valve and Expansion Valve (Required, Not included with compressor): The liquid injection
system may be piped, but it is necessary to consider the required space for adjustment of the expansion valve while
testing or running the compressor. Please refer to installation guide in the following section for connection points.

Note A: It is necessary to adjust the Ball Valve to feed small amounts of liquid (drops) to the
compressor motor.

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COMPRESSOR INSTALLATION & START-UP GUIDE REVISION M

Chapter - 4. Electrical Wiring

1. If the compressor application is low voltage, the following items should be considered:

2. Use conduit to insulate and protect the main power cables between the control panel and compressors’ electrical
terminal box.

3. Press each main power cable connecting head with bolts firmly on each power terminal in electrical terminal box.
Keep enough space and distance between the main power cable heads.

4. Choose suitable electrical accessories to meet the required critical running conditions. An AC-3 contactor is
recommended to meet the rated capacity of power. Select an overload protector with a response time of 15 seconds
for overload.

5. Ensure the electricity voltage drop between each two phases is less than 2%. If unable to reduce the length of main
power cable then a larger diameter of main power cable should be chosen. Please refer to Figure 7-A shown below.

The chart below is an estimate for wire sizes based on maximum continuous current being used.
Local electrical codes should be followed prior to wiring the compressor and selecting a wire size.

Main power cable Size 8 awg 6 awg 4 awg 2 awg 1 awg 0 awg 00 awg 3/0 awg 4/0 awg 4/0 awg 300 mcm 500 mcm
AWG / MCM (mm2) (8 mm2) (14 mm2) (22 mm2) (30 mm2) (38 mm2) (50 mm2) (60 mm2) (80mm2) (100 mm2) (125 mm2) (150 mm2) (200 mm2)

Maximum continuous current

55 80 100 125 145 175 200 230 270 310 360 425
(Amp)

Table 7-A Main Power Cable Size vs MCC

Maximum main power cable temperature is at 60°C. Maximum ambient temperature is at 35°C.

6. To avoid any danger or accidents due to the shortage of electrical power, you are required to follow local Electrical
Regulations for the grounding of the electrical terminal box, heater and compressor body etc.

7. The motor PTC and discharge PTC are temperature sensors with a quick response in relation to the temperature
approach to their setpoint. The thermisters must be connected in series to a controller (INT69HBY – Kriwan provided
with the compressor) in the terminal box for protection of the compressor. An alarm for the motor protector is required to
be embedded on the control panel as an indicator. Do not bypass/jump-out the INT69HBY to start and run the compressor.

Warning: Reverse rotation of the compressor will cause compressor damage

and will void the compressor warranty.

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COMPRESSOR INSTALLATION & START-UP GUIDE REVISION M

Chapter - 5. Wiring Procedures - Y-Delta / Part Winding

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COMPRESSOR INSTALLATION & START-UP GUIDE REVISION M

Motor Terminals
The method to tell the terminals for wiring (V-Phase):
1. Star-Delta Motor - refer to Letter by terminal bolt.
2. PWS Motor - refer to Number by terminal bolt.

Old Style Motor

Terminals Number to right of Bolt
Smaller Compressors 2

Terminal V2

V
Letter to Left of Bolt

New Style Motor

Terminals
Smaller Compressors
Motor Terminals
Larger Compressors

V
2

Terminal V2
Letter top, number under letter

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COMPRESSOR INSTALLATION & START-UP GUIDE REVISION M

Figure 5-A Motor Wiring

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COMPRESSOR INSTALLATION & START-UP GUIDE REVISION M

5.1. Electrical Power Terminals

The power terminals of Hanbell compressors are made from ceramic materials and
are insulated with more than 1000MΩ. Be careful connecting the wiring and follow the
instructions below:

► When tightening the terminal nuts, be careful not to hit the ceramic part of the terminal. The
insulation of the power terminal could be degraded.
► The setting of the torque wrench for tightening the copper nut of the terminal bolts should be
set less than 500 kg-cm (36 pound/inch).
Shut down the chiller first for service if the insulation value of the power terminal is lower
than 5MΩ.

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COMPRESSOR INSTALLATION & START-UP GUIDE REVISION M

Chapter - 6. Across the Line Jumper Bar Installation

Photo shows extra nuts installed under jumper bar

for clearance of power bolt Insulation

Connect line voltage directly on Terminal post

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COMPRESSOR INSTALLATION & START-UP GUIDE REVISION M

Chapter - 7. INT69HBY MOTOR PROTECTION

7.1. Description - INT69HBY DIAGNOSE

Hanbell supplies INT69 HBY Diagnose for motor protection with monitoring functions of phase loss, phase sequence, motor
temperature, and discharge temperature. The module has built in flash codes that are helpful for diagnosing safety faults.
In order to protect the compressor, each RC2 series compressor has been built with three PTC temperature sensors inside
the motor coil and one at the discharge port neck of the compressor. These sensors are connected to the motor module to
monitor coil temperature and discharge temperature. Up to 9 sensors can be connected in series and used with one module.
If the temperature in one of the positions monitored exceeds nominal response temperature of the respective PTC thermistor
(230° F, 4.5 ohms ±20%), the sensor resistance increases and the module trips (M1 and M2 open). The failure results in
a lockout. The module resets when the response temperature drops 3kΩ (when temp decreases below 212°F, 2.75 ohms
±20%). 5 min delay for the first PTC failure, 60 min delay for the 2nd failure, latching lockout for the 3rd within 24 hour period.
Monitoring is inactive for 20 seconds after motor stop to prevent nuisance trips from brief reverse rotation.
Phase failure (loss) and Phase sequence safety trips result in a first time lockout. Phase sequence monitoring is active
1 second after motor start for 10 seconds. Phase loss is monitored 1 second after motor start till motor stop.
Lockout and time delay can be canceled by interrupting power to the module for 5 seconds. An optional power supply reset
button can be added to electrical connection box.

