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mycom 1612LSC series Instruction Manual

Compound 2-stage screw compressor, speed increaser type
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Compound 2-stage Screw Compressor
1612LSC Speed Increaser Type

Instruction Manual

Before operating, servicing, or inspecting this product, read this manual thoroughly to
fully understand the contents.
Keep this Instruction Manual in a safe, designated place for future reference whenever
the manual is needed.
Specifications of this product and contents of this manual are subject to change
without prior notice due to technical improvements, and the like.
1612LSC-52 ／ 1612LSC-62
1612LSC-53 ／ 1612LSC-63
1612LSC-54
CAUTION
2202L5JE-DA-C5-N_2015.05.

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  • Page 1: Instruction Manual

    2202L5JE-DA-C5-N_2015.05. Compound 2-stage Screw Compressor 1612LSC Speed Increaser Type Instruction Manual 1612LSC-52 ／ 1612LSC-62 1612LSC-53 ／ 1612LSC-63 1612LSC-54 CAUTION Before operating, servicing, or inspecting this product, read this manual thoroughly to fully understand the contents. Keep this Instruction Manual in a safe, designated place for future reference whenever the manual is needed.
  • Page 2 2202L5JE-DA-C5-N_2015.05. Preface Preface Thank you for purchasing this compound two-stage screw compressor 1612LSC speed increaser type (hereinafter indicated as “this product”). This instruction manual (hereinafter indicated as “this manual”) describes safety information, operational and maintenance procedures in detail for safe and effective use of this product, and applies to the following types.
  • Page 3 2202L5JE-DA-C5-N_2015.05. Warranty and Disclaimer Warranty and Disclaimer Warranty Clauses MAYEKAWA shall repair or replace parts of this product for no charge if any failure resulting from defects in design or manufacture occurs, under normal use with the purpose and method that are in accordance with the specifications of this product and this manual, within the warranty period.

  • Page 4: Important Information

    2202L5JE-DA-C5-N_2015.05. Important Information Important Information Intended Use of this Product This product is a general-purpose screw compressor intended for refrigeration and cold storage. Do not use the product for any purposes for which it was not intended or which depart from the specifications.

  • Page 5: About This Manual

    2202L5JE-DA-C5-N_2015.05. Important Information Observe the following precautions when performing maintenance work on electrical control.  Electrical maintenance of the product must be performed by certified/qualified personnel and only by those educated about the electrical control of the product.  Before servicing or inspecting the electrical equipment or devices, turn off the motor main power and control power, and perform lockout/tagout to prevent the power from being turned on during work.

  • Page 6: Table Of Contents

    2202L5JE-DA-C5-N_2015.05. Table of Contents Table of Contents Preface ........................ⅰ Revision History ..................... ⅰ Warranty and Disclaimer ..................ⅱ Important Information .................... ⅲ Intended Use of This Product ................... ⅲ Important Information for Safe Use of This Product ............ⅲ About This Manual ......................
  • Page 7 2202L5JE-DA-C5-N_2015.05. Table of Contents Mechanisms ....................2-6 2.5.1 Basics of the Screw Compressor ................ 2-6 2.5.2 Suction Process ....................2-6 2.5.3 Compression Process ..................2-7 2.5.4 Discharge Process ....................2-7 2.5.5 About Volume Ratio (Vi) ..................2-7 2.5.6 Capacity Control Mechanism ................2-9 2.5.7 Bearings and Balance Piston ................
  • Page 8 2202L5JE-DA-C5-N_2015.05. Table of Contents Precautions for Operation ................4-7 4.2.1 Prevention of Liquid Flow-back ................4-7 4.2.2 Purging of Non-condensable Gases ..............4-7 When Stopping the Compressor for a Long Time ........4-8 Maintenance and Inspection Precautions for Maintenance and Inspection ..........5-1 Maintenance and Inspection List..............
  • Page 9 2202L5JE-DA-C5-N_2015.05. Table of Contents 5.4.10.1 Disassembly ....................5-29 5.4.10.2 Inspection ....................5-30 5.4.11 High-stage Suction Cover and Side Bearings ........... 5-31 5.4.11.1 Disassembly ....................5-31 5.4.11.2 Inspection ....................5-31 5.4.12 Low-stage Suction Cover and Side Bearings ............ 5-32 5.4.12.1 Disassembly ....................5-32 5.4.12.2 Inspection ....................
  • Page 10 2202L5JE-DA-C5-N_2015.05. Table of Contents Troubleshooting 01: Compressor does not start up ................6-1 02: Compressor stops immediately after startup ............6-1 03: Unusually low pressure (decrease of suction pressure) ........6-2 04: Low oil pressure (low lubricating oil supply pressure) ..........6-2 05: Intermediate pressure is unusually high ..............

  • Page 11: Safety

    2202L5JE-DA-C5-N_2015.05. Safety Safety Strict Requirements and Prohibitions 1.1.1 Strict Requirements (Do’s) 1.1.1.1 Do’s on Operation  Make sure to install safety and protective devices on the package unit.  Regularly inspect the safety and protective devices if they function properly. ...

  • Page 12: Do's About Personal Protective Gear

    2202L5JE-DA-C5-N_2015.05. Safety  If there are any possibilities of danger during works (especially during cleaning, maintenance and inspection, and troubleshooting), turn "OFF" the motor main power and control power, and perform lockout/tagout.  In the following situations, workers may neglect to perform power source shutoff or lockout/tagout.

  • Page 13: Prohibitions (Don'ts)

    2202L5JE-DA-C5-N_2015.05. Safety 1.1.2 Prohibitions (Don’ts)  Do not remove or relocate any safety device, including electrical interfaces.  Do not disable any safety device by short-circuiting or bypassing without any permission.  Do not leave this product unsafe and unattended, by removing a safety cover or some other measures.

  • Page 14: Residual Risks

    2202L5JE-DA-C5-N_2015.05. Safety Residual Risks The following information assumes that this product is operated or inspected/maintained while being used in general refrigerating/cold storage/gas compression package units. Note that all hazardous sources cannot be predicted for the applications mentioned. Devise appropriate countermeasures for hazardous sources in your systems. Table 1-2 Hazardous Sources Countermeasures in Countermeasures in...
  • Page 15 2202L5JE-DA-C5-N_2015.05. Safety Figure 1-1 Locations of Hazardous Sources (compressor) Compound 2-stage Screw Compressor 1.3 Residual Risks 1612LSC Speed Increaser Type...

