We have done this technical data guide to enable you to choose between our standard solutions and optionals.
The guide is divided in four nominal evaporation temperatures of -12ºC, -20ºC, -30ºC and -40ºC ranges.
Each one is a separated guide to make easier to work with them.
Ask for it!
Technical Guide for Screw Compressor Packages easy definition HW -30
1.
2. INDEX
GENERAL CHARACTERISTICS
3
Motor compressor unit
3
Identification code of the unit.
4
Description of the components
5
Mechanical elements as optionals
9
Electrical elements as options
TECHNICAL DATA AND PERFORMANCE OF THE UNIT
12
Technical data of the standard unit
12
Performance of the unit with nominal Vi
14
Performance of the unit with nominal Vi and fitted with condensing high pressure (apc) as
optional
25
How to select the motor size
36
Sound levels
48
Auxiliary data charts
50
OPERATING AREA
52
HOW TO SELECT A UNIT
53
Example nº 1 of how to select a unit
53
Example nº 2 of how to select a unit
54
DIMENSIONS AND CONNECTION POINTS
57
2
3. GENERAL CHARACTERISTICS
Motor compressor unit.
The new version of motor compressors groups has been designed in order to meet the requirements of the medium-high
power of the industrial refrigeration installations.
These motor compressors groups use NH3 as refrigerant, which is high energetically efficient and environmentally
friendly. They can be installed inside the rooms (machine room).
The products range is divided in thirteen sizes with a nominal refrigeration power range from 140 to 1010 kW. The
units are fitted with the standard equipment with the possibility of adding a wide range of option items, which allows us
to adapt our products to the requirements of the different designs of installations.
Each unit is fitted with the following standard equipment: a screw compressor WRV; an electric motor IP23; an
horizontal oil separator; a discharge line fitted with manual valve and check valve; a suction line fitted with filter, a
manual valve and a check valve; an oil circuit fitted with an oil pump and an oil cooler by thermosyphon. These main
elements will be delivered together with an oil charge.
The superfeed system is a very important option, because it increases considerably the efficiency of the unit energy.
All our units are factory aligned and with the oil circuits previously tested, in order to allow a quick and safe
installation.
Identification code of the unit.
Find below the description of the nomenclature, made of a sequence of alphanumeric characters that is used to identify
the groups and their option items.
GMT HW 320 -30 s mcv eaw cc dcc pam apc tra
Other options
Group type
GMT HW -30 Motor compressor
group WRV, nominal evaporating
temperature -30 ºC
Units sizes :
140,170,210,290,320,360,420,480,
570,630,710,1010
Options for control panel-board
cc : control panel-board with Twido
ccs : control panel-board with ET200
ccs+: control panel-board with S7-300
Options for oil cooler
eaw : cooling oil by water
eai : cooling oil by injected NH3
Superfeed option
s : NH3 superfeed
scr : NH3 superfeed, + regulation valve.
Options for motor
mcv : motor, activated by a variable speed drive up to 3000 rpm.
m+ : oversized motor.
__hz: motor, activated by a variable frequency drive > 50 hz
3
4. Description of components.
1.- Compressor. It is an oil flooded type, rotary and positive-displacement machine, fitted with a capacity control of
10 100%. The compression process is made by a housing and a gearing set, which consists on two helicoidal type
rotors (a four lobes male rotor and a six holes female rotor). This gearing set allows the gas to go from a suction door to
a reducer size discharge door.
There
are
three
types
of
compressors:1) WRV type, which
is available in six different sizes
and each one has got an Vi rate or a
set volumetric rate.2) WRVi type
which is available in six different
sizes whose Vi volumetric rate can
be easily modified between 2,2
5,0, by changing the size of the
compressor discharge outlet. 3)
The WRVH type is applied to the
previously
mentioned
twelve
models. It can work with pressures
up to 24 bars and will be used for
working
at
condensing
temperatures over 45 ºC.
2.- Electric motor. It is a
triphasic, low voltage machine,
fitted with: a squirrel-cage rotor, an
internal refrigeration system 400 V, 50 Hz, a class B insulation, an IP23 protection device according to the standard EN
60034 - Part V, construction shape according DIN IEC 34, IM B3, an IP55 protection device of the terminal box.
3.- Oil separator. It is a receiver, built according to category IV, design pressure of 21 bar, according to the pressure
equipment directive PED 97/23/CE. It meets two important functions: the first and most important one is to separate
oil from the discharge gas. It makes it in two steps:
Step 1: Via a primary separator, that allows achieving an efficiency level up to 50 ppm.