7.2. Flash Codes

PTC Temperature Error

Sensor Input Error

Time delay active (PTC < Reset) Supply Voltage Too Low

Phase Sequence
Reset delay for “Supply Voltage Too Low”

Phase Failure

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COMPRESSOR INSTALLATION & START-UP GUIDE REVISION M

7.3. Flash Code Overview

Green lit Compressor Operational

Green flashing Compressor Running
Red/Orange flashing Error, Compressor is switched off; for description see
table below
1st flashing sequence 2nd flashing sequence Description
(Red LED) (Orange LED)
1 1 Motor temperature; Static switch
off, Permissible winding
temperature exceeded
3 Motor temperature;
Reset delay after static switch off
4 Motor temperature;
Sensor input detected
open circuit or short circuit
2 1 Motor voltage;
Incorrect phase sequence
2 Motor voltage;
Phase failure/asymmetry
3 1 General;
Supply voltage too low
5 General;
Reset delay after “General” error

Error Active Condition Time delay

Motor temperature Always Rtrip 4,5kΩ ±20% 1. / 24h 5min 2. / 24h 60min
static trip Rreset 2,75kΩ ±20% 3. / 24h locked out
Time delay starts after cooling down
Operation cycle Always >3 switch off within 30s 5min
limitation
Phase sequence 1s after motor start for 10s Locked out

Phase loss failure 1s after motor start till motor stop, Locked out
monitoring is inactive for 20 seconds
after motor stop to prevent nuisance
trips from brief reverse rotation.

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COMPRESSOR INSTALLATION & START-UP GUIDE REVISION M

7.4. How to Wire INT69HBY Diagnose

The following diagram shows the proper wiring connections for the module. The module is connected
to L1, L2 and L3 for phase monitoring. Stake on connectors at terminal “A” are connected in series with
the discharge PTC and wired back to S1 and S2.

INT69HBY DIAGNOSE WIRING DIAGRAM

(Uses Power Interruption Reset Button)

(ffl A
u z
1 7
Motor Module Fault

---- -Neutral
Power
Supply

_________ � __ 1�40
Reset Button

Date 03/24/2022
�CRO
Ol'lt'TROL Revision D
YSTEMS
CAD Tech I. Mitchell
Hanbell Compressor Installation and Startup Guide Rev O (Rev. C) (2021-07-21 ).dwg

Diagram shows a typical setup using MCS Controls.

Your wiring may be different from this diagram.

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COMPRESSOR INSTALLATION & START-UP GUIDE REVISION M

Chapter - 8. RC2-100, 140 Installation Guide

¢ Capacity control system module :

A. Step-less capacity control: Gasket Bolt
1 ( step-less )+ 2 ( 33%)
B. 3 step capac-ity control: ECO stop valve
2 ( 33%) + 3 ( 66%)
C. Step-less+step capacity control: ECO port
1+2+3

1. Solenoid valve only stepless

Bolt 2. Solenoid valve 33%
' 3. Solenoid valve 66%
� Bushing
I

Gasket
!
Bolt Suction flange
Check valve□ �

( Compression chamber)
Liquid injection expansion valve

Discharge PSI Sensor -'f---, Suction

Gasket
Mounting
filter

Angle valve
liquid injection solenoid valve

High Oil Sight Glass Discharge port

Power bolt
PTC terminal
INT69HBY

A .Angle valve
B. Refrigerant service valve
Oil PSI Sensor
Mounting

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COMPRESSOR INSTALLATION & START-UP GUIDE REVISION M

Chapter - 9. RC2-170 ~ 580 Installation Guide

RC2-620 (The difference compared with RC2-70~580)

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COMPRESSOR INSTALLATION & START-UP GUIDE REVISION M

Chapter - 10. RC2-710 ~ 930 Installation Guide

Bolt -Bolt
stop valve Stop valve
Discharge Gasket
flange ...Bolt

Soleniod valve description : Bushing

I. Solenoidvalve ( only step-less)
2. Solenoidvalve ( 25% .30% ,35%) Gasket
3. Solenoidvalve t 50% ) Check valve
4. Solenoidvalve ( 75%)
Gasket
Capacity control system module : Suction filter Flange
A. Step-less capacity control:
1 (step-less)+ 2 ( 25% ,30% ,35%) Gasket
B. 4 step capacity control:
2 (25% ,30% ,35% ) + 3 ( 50%) + 4 ( 75% )
C. Step-less+step capacity control: Spring
Gasket
1+ 2 +3+4
Suction Filter
Gasket
Discharge PSI Sensor
Stop pin
Mounting
O-ring ( Only for applicationof oil cooler )
Plug