  • Page 16: Safety Devices

    2202L5JE-DA-C5-N_2015.05. Safety Safety Devices For safe use and protection of this product, make sure to attach safety devices to this product in accordance with the regulations and the following instructions. Safety devices cannot be kept in normal condition unless inspected and maintained at regular intervals. Their maintenance and inspection need to be performed as an important part of the maintenance/inspection work project.

  • Page 17: Compressor Protection Devices

    2202L5JE-DA-C5-N_2015.05. Safety 1.4.3 Compressor Protective Devices  Be sure to adjust the set values and check operation of the protective devices at the commissioning.  Overview/Function/Purpose These protective devices are used to protect this product.  Protecting from discharge temperature rise (DT) This device stops the compressor operation when the discharge temperature of the compressor exceeds the set value.
  • Page 18 2202L5JE-DA-C5-N_2015.05. Safety  Connection Positions and Settings Specify the connection position and setting for each compressor protective device, and make sure to provide users of this product with them. Make sure that the set values do not exceed the operating limits shown in Chapter 2, section 2.3.2 and Table 2-2 of this manual.

  • Page 19: Model Designation Of The Compressor

    Low-stage rotor diameter of 160 Means the working fluid (Example: N = ammonia, F = Freon, P = Propane , HE = helium) Compound 2-stage Screw Compressor 2.1 Overview of the MYCOM 1612LSC Speed Increaser Type 1612LSC Speed Increaser Type...

  • Page 20: Compressor Specifications

    Design pressure Capacity control range (Actual load) 10 to 100 Rotation direction Crockwise viewed from motor Suction flange low-stage MYCOM 125A (5″) Discharge flange low-stage MYCOM 80A (3″) Suction flange high-stage MYCOM 80A (3″) Discharge flange high-stage MYCOM 65A (2½″)

  • Page 21: Operation Limits

    2202L5JE-DA-C5-N_2015.05. 2 Compressor Specifications and Structure 2.3.2 Operation Limits Table 2-2 Operation Limits of 1612LSC Speed Increaser type Items Operation Limits Maximum discharge pressure 1.96 Minimum suction pressure −0.080 Maximum intermediate pressure 0.588 Minimum intermediate pressure > Suction pressure Oil supply pressure ･...

  • Page 22: Outer Dimensions

    2202L5JE-DA-C5-N_2015.05. 2 Compressor Specifications and Structure 2.3.3 Outer Dimensions Figure 2-1 1612LSC Speed Increaser Type Outer Dimensions Compound 2-stage Screw Compressor 2.3 Compressor Specifications 1612LSC Speed Increaser Type...

  • Page 23: Structure Of Compressor

    2202L5JE-DA-C5-N_2015.05. 2 Compressor Specifications and Structure Structure of Compressor  For the names and locations of the compressor components, refer to Section 7.1 “Development Views, Assembly Sectional Views” and Section 7.2 “Parts Configuration Table” in this manual. Figure 2-2 1612LSC Speed Increaser Type Sectional View The 162LSC screw compressor consists of the following four main blocks: the shaft seal block which prevents leakage of the refrigerant gas and lubricating oil from the compressor’s axis;...

  • Page 24: Mechanisms

    2202L5JE-DA-C5-N_2015.05. 2 Compressor Specifications and Structure Mechanisms 2.5.1 Basics of the Screw Compressor The screw compressor is a positive displacement rotary compressor. As shown in Figure 2-3 Compressor Mechanism, the refrigerant (gas) is continuously compressed by changing the volume between the casing and the male and female meshed screw rotors, which have different profiles.

  • Page 25: Compression Process

    2202L5JE-DA-C5-N_2015.05. 2 Compressor Specifications and Structure 2.5.3 Compression Process As the rotors further rotate, the sealing line between them moves toward the discharge side and the volume between the rotor lobes decreases and compresses the trapped gas. Figure 2-5 Compression Process Figure 2-6 Discharge Process 2.5.4 Discharge Process Through the compression process, the volume between rotor lobes decreases to a predetermined...
  • Page 26 2202L5JE-DA-C5-N_2015.05. 2 Compressor Specifications and Structure (A) When Vi matches operation conditions The required compression ratio and Vi are both low The required compression ratio and Vi are both high (B) When Vi does not match operation conditions Vi is too low compared to Vi is too high compared to the required compression ratio the required compression ratio...

  • Page 27: Capacity Control Mechanism

    2202L5JE-DA-C5-N_2015.05. 2 Compressor Specifications and Structure 2.5.6 Capacity Control Mechanism The capacity control structure involves the moving of a slide valve, bypassing suction gas just before compression on the suction side, which shortens the portion of the rotor used for compression. The slide valve is at the bottom of the casing where the rotors mesh together, and is constructed to move parallel to the rotor’s axis.

  • Page 28: Gas And Oil Flow

    2202L5JE-DA-C5-N_2015.05. 2 Compressor Specifications and Structure Gas and Oil Flow The screw compressor’s compression process is described earlier in this manual. Gas for the compound speed increaser type 1612LSC compressor passes from the evaporator and through the suction strainer and check valve, and is sucked into the center part of the compressor ①, and it is ②...

  • Page 29: Installation

    2202L5JE-DA-C5-N_2015.05. 3 Installation Installation General Precautions for Installation  This chapter is based on the assumption that the compressor is installed to a standard refrigeration/cold storage package unit. If the package unit is not a standard refrigeration/cold storage package unit, prepare an installation procedure manual referring to this chapter and considering safety precautions, before installing the compressor.
  • Page 30 2202L5JE-DA-C5-N_2015.05. 3 Installation 3. Check the wire ropes before use. Thoroughly check the wire ropes for problems such as kinks, knots, and broken strands. Do not start lifting unless the wire ropes have been verified and have no problems. If you cannot make a correct evaluation or judgment, entrust an expert to inspect. 4.
  • Page 31 2202L5JE-DA-C5-N_2015.05. 3 Installation  Outer Dimensions, Mass and Lifting Position 1612LSC speed increaser type common Mass (kg) Length (mm) 1372 Figure 3-1 Outer Dimensions, Mass and Lifting Position of Compressor Lifted View Compound 2stage Screw Compressor 3.2 Installation Works 1612LSC Speed Increaser Type...

  • Page 32: Preparation For Installation

    Figure 3-2 MYCOM Flange Dimensions * In external dimensions figures 2-1 in “2.2.2 Outer Dimensions” in chapter 2 of this manual, these MYCOM flange dimensions are noted as MYK**A. Compound 2stage Screw Compressor 3.2 Installation Works 1612LSC Speed Increaser Type...