Step 2: Via a secondary separator, which uses coalescent filters that allows achieving an efficiency level up to 5 ppm.
The oil separator performs the second function of being the metallic structure on which is support the GMT unit. This
structure consists on two legs and both metallic supports corresponding to the motor and the compressor.
The separator is fitted with two sight-glasses located on its primary area and one sight-glass located on its secondary
area. It is also equipped with two oil heating resistors and the oil charge. On one of its side, there is a removable cap to
replace the coalescent filters when they lose separation efficiency
4.- Oil circuit. It is necessary to check the good quality of the oil in order to ensure the correct operation of the
compressor. The oil shall be clean and with the proper temperature so that it will get the required viscosity (when
entering the compressor) to perform correctly the functions of injection, lubrication and control capacity.
Main components:
4
5. 4.1.- Suction line of the oil pump. It consists on a valve and a filter fitted with grid of 100 for the
factory-test and another filter of 500
for its shipment.
4.2.- Oil motor pump. It is a gear
pump, formed by a rotor, an idler gear
and a half moon which has been fixed
inside its housing. Thus, there are only
two moving parts inside the oil motor
pump. Since the rotor is in gear with the
idler gear, the power applied to the
rotor is transmitted to the idler gear.
This pump has been designed taking
into account the requirements of the
compressors used in the refrigeration
area.
4.3.- Discharge line of the oil
pump. Connect the discharge line of
the oil pump to the oil cooler. The
discharge line is fitted with a stop valve.
4.4.- Oil bypass line. Its function is
to return to the separator, the excess of
oil flow that has been pumped by the oil pump. This excess is determined by keeping a pressure differential of
2,8 bars between the oil manifold pressure and the oil separator pressure. This line is fitted with a stop valve
and a regulating differential valve.
4.5.- Oil cooler. These coolers are specially designed for maritime and industrial refrigeration of oil. An oil
cooler is cooled by liquid NH3. It uses the thermosyphon system and operates with tubes bundle. It has a
compact design and is very light. It is necessary to extend the lifetime of the compressor and it operates as
follows: It cools the oil at 50 ° C to keep perfect conditions to lubricate the compressor.
4.6.- Oil return line. The oil that has been separated by the secondary separator should be incorporated into
the oil circuit, via the oil return line. This line connects the area of the secondary separator with the suction
line, by using stop valve, filter, needle valve and pipe.
4.7.- Line that connects the oil cooler to the micronic filter. It consists of a stop valve. .
4.8.- Micronic filter. Its function is to prevent metal particles and impurities to return to the compressor. It is
fitted with a removable cap in order to replace the filter with a new one, when necessary.
4.9.- Line that connects the micronic filter to the oil collector. It consists of a stop valve and a relief
valve.
4.10.- Oil collector. It distributes the oil in the compressor, through the injection connections, the lubrication
of front bearings and shaft, the lubrication of the rear bearings and the supply of the capacity control. It is also
fitted with a pressure connection and an oil injection temperature probe of 4-20 mA.
5
6. 4.11.- Capacity control system. It consists of a four-ways valve and four tubes, one oil connection, oil
return, charge and discharge valves.
.
5.- Coupling. It is a rigid type, made of steel sheets, which can absorb angular misalignment between 1 º and 1.3 º per
sheet, axials between 2 and 2.6 mm. and radials between 2 to 2.5 mm., depending on the model.
6.- Coupling protection device. It is made of aluminium and prevents access to moving parts of the group.
7.- Suction line. It consists of a stop valve, a check valve and a filter fitted with a grid of 150. It is also fitted with a
connection for capacity control, a connection for oil return, a connection for low pressure, a connection for a free valve
and a blind device to capture the suction temperature.
8.- Discharge line. It consists of a check valve and a stop valve.
9.- Set of safety valves. It consists of two safety valves placed in parallel on the oil separator, which have been set
at 21 bar, a safety valve mounted on the oil cooler and located on the side of the tubes also set at 21 bar and a relief
valve mounted in the oil cooler and located on the shell side. All of them led to a common collector.
10.- Set of automatisms. Formed by a manifold, in which four gauges, three pressure probes of 4-20 mA and four
stop valves are integrated. It is also fitted with an oil level pressure switch and
a twice high pressure switch with a single output. Three temperature probes of
4-20 mA, to measure the temperature of oil, which is going to be injected in
the compressor, the oil temperature in the oil separator and the discharge
temperature.