( Compressionchamber)
Liquid injection expansion valve
Oil PSI Sensor Mounting
Liquid injection solenoid valve

Discharge port
Suction port

Cable box
Power bolt
PTC terminal
INT69HBY
Connector

Refrigerant ECO Stop valve

service valve High Oil Sight Glass
Oil Heater
Angle valve

Suction PSI Sensor

Mounting

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COMPRESSOR INSTALLATION & START-UP GUIDE REVISION M

Chapter - 11. Maintenance Area Requirement

Please refer to the below tables for recommended minimum space requirements

RC2-100 RC2-140 RC2-180 RC2-170 RC2-200 RC2-230 RC2-260 RC2-300

A.(cm) 5.9” (15) 16.1” (41) 18.1” (46) 18.5” (47) 20.1” (51)
B.Outwards(cm) 11” (28)
C.(cm) 9.8” (25) 10.2 (26) 11.8” (30) 13” (33)
D.(cm) 5.9” (15)
(6XFWLRQ¿OWHU(mm) 3.7” (95) 4” (103) 5.6” (143)
)2LO¿OWHU(mm) 7.8” (200)
RC2-310 RC2-320 RC2-340 RC2-370 RC2-410 RC2-470 RC2-510 RC2-550
A.(cm) 20” (51) 22” (56) 21.3” (54) 23.3” (59) 21.7” (55) 23.3” (59)
B.Outwards(cm) 11” (28)
C.(cm) 13” (33) 11.8” (30) 13.8” (35) 14.6” (37)
D.(cm) 5.9” (15)
(6XFWLRQ¿OWHU(mm) 5.6” (143 6” (153)
)2LO¿OWHU(mm) 7.8” (200)
RC2-580 RC2-610 RC2-620 RC2-710 RC2-790 RC2-830 RC2-930
A.(cm) 21.7” (55) 23.6” (60) 23.6” (60) 25.6” (65) 31.5” (80)
B.Outwards(cm) 11” (28) 13.8” (35) 11” (28) 13.8” (35)
C.(cm) 13.8” (35) 14.6” (37) 17.7” (45)
D.(cm) 5.9” (15) --- 5.9” (15) ---
(6XFWLRQ¿OWHU(mm) 6” (153) 8.2” (210) 6” (153) 8.2” (210)
)2LO¿OWHU(mm) 7.8” (200) 9.1” (232) 7.8” (200) 9.1” (232)

Table 7-A Compressor Recommended Space for Maintenance

1. 5HVHUYHHQRXJKVSDFHIRUFRQQHFWLRQDQGLQVWDOODWLRQRIWKHHOHFWULFDOWHUPLQDOER[VHUYLFHVWRSYDOYHVDQGVROHQRLG
valves on the compressor.
2. Consider the compressors’ future overhaul when determining space requirements. All compressors’ outside parts
and electrical controller lines and terminal connections etc should be spaced for easy dismantle and re-assemble.

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COMPRESSOR INSTALLATION & START-UP GUIDE REVISION M

Chapter - 12. Compressor Piping

1. To avoid abnormal vibration and noise pay close attention to how the compressor is piped.
2. When soldering copper pipe or bushings to the compressor, a 15% silver solder should be used. Once all piping is
completed, perform a pressure test to ensure there are no leaks (maximum compressor pressure 350 psi or 24 bar). The
cleanliness of the system should be checked after pipe welding to help avoid any debris operating inside the system
that can cause compressor damage during operation. Nitrogen must be used to purge the refrigerant or oil lines when
any solder is being done.
3. To avoid compressor harmonic vibration transferred by the structure and piping to the chiller while in operation, a cushion
or shock absorber should be installed on the suction and discharge tube.
4. Refer to Figure 8-A showing a 6mm to 15mm.
5. Rubber pads are installed under the compressor-mounting feet to help isolate the vibration and noise transferred from
other portions of the system.

Anti-Vibration Rubber Fixed Bolt Compressor mounting pad

(6-15mm)

Figure 8-A Absorber Installation

6. In order to reduce vibration, copper tubes for suction and discharge pipes are recommended; copper suction and discharge
pipes will minimize the vibration from the piping while the compressor is running. In the case of steel piping, it is very
important for suitable welding to avoid the inner stress on piping due to harmonic vibration and noise, which will reduce
the compressor life.
7. Remove oxidized impurities, swarf or debris caused by welding on piping tubes, if these impurities, swarf or debris are
in the compressor, the oil filter will be clogged resulting in the lubrication system bearings and capacity control system
malfunctioning.
8. The suction and discharge bushings are forged steel that can be welded directly with piping connectors (standard size
for copper piping, if connecting to steel piping contact your Hanbell representative) After welding the flanges and pipes,
they should be cooled down by ambient air.
9. Water dousing is prohibited. Do not use water to cool down the pipes and flanges after welding.