  • Page 33: Installation

    2202L5JE-DA-C5-N_2015.05. 3 Installation 3.2.5 Installation 3.2.5.1 Installation Check that the surface of the package unit for compressor installation is even and horizontal. If it is not flat and horizontal, tightening the bolts may lead to compressor deformation, and operation may be affected.

  • Page 34: Piping Connection

    2202L5JE-DA-C5-N_2015.05. 3 Installation 3.2.5.3 Piping Connection  Refrigerant Piping When connecting the refrigerant piping to the compressor, follow the instructions below.  The compressor is one of the few devices with moving components in the package unit. The moving components are adversely affected by foreign substances within the system (scale, dust, spatter, etc.).

  • Page 35: Airtightness Test

    2202L5JE-DA-C5-N_2015.05. 3 Installation  Compressor Protective Devices (Safety Devices) To protect the compressor, install the protective devices as indicated in Section 1.4.3 "Compressor Protective Devices" in this manual Chapter 1. 3.2.6 Airtightness Test Perform an airtightness test on the package unit before starting commissioning. To prevent water entry in the package unit, use nitrogen gas or dry air for the airtightness test.

  • Page 36: Compressor And Package Unit Operation

    2202L5JE-DA-C5-N_2015.05. 4. Compressor and Package Unit Operation Compressor and Package Unit Operation Lubricating Oil (Refrigerant Oil) Lubrication management is very significant to keep the compressor in a good operating condition. Take the following notes when managing lubricating oil. 4.1.1 Precautions for Selecting the Lubricating Oil ...

  • Page 37: Oils For Systems Using Hydrofluorocarbon (Hfc) Refrigerants

    2202L5JE-DA-C5-N_2015.05. 4. Compressor and Package Unit Operation  Mineral oils (incompatible oils) Kinematic viscosity Brand Manufacturer Type (40°C) mm SUNISO 3GS Sun Oil Naphthene base SUNISO 4GS Sun Oil REFOIL NS 3GS Nippon Oil GARGOYLE ARCTIC C HEAVY Exxon Mobil GARGOYLE ARCTIC 300 Exxon Mobil CAPELLA WF46...

  • Page 38: Change Of Lubricating Oil Brand

    2202L5JE-DA-C5-N_2015.05. 4. Compressor and Package Unit Operation  Polyolester Synthetic Oil (POE) for R134a (Incompatible synthetic oil) Brand Kinematic viscosity (40°C) mm Manufacturer Type JX Nippon Oil and JOMO Freol α100 Energy Corporation  When using lubricating oil of a brand not described in this section, or when using lubricating oil along with refrigerants or gases not described in this section, please contact us.

  • Page 39: Precautions For Handling Lubricating Oil

    2202L5JE-DA-C5-N_2015.05. 4. Compressor and Package Unit Operation 4.1.4 Precautions for Handling lubricating Oil  When refilling lubricating oil, ensure that it is clean and does not contain foreign matters.  Be careful that air and water are not mixed in when refilling. ...

  • Page 40: Lubricating Oil Management Criteria

    2202L5JE-DA-C5-N_2015.05. 4. Compressor and Package Unit Operation 4.1.5 Lubricating Oil Management Criteria Lubricating oils that are managed by the criteria are classified into the following categories: (1) Synthetic oils: Polyalkylene glycols (PAG) (2) Mineral oils: Naphthenic base oils and paraffinic base oils (3) Synthetic oils: Alkylbenzene (AB) and Polyalphaolefine (PAO) (4) Synthetic oils: Polyolesters (POE) ...

  • Page 41: Lubricating Oil Replacement Timing

    2202L5JE-DA-C5-N_2015.05. 4. Compressor and Package Unit Operation 4.1.6 Lubricating Oil Replacement Timing 4.1.6.1 After Starting the Initial Operation As the oil can easily be contaminated and degraded relatively quickly during the initial operation due to scales and deposits remaining in piping and vessels, be sure to sample and analyze the oil after 500 hours of operation.

  • Page 42: Compound 2-Stage Screw Compressor 1612Lsc Speed Increaser Type

    2202L5JE-DA-C5-N_2015.05. 4. Compressor and Package Unit Operation Precautions for Operation If the package unit is used in the refrigeration cycle, please keep in mind the contents of this section in particular. 4.2.1 Prevention of Liquid Flow-back Liquid flow-back is a phenomenon where refrigerant that did not completely evaporate with the gas reaches the compressor.

  • Page 43: When Stopping The Compressor For A Long Time

    2202L5JE-DA-C5-N_2015.05. 4. Compressor and Package Unit Operation When Stopping the Compressor for a Long Time When stopping the compressor for a long period of time, make sure to perform the following steps.  Turn off the motor main power.  Turn off the heater power and control panel power. ...

  • Page 44: Maintenance And Inspection Precautions For Maintenance And Inspection

    2202L5JE-DA-C5-N_2015.05. 5 Maintenance and Inspection Maintenance and Inspection Precautions for Maintenance and Inspection When reading this Section, also refer to Section 1.1 in this manual Chapter 1.  When entering the machine room for maintenance services, ensure that sufficient ventilation has been started and measure the oxygen concentration so that there is no risk of oxygen deficiency.
  • Page 45 2202L5JE-DA-C5-N_2015.05. 5 Maintenance and Inspection  When checking the operation data of units and executing other daily maintenance services, pay particular attention to avoid touching the area heated to a high temperature causing skin burns or inadvertently moving the handle of a valve leading to an erroneous operation.

  • Page 46: Maintenance And Inspection List

    2202L5JE-DA-C5-N_2015.05. 5 Maintenance and Inspection Maintenance and Inspection List 5.2.1 Daily Management As daily management, check the items listed in Table 5-1 "Daily Inspection Items" and record the results. Logging these operation data on a daily basis aid in finding out any abnormal conditions of the compressor.
  • Page 47 2202L5JE-DA-C5-N_2015.05. 5 Maintenance and Inspection Inspection Items Inspection Contents Check Points and Actions Oil supply °C Whether within upper and  Contamination on cooling pipes temperature lower limits of oil cooler Capacity control Whether operation is normal  Damage to solenoid valve coil Indicated load Improper adjustment of manual ...

  • Page 48: Periodic Inspection

    2202L5JE-DA-C5-N_2015.05. 5 Maintenance and Inspection 5.2.2 Periodic Inspection Conduct inspection for the following items according to the specified intervals. In addition, observe relevant laws and regulations on the inspections and recording of the results that are provided for other related items such as any safety devices (e.g. gas leak detectors), or other utility (gas/electricity) protection devices that constitute the cooling package unit together with the compressor.