6
7. Mechanical elements as optionals.
s.- Superfeed. It is an option that involves an increase of the refrigeration capacity.
This increase is higher than the one of the absorbed power, which means an increase of
the efficiency of the group. It can be used for two reasons: 1) to increase the efficiency of
the group and 2) to reach a certain output without increasing the size of the compressor.
It consists of a stop valve (4), a check valve (3), a filter (1) and a thermowell (2) for
measuring temperature.
scr.- Superfeed with regulating valve. It is a complement of the Superfeed option,
described in the previous paragraph. It will be used when
there are several groups working in parallel in the same
installation. In this way, when a group reduces its capacity,
(the superfeed intermediate pressure comes close to the
suction pressure), this option will prevent losing
performance and efficiency in both groups and it will allow
operating at 100% capacity. To perform this function, it is
fitted with the following components: filter (1), check valve
(2), thermowell to take temperatures (3), pilot regulation
(4), regulating valve of differential pressure (5) and stop
valve (6), piping, low pressure connection.
mcv.- Motor activated by a variable frequency
drive between 1500 and 3000 rpm. This option can be used: 1) To start the compressor, via a controlled variation
of the frequency. 2) To improve the efficiency of the group with part load. It consists of the replacement of the standard
motor, described in Section 2 on page 5, with a motor fitted with NDE insulated bearing and reinforced wiring
insulation.
m +.- Oversized motor. This option is similar to that described in the previous section, except that we are located in
the area of red characters in the chart and the absorbed power is greater than the one provided by the standard motor.
Therefore, we should choose this option m+, to increase one size the standard motor.
__hz .- Operating with the variable frequency drive > 50 Hz. Depending on the group, the working point and
the operating maximum frequency, it may be necessary to change the oil separator, oil cooler, Ø of piping, oil pump,
electric motor, to use this option. Therefore, consult it before ordering it.
eaw .- Oil cooling by water. This option uses water to cool oil, via a cooler which has been designed for this
purpose.
eai .- Oil cooling by injection. This option ignores the cooler and replace it with an injection of NH3 to a
connection that has the compressor casing. Is made through a solenoid valve and a thermostatic valve which controls
the discharge temperature.
tra
.-
Oil
thermoregulation.
This
option
allows
maintaining at all times the oil temperature controlled and
therefore its optimum lubrication conditions. To obtain this
situation, it is necessary to install an oil bypass (4), which
starts in a "T" connection (2), and ends in a three-ways valve
7
8. (1), which keeps the oil injection temperature controlled. This option also involves a change of location of the safety
valve (3) oil cooler side shell.
dcc .- Twin connections. This option is used when a group is designed to serve multiple services at different times.
This option modifies two elements: A) The suction line is modified by adding a “T” connection (3) and another stop
valve (4). The rest of the elements such, as the filter (1), the check valve (2), and the stop valve (5) are not changed. B)
The discharge line is modified by adding a "T" connection (2) and an angle
stop valve (3). The rest of the elements such as the check valve (1) and the
angle stop valve (4) are not changed.
pam
.-
Marine
atmosphere paint. This
option is used for units
located outdoors. It consists
of:
1.
The
IP23
protection standard motor is replaced with an IP55 protection
motor.
2.
The welding of the metal sheets of the separator, motor support, compressor support, unit legs shall be
continuous welding and not by segments.
3.
The separator and its metal sheets, the supports and the legs will be treated with a blasting procedure of 5
to 2 ½ grade.
4.
Paint as follows:
a.
Apply an epoxy primer coating with 60% of Zinc powder. Thickness: 60 microns.
b.
Then, apply an anti-corrosive intermediate coating of epoxy-polyamide. Thickness 100 microns.
c.
Finally, apply a polyurethane-acrylic enamel. Thickness: 30 microns.
apc .- Condensing high pressure. If in the design of the installation, it has been considered the possibility of
working at condensing temperatures between 39 and 45 º C and since part loads are not accepted in these cases, it is
necessary to equip the unit with the option apc. This option involves installing one oversized oil cooler and the
appropriate electric motor for working at the above mentioned temperatures.
8
9. Electrical elements as optionals.
bdc .- Field bus. Prewired in the group between the digital and analogic automatisms throw I/O distributors to a field
bus. It makes easier and simplifies the communication between the group and the electrical panel that is reduced to 2
hoses of 5 wires each for communication and power supply . The components all of them with IP67 protection grade
are :
1
Monobloc distributor for field bus CANopen type 8 I/O.
