Name: J&E Hall HallScrew HSO 2000 Series
Brand: J&E Hall
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HallScrew HSO 2000 Series

Open Drive Single Screw Compressors

HSO 2024, HSO 2028, HSO 2031 and HSO 2035

Manufactured after 06/03

Installation, Operation and

Maintenance Manual

Safety3
Personnel Permitted to Install, Commission and Maintain the Plant3
Mechanical3
Examination of Pressure Systems4
Noise Hazard4
Electrical4
Lubricating Oils5
Ammonia Refrigerant 7175
Hydrochlorofluorocarbon and Hydrofluorocarbon Refrigerants6
Table of Contents7
Contentslist of Figures7
List of Figures9
List of Tables9
About this Publication10
Safety Warnings and Symbols10
Units of Measurement10
Terminology10
Ordering Extra Copies10
Misuses that Invalidate Guarantee11
Application11
System Provisions11
Prolonged Storage12
Commissioning Provisions12
General Description13
Main Features13
Construction13
The Compression Process14
The Compression Process16
Suction16
List of Figures Fig 1 Compression Process16
Compression17
Discharge17
Capacity Control and Volume Ratio18
Fig 2 Capacity Control Slide Valve in Operation18
Slide Valve Actuation19
Minimum Load Interlock19
Capacity Control Solenoid Valve Arrangements20
Capacity Control Arrangement Using Separate Pairs of Solenoid Valves20
Compressor Loading20
Compressor Unloading20
Hold Slide Valve Position20
Table 1 Capacity Control Solenoid Valve Options20
Flow Control Valves21
Fig 3 Capacity Control Arrangement Using Separate Pairs of Solenoid Valves22
Capacity Control Arrangement Using a 4-Way Solenoid Valve23
Compressor Loading23
Compressor Unloading23
Hold Slide Valve Position23
Flow Control Valves23
Fig 4 Capacity Control Arrangement Using a 4-Way Solenoid Valve24
Capacity Control by Inverter Drive25
Inverter Size25
Inverter Set-Up25
Linear Variable Displacement Transducer (LVDT)26
HB Linear Variable Displacement Transducer (HBLVDT)26
To 20 Ma Calibration - Compressor Stopped26
To 20 Ma Calibration - Compressor Running27
Fig 5 HBLVDT Arrangement and External Wiring Connections27
Fig 6 HBLVDT External Wiring Connections for Explosion-Proof Version28
Fitting a New HBLVDT Electronics Module29
MSI Linear Variable Displacement Transducer (MSI LVDT)30
Fig 7 MSI LVDT Arrangement and Wiring Connections30
Fig 8 Signal Conditioning Module31
Table 2 MSI LVDT/HBLVDT Part Number Cross-Reference31
Compressor Lubrication, Sealing and Cooling32
Capacity Control Actuation32
Bearing Lubrication32
Shaft Seal Lubrication, Sealing and Cooling32
Oil Injection for Sealing and Cooling32
Oil Support System34
Oil Injection/Lubrication34
Oil Drain34
Oil Drain Sensor34
Oil Separation35
Oil Separator Design35
Oil Separator Provisions35
Oil Return36
Suction/Discharge Non-Return Valve36
Oil Heaters36
Oil Low Level36
Oil Balance Lines36
Oil Circulation37
Oil Differential Pressure Monitoring37
Table 3 Pumping Capacities for Continuously Running Oil Pump37
Oil Differential Pressure 1 (ODP1)38
Table 4 Summary of Differential Pressure Sensing38
Oil Flow Switch39
Oil Differential Pressure 2 (ODP2)39
Oil System Differential Pressure Drop39
Maintaining Discharge Pressure at Start up39
Oil Filter40
Compressor Cooling40
Fig 9 Maintaining Discharge Pressure at Start up40
Lubricating Oils41
Prolonged Storage42
Placing the Compressor into Store42
Taking the Compressor out of Storage43
Installing the Compressor44
Lifting the Compressor44
Making Connections44
Fig 10 Lifting the Compressor44
Electrical Wiring Connections and Interlocks45
Commissioning and Operation46
Checks Prior to the First Start46
General Checks46
Compressor Drive Motor47
Checking Compressor Rotation47
Lubrication System48
First Start48
Normal Starting and Running50
Adding Oil to the System51
Running-In the Compressor52
Filters and Strainers52
Compressor Suction Strainer52
Oil Filter52
Refrigerant Filter/Drier52
Monitoring for Moisture52
Lubricating Oil52
Checking for Leaks53
Compressor Drive Motor Coupling53
Compressor and Drive Motor Holding-Down Bolts53
Pumping down and Opening up the Compressor54
Preparing for Pump down54
Pumping down the Compressor54
Isolating the Electrical Supply54
Removing the Residual Refrigerant Gas55
Opening up the Compressor55
Re-Instating the Compressor55
Maintenance57
Spare Parts57
Filters and Strainers57
Running-In58
Maintenance Schedule58
Maintenance Intervals58
Daily58
Table 5 Filter and Strainer Locations58
Weekly59
Monthly59
Every Year, or at Intervals of 5,000 Operating Hours60
Every 3 Years, or at Intervals of 15,000 Operating Hours61
Every 6 Years, or at Intervals of 25,000 Operating Hours61
Every 12 Years, or at Intervals of 50,000 Operating Hours61
Every 24 Years, or at Intervals of 100,000 Operating Hours62
Prolonged Shutdown62
Maintenance Check List62
Table 6 Maintenance Check List63
Oil Acid Content Record64
Table 7 Oil Acid Content Record - Plants Charged with Refrigerant Other than Ammonia (R717)64
Appendix 1 Compressor Data65
Appendix 2 Oil Support System Schematic Flow Diagrams73
Fig 11 Key to Schematic Flow Diagrams73
Fig 12 no Oil Pump74
Fig 13 Start-Up Oil Pump: Common Oil Lines for Injection and Lubrication75
Fig 14 Continuously Running or Demand Oil Pump: Common Oil Lines for Injection and Lubrication76
Appendix 3 Limits of Operation Envelopes77
Appendix 4 HS 2000 Series Compressor Replacement Parts82
Appendix 5 Plant Performance Record86
Appendix 6 Pepperl & Fuchs Signal Conditioning Module KFU8-USC-1.D Set-Up88
Table 8 Basic Set up for 4 Ma and 20 Ma Output Values at Minimum and Maximum Slide Valve Positions89
Table 9 Setting the Display to Read 0 at Minimum Load and 100 at Maximum Load91
Table 10 Setting the Relay Switch Value92

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J&E Hall HallScrew HSO 2000 Series Specifications

General

Type	Screw compressor
Refrigerant	R134a, R404A, R507, R22, R717
Control System	Microprocessor
Capacity Control	Slide valve control
Cooling Method	Oil cooled

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