  • Page 49: Guidelines For The Timing Of Compressor Overhaul

    2202L5JE-DA-C5-N_2015.05. 5 Maintenance and Inspection 5.2.3 Guidelines for the Timing of Compressor Overhaul The compressor overhaul interval is largely affected by the compressor operating conditions, type and status of refrigerant and oil, and the system/equipment in which the compressor is operated. The table below shows the recommended interval of overhaul, as a guideline.

  • Page 50: Compressor Disassembly Preparation

    2202L5JE-DA-C5-N_2015.05. 5 Maintenance and Inspection Compressor Disassembly Preparation Although screw compressors are very reliable machines, it is still necessary to perform overhaul to inspect internal parts after a certain period of operation. This chapter 5 explains the essential points of disassembly methods, where to inspect on parts, and reassembly procedure of the compound 2-stage screw compressor 1612LSC speed increaser type.
  • Page 51 2202L5JE-DA-C5-N_2015.05. 5 Maintenance and Inspection Part Name Code No. Remarks Q’ty. CS01200-160N 12-1 Gasket, Bearing Head (1) CS01200-1612CN 12-2 Gasket, Bearing Head (2) CS01700-1612CN 17-2 Gasket, Bearing Cover (2) CS02300-1612CN Gasket, Balance Piston Cover CS02700-1612C3 27-1A Main/Side Bearing (1) A CS02800-1610C1 27-1B Main/Side Bearing (2) B...
  • Page 52 2202L5JE-DA-C5-N_2015.05. 5 Maintenance and Inspection Part Name Code No. Remarks Q’ty. NG12-010 Snap ring C type External S10 CS08200-200B V-ring, Indicator Cam VH10 NBR CS08300-200 Spring PA11-016 O-ring JIS B 2401 P16 PA11-016 O-ring JIS B 2401 P16 CR72000-125N MYK 125A(5") 93-1 Gasket, Suction Flange (1) CR72000-080N...

  • Page 53: Refrigerant Gas Recovery

    2202L5JE-DA-C5-N_2015.05. 5 Maintenance and Inspection 5.3.3 Refrigerant Gas Recovery At the time the compressor operation is stopped, the pressure inside the compressor is still high. As such, it is necessary to lower the pressure down to the atmospheric pressure before starting the disassembly process.

  • Page 54: Removing Parts Connected To The Unit

    2202L5JE-DA-C5-N_2015.05. 5 Maintenance and Inspection 5.3.4 Removing Parts Connected to the Unit  If there is residual high-pressure refrigerant gas or oil dissolved in the refrigerant, the gas and oil may blow off when closed valves (components) are opened. This may result in injury such as frostbite and loss of vision. Always check and confirm the pressure in the compressor, before opening any pipe connections and valves.

  • Page 55: Compressor Removing And Lifting

    2202L5JE-DA-C5-N_2015.05. 5 Maintenance and Inspection 5.3.5 Compressor Removing and Lifting  The work to lift up or move the compressor must be performed by a qualified operator.  Make sure that the lifting equipment and wires have sufficient load capacity for the compressor before starting the compressor lifting work.

  • Page 56: Disassembly And Inspection

    2202L5JE-DA-C5-N_2015.05. 5 Maintenance and Inspection Disassembly and Inspection Generally, compressors are disassembled in the order shown in Figure 5-1 Illustrated Disassembly Sequence but the order in the figure is just an example and the actual order may differ according to individual situations.
  • Page 57 2202L5JE-DA-C5-N_2015.05. 5 Maintenance and Inspection Figure 5-1 Disassembly Order Description Compound 2-stage Screw Compressor 5.4 Disassembly and Inspection 1612LSC Speed Increaser Type 5-14...

  • Page 58: Shaft Seal Block

    2202L5JE-DA-C5-N_2015.05. 5 Maintenance and Inspection 5.4.1 Shaft Seal Block Part name Mating ring Mating Insert lock pin ring O-ring Seal collar Rotating Seal collar set screw ring O-ring Figure 5-2 Details of BBSE Type Mechanical Seal Assembly 5.4.1.1 Disassembly a) Of the eight hexagon socket head cap screws [53] on the seal cover [51], remove six screws leaving two diagonally opposite screws.

  • Page 59: Inspection

    2202L5JE-DA-C5-N_2015.05. 5 Maintenance and Inspection Loosening Screws Fastened Seal Cover Seal Cover and Mating Ring Loosening the Seal Collar Set Screw Seal Retainer h) Pull out the seal collar part with your fingers. When pulling out, ensure that the tips of the set screws do not hit the shaft.

  • Page 60: Unloader Indicator

    2202L5JE-DA-C5-N_2015.05. 5 Maintenance and Inspection 5.4.2 Unloader Indicator Figure 5-3 1612**C Unloader Indicator Block Table 5-7 Unloader Indicator Components Part Name Remarks Part Name Remarks Indicator assembly Indicator glass Micro-switch base plate 125L** Electric wiring connector Hexagon socket head cap M6ｘ25 Connector support 125L**...

  • Page 61: Disassembly

    2202L5JE-DA-C5-N_2015.05. 5 Maintenance and Inspection 5.4.2.1 Disassembly  When removing wiring only Remove the indicator cover before pulling out the unloader indicator wiring because the indicator has a terminal board for wiring. Perform the work as described below and after removing the wiring reattach the cover for protection.

  • Page 62: Inspection

    2202L5JE-DA-C5-N_2015.05. 5 Maintenance and Inspection  When removing entire unloader indicator assembly, with the wiring left as it is a) After the disassembly in the previous section, the internal potentiometer [129], micro-switches [125], and micro-switch base plate [121] with micro-switch cam [127] attached can be removed. Micro-switch base plate is fastened to the unloader cover with two hexagon socket head cap screws [122].

  • Page 63: Unloader Cover

    2202L5JE-DA-C5-N_2015.05. 5 Maintenance and Inspection 5.4.3 Unloader Cover The unloader cover [74] contains the indicator cam [77], which converts the linear motion of the unloader slide valve to a rotational motion, and its attachment parts. 5.4.3.1 Disassembly a) Remove the hexagon socket head cap screws [76] for attaching the unloader cylinder cover.

  • Page 64: Unloader Piston And Unloader Cylinder

    2202L5JE-DA-C5-N_2015.05. 5 Maintenance and Inspection 5.4.4 Unloader Piston and Unloader Cylinder 5.4.4.1 Disassembly a) Screw two M8 eyebolts into the unloader piston [64], and pull out it to the no-load position (utmost front position). b) Unbend the rotation stopper tooth of the lock washer [70], loosen and remove the lock nut [69].