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COMPRESSOR INSTALLATION & START-UP GUIDE REVISION M

Chapter - 13. Pre-Start-Up Procedure

1. Oil Charging: Only lubricants listed in Hanbell’s Technical Manual are to be used. NO SUBSTITUTES. Make sure the
oil level is to the middle of the high side sight glass, which is the terminal box side of the compressor. (For compressors
with internal oil separators)
2. Oil Heater: The heater needs to be energized for 24 hours prior to running the compressor and energized when the
compressor is off.
3. Make sure all valves are open (stop, angle valves with transducers, etc.)
4. Make sure all solenoids are wired correctly.
5. Make sure the motor module (INT69HBY) is wired correctly.
6. Make sure the electrical system is wired correctly and properly grounded.
7. Verify the controller is wired correctly. (Dry run)

Lubricant Charge
Oil Needed
Model #
(In Gallons)
RC2-100 1.9
RC2-140 1.9
RC2-170 1.9
RC2-180 1.9
RC2-200 2.1
RC2-230 3.7
RC2-260 3.7
RC2-300 4.2
RC2-310 4.2
RC2-320 4.2
RC2-340 4.2
RC2-370 4.2
RC2-410 4.0
RC2-470 4.8
RC2-510 5.3
RC2-550 6.1
RC2-580 5.3
RC2-610 6.1
RC2-620 6.1
RC2-710 7.4
RC2-790 7.4
RC2-830 7.4
RC2-930 7.4
RC2-1090 N/A
RC2-1280 N/A
RC2-1520 N/A
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COMPRESSOR INSTALLATION & START-UP GUIDE REVISION M

13.1. Oil Types

Note: For other applicable oil types, please consult with MCS / HANBELL first for approval
TOTAL SUN CPI CPI MOBIL
SPECIFICATION UNITS LUNARIA SUNISO SOLESI CP-4214 SHC
56 68 4GS 5GS 170 100 150 320 68 120 220

COLOR, ASTM 1.5 L1.2.0 LI.0 L1.0 - - - - L0.5 L.05 L0.5

SPECIFIC GRAVITY 0.883 0.883 0.914 0.925 0.95 0.96 1.01 1.05 0.834 0.838 0.846

400C 56.0 68.0 54.5 96.5 175 123 168 293 68 95 209
mm2 / s
VISCOSIT (cSt)
100C 7.0 7.8 6.07 8.12 16.5 14.2 20.2 32.0 10.0 13.7 25.0

FLASH POINT 0
C 220 230 188 198 265 292 290 271 250 255 260

POUR POINT 0
C -40 -35 -35 -25 -30 -35 -43 -35 -45 -45 -39

T.A.N MgKOH/g 0.01 0.01 0.00 0.01 - - - - - - -

COPPER STRIP 1000C/3hr 1a 1a 1a 1a - - - - - - -

MOISTURE ppm 15 15 20 20 - - - - - - -

FLOC POINT 0
C -75 -75 -45 -35 - - - - - - -

DIELETRIC STRENGTH
KV 75 70 50 50 46.6 - - - - - -
2.5mm

Applicable oil types (R134a, R404A, R407C)

CPI MOBIL ICI
SOLEST EAL EMKARATE
UNITS
68 120 220 370 68 100 RL411 RL375 RL421

COLOR, ASTM - - - - 0.5 0.5 1.5 L2.0 L1.0

SPECIFIC GRAVITY 0.945 0.94 0.95 0.955 0.971 0.966 0.9723 0.9783 0.9759

400C 64 131 215.9 385.96 62.5 95.8 48.0 74.1 134

mm2 / s
(cSt)
VISCOSIT 100C 8.9 14.53 20.8 29.23 8.3 10.5 7.3 10.1 15.0

FLASH POINT 0
C 266 254 271 302 254 260 273 246 265

POUR POINT 0
C -43 -36.5 -25 -21 -43 -37 -40 -35 -37

T.A.N MgKOH/g - - - - - <0.05 <0.05 <0.05

COPPER STRIP 1000C/3hr - - - - - - - -

MOISTURE ppm - - - <100 <100 - - -

FLOC POINT 0
C - - - - - - - -
DIELETRIC STRENGTH
KV - - - - - - - -
2.5mm
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COMPRESSOR INSTALLATION & START-UP GUIDE REVISION M

Do not start the compressor without first reviewing the Start-up section of this document.
Standing at the suction end of the compressor the motor rotates counter clockwise.

IMPORTANT
NOTE: RC2-AF, RC2-BF, and LA Series Compressors do not have
an Oil Separator or Sump

These compressors do not hold oil and therefore have no oil filter, oil level switch, or heater. Therefore you must have an
external oil separator with an oil sump and oil level float. Also, on the return line from the oil sump to the compressor you must
have an oil filter and oil flow switch. Please follow the piping diagram below. Please ensure there is oil charged in the piping
feeding the compressor to avoid a dry start-up.

13.2. HANBELL FLOODED TYPE WITH OIL SEPARATOR

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COMPRESSOR INSTALLATION & START-UP GUIDE REVISION M

13.3. HANBELL FLOODED TYPE WITH OIL SEPARATOR & OIL COOLER

To obtain high oil filtering efficiency low pressure drop loss and non-interruption with lubricant supply system, the oil separator is
built outside the compressor. The installation of lubricant circuit is a very important issue during the whole procedures. So,
before starting, please make sure to read all the instructions of this manual carefully and ensure each step is done in
accordance with the specifications.