(1)
4 analogic inputs distributor Compact type (3)
6
Modular coupling for CANopen type field bus(2)
Keypad consisting in :
o
Box. (4)
o
Emergency stop. (5)
o
Two “run” and “breakdown” indicators in the
front side of the box. (6)
2
5
4
3
Wiring as per IP67 protection grade installation type.
cc .- Control panel-board. This control panel-board consists of an electric panel board (protection level IP66), with
the following main elements:
TWIDO PLC with 24 digital inputs, 16 digital outputs and 8 analog inputs.
Communication Interface, placed on the front part of the panel.(1)
A protection bipolar circuit breaker for the PLC.
A protection DC bipolar circuit breaker for the PLC
power supply.
Monopolar protection circuit breaker for the capacity
valves.
Shut-off general switch in discharge line, placed on one
lateral side of the panel. (2)
2
1
3
4
Two indicators: Breakdown and Run, located on the
front part of the panel. (3)
Emergency stop on the front of the panel.(4)
Six output relays of 230V ca.
Connections terminals BC and user terminals BU.
Base of switch.
Main functions of the control system. Regulation of the suction pressure, PID capacity control between 10 and
100%, control of oil minimum temperature, control of the compressor operating hours, starts timing, configuration of
parameters by touch keyboard, diagnostic and historical data of alarms. Control for operating the group inside its limits.
9
10. Functions related to the digital inputs. Confirmation compressor running,, confirmation oil resistances running,
emergency stop, indication 10% of capacity, oil level pressure switch and high pressure switch.
Functions related to digital outputs. Order for compressor control, order, order for oil resistances control, order
for emergency stop, control of capacity charge valve, control of capacity discharge valve, through signal to relay, green
pilot running, red pilot breakdown.
Functions related to analog inputs. Consumption of the compressor motor, indication of the compressor capacity,
discharge pressure, suction pressure, oil temperature inside separator, oil temperature to compressor and discharge
temperature.
Communication Interface. It consists of a programmable touch screen of 5,7” in 16 levels of grey colours, with a
resolution of 1024 x 1024, connected to the PLC by the serial port COM2 RJ45 (RS485)
ccs .- ET 200 control pane. EControl panel with IP66 protection grade with the following main elemments :
PLC Siemens CPU ET 200 with 8 digital inputs, 8 digital outputs, and 8 analogic inputs.
Communication interface in the front side of the box.
Bipolar nagnetothermic circuit breaker to protect the PLC.
Bipolar magnetothermic DC circuit breaker to protect the PLC’s power supply.
Monopolar protection circuit breaker for the capacity valves.
Shut-off general switch in discharge line, placed on one lateral side of the panel.
Two indicators: Breakdown and Run, located on the front part of the panel.
Emergency stop on the front of the panel.
Six output relays of 24V cc.
Connections terminals BC and user terminals BU.
Base of switch.
With functions similar to the ones described in the cc optional
Communication interface CScreen of 4,5” with 160 x 64 pixel resolution monoccrome ( yellow-green) . Control
elements consisting in 8 function programable keys ( 4 with led ), 23 system keys communication with PLC through
RS232 serial port.
Ccs+ .- S7 300 control panel. Control panel with IP66 protection grade with the following main elemments :
PLC Siemens CPU S7 313C with 24 digital inputs, 16 digital outputs, and 8 analogic inputs.
Communication interface in the front side of the box.
Bipolar nagnetothermic circuit breaker to protect the PLC.
Bipolar magnetothermic DC circuit breaker to protect the PLC’s power supply.
Monopolar protection circuit breaker for the capacity valves.
Shut-off general switch in discharge line, placed on one lateral side of the panel.
Two indicators: Breakdown and Run, located on the front part of the panel.
Emergency stop on the front of the panel.
10
11.
Six output relays of 24V cc.
Connections terminals BC and user terminals BU.
Base of switch.
With functions similar to the ones described in the cc optional
Communication interface The same as described in the ccs optional.
11
12. TECHNICAL DATA AND PERFORMANCE OF THE UNIT
Technical data of the Standard unit.