  • Page 65: Speed Increaser Gear Casing Cover

    2202L5JE-DA-C5-N_2015.05. 5 Maintenance and Inspection 5.4.5 Speed Increaser Gear Casing Cover The 1612LSC model is speed increaser type compressor, so remove the speed increaser gear casing cover [171] as drive shaft cover. 5.4.5.1 Disassembly Loosen the hexagon socket head cap screws [195]. Before removing these bolts, screw two stud bolts into the threaded holes at the top of the cover.

  • Page 66: Speed Increaser Gear Casing Block

    2202L5JE-DA-C5-N_2015.05. 5 Maintenance and Inspection 5.4.6 Speed Increaser Gear Casing Block The speed increaser gear casing block needs be disassembled when inspecting the thrust bearing block on the low-stage, pulling out the rotors, or inspecting the speed increaser gears. For replacing the thrust bearing [189], pilling out the speed gear increaser gear spindle [188] is required.
  • Page 67 2202L5JE-DA-C5-N_2015.05. 5 Maintenance and Inspection e) Screw the previously removed three bolts [18-1] into the jacking threaded holes in the flange of the speed increaser gear casing, and screw them alternately and evenly to separate the flange from the speed increaser gear casing (picture below). f) After disengaging alignment pins, pull out the casing with parallel direction to the speed increaser gear spindle shaft (following picture to the left).
  • Page 68 2202L5JE-DA-C5-N_2015.05. 5 Maintenance and Inspection h) Unbend the rotation stopper tooth of the lock washer [270] for the lock nut [269] as shown in the picture below, then loosen the lock nut and remove it with the torsional slip washer [237-D] and the lock washer.

  • Page 69: Inspection

    2202L5JE-DA-C5-N_2015.05. 5 Maintenance and Inspection o) Unbend the rotation stopper tooth of the lock washer [194], loosen and pull out the lock nut [193] with the torsional slip washer [237-C] and the lock washer. p) As shown in the below left picture, when you tap the speed increaser gear spindle shaft end face lightly with fitting a plastic block or the like, the spindle will fall off.

  • Page 70: Separating High-Stage And Low-Stage

    2202L5JE-DA-C5-N_2015.05. 5 Maintenance and Inspection 5.4.7 Separating High-stage and Low-stage Separate the high-stage and low-stage when inspect the high-stage thrust bearing block or pull out each stage’s rotor is required. Structurally, it does not matter even if separated at the first step of disassembly. Separating High-stage and Low-stage 5.4.7.1 Disassembly a) As explained in Section 5.3.5 of this chapter, put the compressor on a special table and remove the...

  • Page 71: Gear Coupling

    2202L5JE-DA-C5-N_2015.05. 5 Maintenance and Inspection 5.4.8 Gear Coupling The gear coupling, which is used as a power transmission means, is divided into the high-stage and the low-stage blocks, with each block attached to the corresponding M rotor shaft, and these two blocks are directly connected by a drive sleeve.

  • Page 72: Balance Piston Cover

    2202L5JE-DA-C5-N_2015.05. 5 Maintenance and Inspection 5.4.9 Balance Piston Cover Disassemble the balance piston cover when pulling out the rotors or inspecting the side bearing [28-2] or balance piston [30]. a) Loosen all hexagon socket head cap screws [24] 3 or 4 rotations, lightly tap the side of the balance piston cover [22] with a soft hammer, and peel off the sticking balance piston cover gasket [23].

  • Page 73: Compound 2-Stage Screw Compressor 1612Lsc Speed Increaser Type

    2202L5JE-DA-C5-N_2015.05. 5 Maintenance and Inspection b) Since the 1612C model has a balance piston sleeve attached to the high-stage, remove the hexagon socket head cap screws [34] for stopping the balance piston sleeve [33] from rotating. Make sure not to lose the attached special spring washer [335] for the hexagon socket head cap screw.

  • Page 74: High-Stage Suction Cover And Side Bearings

    2202L5JE-DA-C5-N_2015.05. 5 Maintenance and Inspection 5.4.11 High-stage Suction Cover and Side Bearings If the work sequence is such that the thrust bearing block is disassembled first and then the suction cover is removed, there is a risk that, when the suction cover is separated from the main rotor casing, the rotor may also be pull out and dropped.

  • Page 75: Low-Stage Suction Cover And Side Bearings

    2202L5JE-DA-C5-N_2015.05. 5 Maintenance and Inspection 5.4.12 Low-stage Suction Cover and Side Bearings Similarly to the case of the high-stage, remove the low-stage suction cover before disassembling the low-stage thrust bearing block in order to prevent the rotor dropping at the time of removing the suction cover. Also in the same way of the high-stage, the lock nut fastening the thrust bearing should be loosened beforehand.

  • Page 76: Inspection

    2202L5JE-DA-C5-N_2015.05. 5 Maintenance and Inspection e) And then, unbend the rotation stopper tooth of the lock washer [40-1] (following picture to the left), loosen the lock nut [39-1] (following picture to the right). f) Unscrew and remove four hexagon head cap screws which secured the oil injection pipe gland [164] located in the lower area of the low-stage suction cover (following picture to the left )..

  • Page 77: Thrust Bearings Block

    2202L5JE-DA-C5-N_2015.05. 5 Maintenance and Inspection 5.4.13 Thrust Bearing Block Thrust bearing (picture to the right) is a face-to-face angular contact ball bearing. This bearing only receives thrust load and does not receive the radial load perpendicular to the shaft because there is a gap between the outer ring of the thrust bearing and the bearing head.

  • Page 78: Disassembly Of Low-Stage Thrust Bearing Block

    2202L5JE-DA-C5-N_2015.05. 5 Maintenance and Inspection Pulling Out Thrust Bearing Outer race Spacer and Alignment Spacer 5.4.13.2 Disassembly of Low-stage Thrust Bearing Block Figure 5-11 Low-stage Thrust Bearing Block a) The roller bearing [185] outer race supporting the speed increaser dear spindle shaft end is installed in the upper part of the low-stage bearing head (above picture).

  • Page 79: Inspection (High-Stage/Low-Stage)

    2202L5JE-DA-C5-N_2015.05. 5 Maintenance and Inspection c) Remove the lock nut [39-1] that has been loosened. Then, remove the torsional slip washer [237-1], and lock washer [40-2], and thrust washer [250-2]. b) At the M rotor side, remove the thrust washer [250-], thrust bearing [38-1A] and thrust bearing alignment spacer [42-1A] in the order.