Illustration of RCF compressor and its external oil separator and accessories recommendation

1.External oil separator 7. Oil level switch

2. Oil cooler 8. Oil temperature sensor
3. Oil filter and cartridge 9. Oil heater
4. Lubricant flow switch 10. Manually adjustable flow valve
5. Oil solenoid valve 11. Compressor
6. Sight glass

In the lubricant circuit, installing the oil solenoid valve in the proper place is very important. As the compressor is shut down,
lubricant will automatically inject into the compressor due to pressure differential. It will easily make the system difficult to
restart because of low oil level or lubricant injection inside the compressor chamber.

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COMPRESSOR INSTALLATION & START-UP GUIDE REVISION M

Chapter - 14. Start-up Procedure

• Check using a rotation testing instrument, checking the rotation by starting the compressor can and will cause
damage to the compressor.

• Compressor rotation is counterclockwise CCW. (Reverse rotation is not covered by warranty).

IMPORTANT
• Before stating the compressor, the rotation must be correct. This can be achieved with the use of a Phase
rotation meter ( FLUKE-9040, or IDEAL® 61-520 are examples of this type of meter).

• Checking the rotation by starting the compressors and watching the suction and discharge is not the correct
way to test rotation.

• Proper rotation is critical. If the compressor is operated in reverse, severe damage may occur.

• Recheck oil level. The oil level should be to the middle of the high side sight glass.

• Hanbell recommends suction superheat 10°F to 20°F, discharge superheat 30°F and a pressure differential of
at least 70 psig.

14.1. These Safeties ARE Required at Startup to Maintain Hanbell Warranty

a) Motor Module Trip (INT69HBY): Open for 1 second

b) Low Oil Level Float Trip: Open for 60 seconds +30 seconds extension
IMPORTANT
c) Unsafe Suction: Less than 5 psi for 3 seconds +25 seconds extension
d) High Discharge Temperature: Greater than 230°F for 2 seconds
e) Low Differential Pressure: Less than 65 psi for 60 seconds (Oil-Suction) +60 seconds extension
f ) Unsafe Differential Pressure: Less than 35 psi for 5 seconds (Oil-Suction) +25 seconds extension
g) Dirty Filter (Discharge Pressure - Oil Pressure): Greater than 20 psi for 60 seconds
h) Low Discharge Superheat: Less than 20°F for 300 seconds

+ Indicates allowable time extension added to the trip delay during the first 5 minutes of
compressor operation while starting.

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COMPRESSOR INSTALLATION & START-UP GUIDE REVISION M

Chapter - 15. Hanbell with VFD

15.1. Wiring & Controls Set Up

• For a new installation, DO NOT CONNECT the L1, L2, and L3 Red, White and Blue wires to the INT69HBY
motor module.
• For an existing installed compressor REMOVE the red, white and Blue wires from the INT69HBY motor
module.
• Place the amp sensor(s) on the line side of the VFD.
• Select only a constant torque VFD type to use.
• Set for no Direct Current (DC) braking
• Set Acceleration Time to 3-5 second

15.2. Compressor Set Up

• Remove the 50% load solenoid coil (50% is no longer used).
• The 25% load solenoid is used as the Fast Unload.
• Remove the Load solenoid stem and install a Load Cap in its place.

Final Configuration

50%

75%

LOAD
25%

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COMPRESSOR INSTALLATION & START-UP GUIDE REVISION M

15.3. Solenoids

15.3.1 Solenoid Identification (Normally Open / Normally Closed)

NORMALLY OPEN SOLENOID NORMALLY CLOSED SOLENOID

CAN BE IDENTIFIED BY NOTCHES ON NUT THERE ARE NO NOTCHES ON THE NUT

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COMPRESSOR INSTALLATION & START-UP GUIDE REVISION M

15.3.2 Infinite Capacity (Stepless) Minimum (50-100%)

UNLOAD

LOAD

START UNLOAD

1. For new continuous (step-less) capacity control system, Hanbell equipped all solenoid valves a Normally Closed.
If it is necessary to be equipped with other type solenoid valve, please specify it with MCS / Hanbell before order
confirmation.
Verify compressor load solenoid as Normally Open or Normally Closed.
2. If normally Open Solenoid, wire through the Normally Closed Relay Output.
3. If normally Closed Solenoid, wire through Normally Open Relay Output.