UNIT MODEL
Refrig. capacity (1)
Absorved power(1)
COP(1)
Volumetric rate Vi
Refrigerant
Oil
140
133,6
74,5
1,8
5,0
170
165,8
94,3
1,8
5,0
210
207,5
115,5
1,8
5,0
290
282,0
155,8
1,8
5,0
320
311,2
166,3
1,9
5,0
360
414,0
217,2
1,9
5,0
420
480
504,8
471,1
223,5
238,1
2,3
2,0
5,0
5,0
NH3
Ultacool 68
570
562,5
304,4
1,8
5,0
630
620,9
323,3
1,9
5,0
710
705,3
353,8
2,0
4,8
1010
1007,3
515,6
2,0
4,6
Units
Kw
Kw
Data of compressors.
Type
Rotatory bi-screw
163/145 163/180 204/110 204/145 204/165 204/193 255/110 255/130 255/145 255/165 255/193 321/132
Model
Contimous 10%-100%
Capacity
470
485
760
840
855
900
1150
1205
1270
1340
1405
2800
Weight
0,096
0,1168
0,1865
0,2929
0,3293
0,38
0,7028
0,8135
0,8943
1,0047
1,1595
3,0951
Moment of inertia
41,6
48,5
42,6
55,5
56,5
64,4
53,5
59,4
64,4
71,3
80,2
76,3
Start up torque
4500
4500
4500
4500
4500
4500
3600
3600
3600
3600
3600
3600
Maximum turn speed
Clockwise
Turn direction
Units
Kg
Kgm2
Nm
r.p.m.
Data of oil separators.
Type
Horizontal double phase
406
406
508
508
508
508
508
508
610
610
610
760
Diameter
2200
2400
2600
2800
2800
2800
3000
3000
3200
3400
3600
3800
Length
Coalescent filters RSC0438 RSC0438 RSC1140 RSC1140 RSC1140 RSC1140 RSC1140 RSC1140 RSC1140 RSC1140 RSC1140 RSC1140
1
1
1
1
1
1
1
1
2
2
2
3
Qty of filters
63
71
87
99
99
99
110
110
157
171
185
308
Oil charge
21
Design pressure
Units
mm
mm
lts
bar
12
13. Data of the oil motor pumps.
Type
Nominal flow
Motor power
Turn speed
93,5
2,2
1420
93,5
2,2
1420
215,5
4,0
1450
215,5
4,0
1450
215,5
4,0
1450
215,5
4,0
1450
Gear pump
294,5
4,0
1450
377,6
7,5
950
377,7
7,5
950
377,6
7,5
950
Data of motors.
Type
Nominal power
Nominal voltage
Type of protection
Housing size
Direction of rotation
90
132
160
200
250S
280M
315S
315M
Low voltage asynchronous motor
250
250
280
400
IP 23
315L
315L
315L
Both
315
400
400
315L
315L
315L
Data of connections.
Type
Suction diameter
Discharge diameter
Termosyphon diam.
Superfeed diameter
80
40
100
50
100
50
100
65
100
65
40
40
50
50
50
BW sch40
125
125
65
65
50
50
65
125
80
150
80
150
80
150
80
200
100
65
65
80
100
100
Units
mm
mm
mm
mm
(1) Evaporating temperature = -40 ºC. Condensing temperature = 35 ºC. Useful superheat = 0 ºC. Total superheat = 0 ºC. Loss of charge in suction line = 0 bar.
Loss of charge in discharge line 0,15 bar. Subcooling = 3 ºC. Oil temperature 50 ºC.
(2) Only when the unit is fitted with the superfeed option “s
13
38. HOW TO SELECT THE MOTOR SIZE
The charts allow us to select the motor size to be used : nominal or oversized
GMT HW 140 -30
MODEL
32
Evaporation
T
-37
-36
-35
-34
-33
-32
-31
-30
-29
-28
-27
-26
-25
-24
-23
GMT HW 140 -30 s
MODEL
34
Condensation T
35
36
37
38
Selection of motor size
m
m
m
m
m
m
m
m
m
m
32
Evaporation
T
-37
-36
-35
-34
-33
-32
-31
-30
-29
-28
-27
-26
-25
-24
-23
33
m
m
m
m
m
m
m
m
m
m
33
m
m
m
m
m
m
m
m
m
m
34
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
Condensation T
35
36
m
m
m
m
m
m
m
m
m
m
37
m
m
m
m
m
m+
m+
m+
m+
m+
38
Selection of motor size
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m+
m
m
m
m
m+
m+
m+
m+
m+
m+
m+
m+
m+
m+
m+
m+
m+
m+
m+
m+
38