  • Page 80: High-Stage Rotors And Main Rotor Casing

    2202L5JE-DA-C5-N_2015.05. 5 Maintenance and Inspection 5.4.14 High-stage Rotors and Main Rotor Casing 5.4.14.1 Disassembly a) Either the M rotor or F rotor may be removed first. However, as the M rotor is longer, it is easier to remove the M rotor first. When pulling out the M rotor (or F rotor) first, pull out about 2/3 of the full length of the rotor by holding the shaft upward and turning it in the CW (or CCW) direction.

  • Page 81: Low-Stage Rotors And Main Rotor Casing

    2202L5JE-DA-C5-N_2015.05. 5 Maintenance and Inspection 5.4.15 Low-stage Rotors and Main Rotor Casing Care must be taken because the low-stage rotors are heavy. In addition, since the low-stage M rotor is installed with a mechanical seal; do the work very carefully not to damage the shaft.

  • Page 82: High-Stage Bearing Head And Main Bearings

    2202L5JE-DA-C5-N_2015.05. 5 Maintenance and Inspection 5.4.16 High-stage Bearing Head and Main Bearings There is a gas discharge port, based on the compressor’s operating conditions, on the surface that has the rotor of the bearing head [11-2] assembled on it. This discharge port affects the performance of the compressor. On the bearing head there is also the main bearing which supports one end of the rotor.

  • Page 83: Low-Stage Bearing Head And Main Bearings

    2202L5JE-DA-C5-N_2015.05. 5 Maintenance and Inspection 5.4.17 Low-stage Bearing Head and Main Bearings Apart from when disassembling and inspecting the unloader slide valve, it is not necessary to separate the low-stage bearing head [11-1] and the main rotor casing [1-1]. However, according to the design modification in July 1986, of the low-stage bearing head the part where the unloader push rod is set has been changed.

  • Page 84: Low-Stage Unloader Slide Valve And Guide Block

    2202L5JE-DA-C5-N_2015.05. 5 Maintenance and Inspection 5.4.18 Low-stage Unloader Slide Valve and Guide Block When the low-stage bearing head and the main rotor casing are separated, the slide valve is attached to the bottom of the main rotor casing and moves in parallel with the axis whose position is controlled by the inside guide block [87] and the outside perimeter (of the rotor casing).

  • Page 85: Reassembly

    2202L5JE-DA-C5-N_2015.05. 5 Maintenance and Inspection Reassembly  When reassembling, ensure that the replaced O-rings are of the correct standard (size, material, for secure/moving parts etc.). Incorrect replacement can lead to defects such as oil leakage.  Some gaskets are asymmetrical. In that case, ensure that the assembly direction is correct.
  • Page 86 2202L5JE-DA-C5-N_2015.05. 5 Maintenance and Inspection Figure 5-13 Assembly Order Explanation (example) * The circled numbers in the figure do not correspond to the steps below. Compound 2-stage Screw Compressor 5.5 Reassembly 1612LSC Speed Increaser Type 5-43...

  • Page 87: Low-Stage Unloader Slide Valve And Guide Block

    2202L5JE-DA-C5-N_2015.05. 5 Maintenance and Inspection 5.5.1 Low-stage Unloader Slide Valve and Guide Block a) First, tightly screw the guide block stem [88] into the bottom of the main rotor casing, and then mount the guide block [87] inside the main rotor casing. b) If the slide valve assembly has been disassembled, first make sure that the alignment position between the slide valves [54] and [55] is accurately reproduced and then tighten the hexagon socket head cap screws [58] with spring washers [267] at the specified torque.

  • Page 88: Bearing Head And Rotor Casing

    2202L5JE-DA-C5-N_2015.05. 5 Maintenance and Inspection 5.5.2 Bearing Head and Main Rotor Casing  Since the bearing head gasket [12] is not formed symmetric laterally, pay attention to the installation direction.  If you place the bearing head gasket by just hanging it on the stud bolts, the gasket will protrude into the inside of the rotor casing when the casing is assembled.

  • Page 89: Bearing Head And Main Bearings

    2202L5JE-DA-C5-N_2015.05. 5 Maintenance and Inspection 5.5.3 Bearing Head and Main Bearings a) The main bearing [27] is dimensioned in such a way that it is lightly press fit to the bearing head [11]. Position the notch of the main bearing so that it is aligned with the spring pin [14] in the bearing head (in the case of low-stage work, using a fixture such as a guide rod is helpful as shown in the above picture to the left), then, using a pad, lightly tap in the notch.

  • Page 90: Rotor Assembly

    2202L5JE-DA-C5-N_2015.05. 5 Maintenance and Inspection 5.5.4 Rotor Assembly Note on the rotor profile of 1612**C The rotor profile design was changed from A Profile to O Profile in July 1994. The biggest difference is the lobe tip edges. Profile A has the lobe tip edges while profile O does not have them Make sufficient adjustments to the rotor.

  • Page 91: Suction Cover And Side Bearings

    2202L5JE-DA-C5-N_2015.05. 5 Maintenance and Inspection 5.5.5 Suction Cover and Side Bearings a) The side bearing [28] is dimensioned in such a way that it is gentle press-fit to the suction cover [5]. Press it onto the bearing positioning pin (spring pin) [8] in the suction cover aligning it with the bearing notch.
  • Page 92 2202L5JE-DA-C5-N_2015.05. 5 Maintenance and Inspection c) When assembling the low-stage side, slide the suction cover on the work bench to move it to the assembly location (above picture to the left). When assembling the high-stage side, use a lifting tool shown in above picture to the right or put a stand witch adjusted height.

  • Page 93: Thrust Bearing Block

    2202L5JE-DA-C5-N_2015.05. 5 Maintenance and Inspection 5.5.6 Thrust Bearing Block Figure 5-15 Thrust Bearing Block Table 5-9 Configuration Parts of Thrust Bearing Block Part Name (High-stage) Q’ty 42-2 Thrust bearing alignment spacer (2) 41-2 Thrust bearing outer race spacer (2) 38-2 Thrust bearing (2) 2 sets 250-2...
  • Page 94 2202L5JE-DA-C5-N_2015.05. 5 Maintenance and Inspection  When installing the disassembled thrust bearing as is, check the M/F engravings on the thrust bearing outer race spacers and thrust bearing alignment spacers, and reassemble them in the same way as before disassembly. This is essential to control the end clearance of the rotor discharge side.