UNLOAD (NC) LOAD (NC) STRT UNLD (NC)

Start Energize Not energize Energize
Loading Not energize Energize Not energize
Unloading Energize Not energize Not energize
Stable Not energize Not energize Not energize

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COMPRESSOR INSTALLATION & START-UP GUIDE REVISION M

15.3.3 Step Load 50%, 75%, 100%

50%

75%

(Blank Off Cap)

25%
LOAD
(Load Cap)

15.3.4 Step Load 25% 50%, 75% & 100% (Only 25% at Start-Up and Shut-Down)

50%

75%

Please see APP Note 76 for Step Loading Instruction Kit

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COMPRESSOR INSTALLATION & START-UP GUIDE REVISION M

15.3.5 Solenoid Alignment

IMPORTANT
SOLENOID ALIGNMENT IS CRITICAL TO PROPER FUNCTIONING OF COMPRESSOR

WHEN INSTALLING SOLENOIDS ON THE WHEN INSTALLING A LOAD CAP, MAKE SURE
COMPRESSOR, ENSURE THAT THE HOLES THAT THE CIRCULAR HOLE IN THE GASKET
MATCH FOR PROPER OIL FLOW TO OCCUR. COVERS BOTH OF THE COMPRESSOR OIL
FLOW HOLES.

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COMPRESSOR INSTALLATION & START-UP GUIDE REVISION M

ALSO MAKE SURE HOLES LINE UP IF INSTALLING ORIFICE PLATE

(FOR COMPRESSORS MANUFACTURED BEFORE APRIL 2013)

NOT ALL OIL FLOW HOLES ARE ORIENTED THE SAME WAY. BE SURE TO DOUBLE CHECK
THAT THE SOLENOID HOLES LINE UP PROPERLY AS SHOWN BELOW.

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COMPRESSOR INSTALLATION & START-UP GUIDE REVISION M

PROPER INSTALLATION OF A SOLENOID PROPER INSTALLATION OF A SOLENOID

WITH ORIFICE PLATE WITHOUT ORIFICE PLATE

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COMPRESSOR INSTALLATION & START-UP GUIDE REVISION M

ATTENTION
ORIFICE PLATES WERE REPLACED BY ORIFICE PLUGS IN COMPRESSORS
MANUFACTURED AFTER APRIL 2013

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COMPRESSOR INSTALLATION & START-UP GUIDE REVISION M

Chapter - 16. Slide Amp Calculation

16.1. Slide Amp Calculation through MCS-Connect

MCS Controls with a Hanbell Infinite Control (stepless) compressor, you need to 07-23-2021
Revision follow these
steps when commissioning the compressor to ensure correct operation.

General Concept
Not all compressors will run exactly at the full load amperage rating that the manufacturer provides. Likely
it will be very close, but some fine tuning of the configuration will enable the operator to maximize efficiency
and control of the unit. This manual is designed to walk you through the steps of adjusting your slide amp
calculation through MCS-Connect for optimum performance of your system.

1. Setting the Upper Limit

a. Use MCS-Connect to link with the Magnum control
board and get authorized at Supervisor or Factory
level.
b. While the compressor is running near design
conditions, turn the UNLOAD relay manually OFF,
and the LOAD relay manually ON.
c. Wait until the compressor is fully loaded. Then
check the value in the FLA% in the circuit grid for
that compressor.

• If the FLA% is 101 or above, then increase the slide offset.

• If the FLA% is 97 or below, decrease the slide offset.

d. To access the slide offset you must first have the proper
authorization level to make changes to the unit. Double-click
on the relay for the compressor you are tuning (in this example
COMP is the name of the relay output).
e. A window will pop up (as shown on right) with the slide amp
calculation. Increase or decrease the “Slide Offset” value and
press the OK button to accept the changes.
f. Check the FLA% value again. It should say 99 or 100. If not,
then repeat steps C and D again until you reach a value of 99 or
100.

98
2
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COMPRESSOR INSTALLATION & START-UP GUIDE REVISION M
Revision 07-23-2021

2. Setting the Lower Limit

Now that you have finished calibrating the upper FLA% you may now work on setting the minimum FLA% limit.

a. Begin by turning the LOAD relay manually OFF, and

UNLOAD relay manually ON.

b. Wait until the compressor is fully unloaded and then

check the FLA% value in the circuit grid.

c. Take this number, double click on the “Value” column for setpoint #31 “MIN FLA %” and set this number
as the new value.
(Note: if you have multiple compressors you should use an average of their fully unloaded values).

Set new value here

for MIN FLA%
CLICK SEND CHANGE

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COMPRESSOR INSTALLATION & START-UP GUIDE REVISION M

Chapter - 17. Compressor Warranty Information

Rev. - 07-21-2021
Supersedes previous version:

Compressor Warranty Information and

Suggested Guidelines for Preventive Maintenance

All HANBELL screw compressors are put through strict quality and performance testing prior to shipping from
the factory.
Provided that terms of payment are observed, a two-year (24 month) Manufacturer’s Warranty against factory
defects is offered from the date of installation or 27 months from date of shipment; whichever occurs earlier.
The following procedures and safeguards must be followed for the Warranty to be validated:
• The Warranty Start-up/Status Report Form must be completed and returned for each compressor purchased at the
time of startup.
• An Oil Sample Report must be submitted to and approved by MCS after initial break-in period for each compressor
purchased. Preferably around 72 hours of run time, but no less than 4 hours.
• The compressor must be equipped with an Over/Under Voltage Phase Protection Device.
HANBELL compressors sold by MCS, which are controlled by an MCS micro controller with software and
configuration written and tested by MCS, shall be covered under a three-year (36 months) warranty agreement
on the compressor only.
MCS may, at its option, repair or replace defective items that are under warranty. Repair or replacement
of a warrantied compressor does NOT reset the warranty date; however, the Factory Warranty will
remain in effect for the remaining period of time.
1.1. Maintenance
The technicians should be familiar with the Hanbell compressor before attempting any maintenance on the unit.
Periodical checks and regular maintenance are very important for the long-term and trouble-free compressor
life and for maintaining the warranty. The content here is to help the operator and service people to know how
the regular maintenance can be done and when a suitable time is for each item. Operators and service people
should follow the instructions on these pages when working on the maintenance.
Besides the regular maintenance, Technicians should check the system’s working status by noting down its
working parameters on a set schedule. Most of the time abnormal system conditions can be found via comparing
its working parameters with its daily operating data.
„ Compressor unit should be stopped before doing the maintenance work.
„ Disconnect power from unit before doing the maintenance work.
„ Close all the isolation valves before doing the maintenance work.
„ Wear safety equipment when doing the maintenance work.
„ Ensure adequate ventilation before doing the maintenance work.
„ Take safety precautions for the refrigerant used and work with care.

1.2. Short Term Maintenance

During commissioning period or after a few hundred hours of compressor run time, the following checks and
replacement shall be done in order to protect the compressor and understand the compressor’s working status.

www.mcscontrols.com
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COMPRESSOR INSTALLATION & START-UP GUIDE REVISION M

Hanbell Maintenance

1.2.1 Suction Strainer

The Suction strainer plays a very important role to long-term compressor life. In the initial commissioning, debris
and welding slag might find its way to the compressor’s suction side. With the help of the suction strainer, debris
will be gathered inside the strainer to protect the compressor from rotor damage. Technicians should check the
suction strainer at the end of commissioning and after 200 hours of initial running. Any dirt and unwanted
material should be removed during this check. Wash the strainer basket in solvent and blow clean with air.

1.2.2 Oil Analysis

At the end of commission or after 200 hours of initial running, oil analysis is mandatory and must be
executed at the jobsite. The purpose of doing oil analysis is to understand the compressor’s working
environment and ensure the oil quality. If moisture contamination exists in the system, this will lead to changing
of the oil quality and cause poor lubrication for internal moving parts which can cause severe damage to the
compressor in the future. Technicians should replace the oil immediately to protect the internal moving parts
with good lubrication and recheck the oil again after 200 hours operation. If the oil analysis shows the oil is
in good condition, recheck the oil every 6 months to ensure the condition remains safe.
In the case of being unable to do the oil analysis periodically, consult Hanbell oil change schedule because
the interval of oil change varies by the oil type and compressor operating condition.
Check the oil acidity periodically and change the oil if the oil acidity value measures lower than pH6.

1.3. Long Term Maintenance

The information below is focusing on standard long term maintenance. Technicians should understand that
these items are not assumed to take over all the necessary routine checks. Daily check for operation conditions
is also very important to have a stable operating system.
Please refer to the recommended maintenance schedule found on the following pages. This schedule is only
for the technician’s reference and should be considered as the minimum guideline to maintain the system’s
normal operation. Technicians still can do any examination by their own that will ensure a stable system
operation. In case of any irregular situation or abnormal condition that takes place in the compressor
system. Technicians should stop the compressor and contact the contractor who installed the unit.

1.3.1 Piston Sealing

The Piston is also recommended to be inspected every year to ensure the function of capacity control.
If abnormal wearing is found, the corresponding part should be replaced by a new one. Prior to replacing, the
technicians should do an inspection and determine what is causing the wearing problem.

1.3.2 Vibration Analysis

Vibration analysis can help to detect bearing wear and other mechanical failures. A certified Hanbell Technician
should perform this check.

Overhaul Review
Overhaul review is recommended to be done at least every 3 years. It is the best time to review the internal parts
and replace all wearing parts for the following long-term operation. A certified Hanbell Technician should
perform this review.

Supersedes all other warranties

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COMPRESSOR INSTALLATION & START-UP GUIDE REVISION M

Chapter - 18. Handling POE Oils

Please read as improper handling can cause compressor

failure and void the compressor warranty.

POE oils are very hygroscopic compared to mineral oils, so exposing POE oils to air will
result in their absorbing moisture quicker than mineral oils. When POE oils are exposed to
moisture and heat in a refrigeration system, they will react forming acid that is harmful to the
system.

As a result, it is imperative that contractors keep containers of POE oils sealed, except when
the oils are actually being dispensed. POE oils should also be stored properly in their original
container because many plastics used to package oils are permeable to moisture. It is also
important to keep compressors and systems closed, except when work is actually being done
on the equipment, and to filter out undesirable contaminants. This can be achieved with
proper installation and service techniques as well as the use of correct filters and driers.

Once moisture is in the oil it is extremely difficult to remove, even under a high vacuum it
can take many hours to reduce the level of moisture. Several filter drier changes should be
planned when replacing a compressor. Often an oil change and filter driers are required to
correct the problem.

Oil should be sampled every six months and sent to an oil testing lab.

High moisture and acid levels will cause coppering in the slide chamber and will cause
premature slide failure. In extreme cases copper will be deposited on the compressor screws
and cause high noise levels and compressor failure. High acid levels will also cause
compressor motor failure (Failure due to of lack of maintenance is not covered under warranty).