  • Page 95: End Clearance Measurement

    2202L5JE-DA-C5-N_2015.05. 5 Maintenance and Inspection End Clearance Measurement 5.5.6.1 At this point (i.e., after the thrust bearing block has been fully assembled), measure the clearance between the bearing head end face and the rotor end face on the discharge side. This clearance is called as the end clearance.
  • Page 96 2202L5JE-DA-C5-N_2015.05. 5 Maintenance and Inspection c) Secure the bearing gland by tightening the four screws evenly to the specified tightening torque gradually. Tightening each screw to the specified torque at once will lead to uneven tightening so tighten each screw little by little. c) Then, read the dial gauge measurement.

  • Page 97: End Clearance Adjustment Method

    2202L5JE-DA-C5-N_2015.05. 5 Maintenance and Inspection End Clearance Adjustment Method 5.5.6.2 (1) When the end clearance is smaller than the specified value To deal with this, insert shim material (thrust adjustment liner) of required thickness (difference in thickness from the specified value) between the thrust bearing alignment spacer [42] and thrust bearing inner race.
  • Page 98 2202L5JE-DA-C5-N_2015.05. 5 Maintenance and Inspection c) When reassembling the low-stage compressor section of the -53, -54 and -63 models with a speed increaser gear system, install the speed increaser driven gear [179] on the M rotor shaft by locking the gear with the key [180]. Secure the gear by fastening the lock nut with the lock washer and spacer placed in-between.

  • Page 99: Combining High-Stage And Low-Stage Blocks

    2202L5JE-DA-C5-N_2015.05. 5 Maintenance and Inspection 5.5.7 Combining High-stage and Low-stage Blocks Figure 5-20 Gear Coupling Assembly a) On the high-stage, attach the driven hub [153] of the gear coupling, and fasten the M8 set screw 【 159] for securing the driven hub key [157]. This set screw is knurled and provided with anti-loosening.

  • Page 100: Balance Piston Cover

    2202L5JE-DA-C5-N_2015.05. 5 Maintenance and Inspection f) Lift the high-stage by using lifting tools until it is slightly off the work bench, and move it toward the low-stage. At this moment, on the low-stage, slightly move the M rotor shaft in both directions, so that the gear coupling assembly will fit smoothly (picture below).

  • Page 101: Speed Increaser Gear Block

    2202L5JE-DA-C5-N_2015.05. 5 Maintenance and Inspection 5.5.9 Speed Increaser Gear Block a) In case of disassembling the speed increaser drive gear [174] and speed increaser gear spindle [188], attach the shaft key [175] on the gear spindle and install the speed increaser drive gear on the spindle. Tighten the speed increaser drive gear by fastening the lock nut [269] with the lock washer [270] and torsional slip washer [237-1D].
  • Page 102 2202L5JE-DA-C5-N_2015.05. 5 Maintenance and Inspection e) After installing the jig, turn the speed increaser gear casing upside down to be able to install the speed increaser gear spindle, and place the casing on the work stand used at disassembling. f) Insert the speed increaser gear spindle into the spindle thrust bearing by lightly tapping the end of the spindle with a soft hammer or the like.
  • Page 103 2202L5JE-DA-C5-N_2015.05. 5 Maintenance and Inspection f) Install the thrust bearing gland [190] by finger-tightening the hexagon head bolts [191] evenly with the gland’s oil return hole (for speed increaser gear side bearing lubrication) facing up as shown in the picture below). Finally tighten these bolts after installing the speed increaser gear casing assembly to the bearing head of the low-stage compressor section, that is, after the roller bearing’s inner race on the speed increaser gear spindle has properly engaged with the roller bearing’s outer race on the bearing...

  • Page 104: Installation Of Speed Increaser Gear Casing To Low-Stage Bearing Head

    2202L5JE-DA-C5-N_2015.05. 5 Maintenance and Inspection 5.5.10 Installation of Speed Increaser Gear Casing to Low-stage Bearing Head a) Start this operation after checking the bearing head assembly for the following point: The bearing head has two oil holes, one for lubricating the speed increaser gear and the other for lubricating the roller bearing of the speed increaser gear spindle.
  • Page 105 2202L5JE-DA-C5-N_2015.05. 5 Maintenance and Inspection g) Bend the lock washer tooth into the notch of the lock nut to prevent loosening (following picture to the left). h) Tighten the thrust bearing gland [190] with the hexagon head bolts [191] inserting spring washers [192] in turn and evenly to the specified torque (above picture to the right).

  • Page 106: Unloader Cylinder And Unloader Piston

    2202L5JE-DA-C5-N_2015.05. 5 Maintenance and Inspection 5.5.11 Unloader Cylinder and Unloader Piston Part Name Q’ty Unloader Cylinder Hexagon Socket Head Cap Screw M8X95 O-ring JISB2401 G95 Unloader Piston O-ring JISB2401 P75 Cap Seal BE75 Lock Nut AN05 Lock Washer AW05 O-ring JISB2401 P21 Figure 5-16 Unloader Cylinder Block a) Attach the O-ring [73] to the O-ring groove at the end of the unloader push rod [67] where the unloader piston is to be attached.
  • Page 107 2202L5JE-DA-C5-N_2015.05. 5 Maintenance and Inspection f) Insert a new lock washer [70] and the lock nut [69] into the unloader push rod, tighten the lock nut and bend the lock washer tooth into the notch of the lock nut to prevent loosening. The tightening torque for this lock nut is 80 N·m.

  • Page 108: Unloader Cover

    2202L5JE-DA-C5-N_2015.05. 5 Maintenance and Inspection 5.5.12 Unloader Cover Figure 5-17 Unloader Cover Development View a) Before proceeding to the next procedure, make sure to pull the unloader piston to the no-load position (toward you). b) Attach the ball bearing [78] to the axial part of the indicator cam [77]. When pushing in, push the inner race of the bearing.

  • Page 109: Shaft Seal Block

    2202L5JE-DA-C5-N_2015.05. 5 Maintenance and Inspection 5.5.13 Shaft Seal Block The BBSE (balance bellows single) type of the mechanical seal assemblies used in current standard screw compressors as standard specification. In addition, the BOS (balance O-rings single) type may be used by the specification of the customer. Part Name Mating ring Stationary...
  • Page 110 2202L5JE-DA-C5-N_2015.05. 5 Maintenance and Inspection e) Next, attach the O-ring [49] for the seal retainer (following picture to the right).  Take special care because users frequently omit to attach the O-ring 【49】 for oil seal retainer. Installing Oil seal Retainer Attaching O-ring [49] f) Install the seal collar [109] to the rotor shaft.
  • Page 111 2202L5JE-DA-C5-N_2015.05. 5 Maintenance and Inspection j) Install the seal cover with the gasket, so that the oil drop piping of the seal cover is on the bottom side. At this time, assemble it carefully, either at a right angle or by delaying the upper side slightly, to ensure that the mating ring inside the seal cover does not hit the rotor shaft.