Any questions or concerns please contact [email protected]

or call 239-694-0089 and ask to speak to a sales person

www.mcscontrols.com

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COMPRESSOR INSTALLATION & START-UP GUIDE REVISION M

Chapter - 19. Hanbell Maintenance Forms

Hanbell Maintenance

Company ________________________________________________________________________________________________
Technician _______________________________________________ Phone _____________________________________________
Site Information
Installation Site Name ___________________________________________________________________________________
Unit Information - USE A SEPARATE SHEET FOR EACH COMPRESSOR

Model Number Serial Number Type Oil Used

Unit

Factory recommends that the oil filter cartridge should be checked and cleaned at 24 hours after startup.
Then checked or replaced at 10,000 hours then every 10,000 of run time.
It is important that the oil filter cartridge is not clogged; it might result in the malfunction of the lubrication systems,
bearings and capacity control system.

Recommended Maintenance Schedule

Check Point Running Period
24 1000 2500 5000 10000 15000 20000 25000 30000
hrs. hrs. hrs. hrs. hrs. hrs. hrs. hrs. hrs.
Motor Insulation 0 0 0
Oil Filter Cartridge 0 0 0 0
Suction Filter 0 0
Piston Rings 0 0 0 0 0 0/
Oil Level 0 0 0 0 0 0 0 0 0
Oil Change 0 0   
Discharge PTC 0 0 0 0 0 0
Bearings 0 0 0/
0 Check or Clean, Replace
Note:
This is an estimated schedule to keep the compressor running at its highest efficiency and avoid compressor breakdown, not a basis
for any claim. The appropriate running period for each checkpoint will be vary from working conditions, applications, control logics,
refrigerant, lubricant, etc. Please contact Hanbell or local distributors/agents for more details.
Replacement of piston rings and bearings should be performed by HANBELL authorized technicians.
Every 5000hrs, please ensure the chiller unit keeps its target temperature when discharge superheat is between 10°C and
20°C; Please check vibration level of bearings in compressor every 10000hrs.
Oil Change; use only Hanbell authorized HBR lubricant and do not mix difference brands of the oil together. Oil remaining in the
compressor and system should be totally evacuated prior to changing the oil. It may be necessary to change the compressor oil a
second time to ensure that there is no oil mix.
It is critical to change the oil after a motor burned out because acid and debris may still remain inside the system. Check acidity of the
oil after several hours of operation and continue to perform periodic oil / filter-dryer changes until acidity drops to an acceptable level.
If the burn out is severe, a suction-line filter/dryer and an oversized liquid-line drier should be installed. The filters should be monitored
and replaced if a pressure drop across them is observed. Filters should be replaced until acidity drops to an acceptable level at which
time the suction-line filter can be removed.
Weekly Preventive Maintenance Perform weekly preventive maintenance
Check compressor suction pressure
Check oil level and color
Check compressor discharge pressure
Check the operation of oil heater and solenoid coil
Check entering water temperature
Monthly Preventive Maintenance Check leaving water temperature
Measure ambient temperature
Check compressor amp.

39
 1) FILL OUT THE FORM
Warranty Start Up / Status Report 2) PRINT TO PDF (Creates a file on your desktop or other)
Upon startup, please complete the form with as much detail as possible
3) EMAIL FILE TO [email protected]

Date __________________________ Sales Order # ____________________________

Company ____________________________________________________ Address _____________________________________________________________________________

Name ____________________________________________ Phone _____________________ Mobile ________________________ Email _____________________________________

Installation Site Name __________________________________________________ Manufacturer _________________________ Evaporator Type FLOODED DX AIR COIL
Example: ABC Elementary School Example: Trane CVHE32, York YT

COMP #1: Model # _________________________Serial # _________________________ COMP #1 COMP #2

COMP #2: Model # ________________________ Serial # ________________________ Suction / Oil PSI Differential

Motor Temp
COMP #1 COMP #2
Ambient Temp
19.1. Hanbell Warranty Startup Form

Refrigerant Type
Amps L1
Type of Oil
COMPRESSOR INSTALLATION & START-UP GUIDE

Amps L2
Run Hours

40
Amps L3
Suction Pressure
Volts L1 to L2 (running)
A fillable form is available on our website, download and fill out:

A Saturated Suction Temp

Volts L2 to L3 (running)
Discharge Pressure
Volts L3 to L1 (running)
B Saturated Discharge Temp
H Condenser Sat Temp
Oil Filter PSI
Evaporator Sat Temp
C Suction Line Temp
Evaporator Approach Temp ( F - A =)
D Discharge Line Temp
Sub Cooling Temp (H - E =)
E Liquid Line Temp
Suction Superheat Temp (C - A =)
Evaporator In Temp
Discharge Superheat Temp (D - B =)
F Evaporator Out Temp
https://mcscontrols.com/Documents/Hanbell/Other/Hanbell%20Warranty%20Startup%20Form.pdf

Condenser Approach Temp (H - G =)

Condenser In Temp
Remarks:
G Condenser Out Temp

Oil Sump Temp

REVISION M