  • Page 112: Unloader Indicator

    2202L5JE-DA-C5-N_2015.05. 5 Maintenance and Inspection 5.5.14 Unloader Indicator The unloader indicator contains micro-switches, a micro-switch cam and a potentiometer. Either of them detects the rotational volume change of the shaft of the indicator cam, which converts the axial positional change of the unloader slide valve into circumferential positional change, and sends it as electric signals to the control side of the package unit or refrigerating system.

  • Page 113: Potentiometer

    2202L5JE-DA-C5-N_2015.05. 5 Maintenance and Inspection Potentiometer 5.5.14.1 The potentiometer of the 1612**C indicator is of the full rotation type. It senses the continuously variable position (indicated load of 0 % to 100 %) of the unloader slide valve, and feeds the sensed position as electric signals to the control side of the package unit or refrigerating system.

  • Page 114: Assembly And Adjustment

    2202L5JE-DA-C5-N_2015.05. 5 Maintenance and Inspection c) The micro-switch 【125】 is secured with two long phillips screws 【126】. The micro-switch can be removed by loosening these screws. Do not remove these screws except when the micro-switch needs to be replaced. Leave them as they are when conducting inspections or positional adjustments.

  • Page 115: Troubleshooting

    2202L5JE-DA-C5-N_2015.05. 6 Troubleshooting Troubleshooting Table 6-1 describes typical trouble symptoms of compressors, their causes and actions to be taken. The explanations of this Chapter are assumed that the compressor is used in the general refrigeration cycle. Table 6-1 Troubleshooting 01: Compressor does not start up Direct cause Root cause Action...

  • Page 116: 03: Unusually Low Pressure (Decrease Of Suction Pressure)

    2202L5JE-DA-C5-N_2015.05. 6 Troubleshooting 02: Compressor stops immediately after startup (continued) Direct cause Root cause Action Low pressure protection Insufficient refrigerant flow To correct insufficient liquid supply,  Insufficient liquid supply circuit activates. inspect expansion valve and liquid supply strainer. Take necessary actions.

  • Page 117: 05: Intermediate Pressure Is Unusually High

    2202L5JE-DA-C5-N_2015.05. 6 Troubleshooting 04: Low oil pressure (continued) Direct cause Root cause Action Insufficient oil in oil Extensive oil leak Inspect machine room and around the separator. compressor, and take necessary actions. Check if there is oil floating in cooling water system.

  • Page 118: 06: Unusually High Pressure (Abnormal Discharge Pressure)

    2202L5JE-DA-C5-N_2015.05. 6 Troubleshooting 06: Unusually high pressure (abnormal discharge pressure) Direct cause Root cause Action Heat exchange failure in Heat transmission tubes and/or Clean and wash. condenser (heat fins are contaminated or Depending on the contamination exchanger) blocked. level, use chemical cleaning. Failure or water dripping in fan Identify defective devices, investigate motor, thermo switch, water...

  • Page 119: 07: Discharge Temperature Is Abnormally High

    2202L5JE-DA-C5-N_2015.05. 6 Troubleshooting 06: Unusually high pressure (continued) Direct cause Root cause Action Discharge pressure Failure of high pressure Identify defective devices, investigate detection function is protection device, pressure causes of failure and take necessary defective. sensor, relay, etc. actions. Then, replace failed device(s).

  • Page 120: 08: Leak From Mechanical Seal

    2202L5JE-DA-C5-N_2015.05. 6 Troubleshooting 08: Leak from mechanical seal Direct cause Root cause Action Initial leak after In some cases, immediately In case of initial leak, although leak replacement until sliding after replacement, the amount might increase temporarily, it surfaces settle compressor-specific operating will decrease gradually.

  • Page 121: 09: Squeaking Of Mechanical Seal

    2202L5JE-DA-C5-N_2015.05. 6 Troubleshooting 08: Leak from mechanical seal (continued) Direct cause Root cause Action Poor contact of sliding Foreign matter attached to Replace the whole quantity of surfaces sliding surfaces, due to lubricating oil. contaminated lubricating oil. Install bypass filter to oil supply line. Faulty assembly of parts Disassemble, replace parts and Human error...

  • Page 122: 11: Capacity Control Malfunction

    2202L5JE-DA-C5-N_2015.05. 6 Troubleshooting 10: Capacity control position is indicated incorrectly (continued) Direct cause Root cause Action Inaccurate reading of E/E positioner or/and indicator If deteriorated over time, replace. capacity control indicator is faulty. If there are specific causes such as on the control panel.

  • Page 123: 12: Compressor Generates Abnormal Vibration And/Or Sound

    2202L5JE-DA-C5-N_2015.05. 6 Troubleshooting 12: Compressor generates abnormal vibration and/or sound. Direct cause Root cause Action Shaft poorly aligned with If the shaft vibration value of Conduct shaft alignment again. motor axial direction is high, it may be If this occurs frequently in monocoque caused by this.
  • Page 124 2202L5JE-DA-C5-N_2015.05. 6 Troubleshooting 12: Compressor generates abnormal vibration and/or sound (continued) Direct cause Root cause Action Liquid flow-back during Aperture of liquid In case of temperature-type expansion valve, operation supply expansion check the condition of temperature sensitive * Notable frosting on the valve is large cylinder and capillary tube.
  • Page 125 2202L5JE-DA-C5-N_2015.05. 6 Troubleshooting 12: Compressor generates abnormal vibration and/or sound (continued) Direct cause Root cause Action Foreign substances Welding spatter, etc. Check suction strainer and/or oil filters. Replace entering the flowing from upstream element if defective. compressor side Overhaul the compressor. Collect foreign substances and identify their Tools and/or waste sources.

  • Page 126: Related Documents

    2202L5JE-DA-C5-N_2015.05. 7 Related Documents Related Documents Development Views, Assembly Sectional Views Figure 7-1 Development View (Low-stage) Compound 2-stage Screw Compressor 7.1 Development Views of the Parts 1612LSC Speed Increaser Type...
  • Page 127 2202L5JE-DA-C5-N_2015.05. 7 Related Documents Figure 7-2 Development View (High-stage) Compound 2-stage Screw Compressor 7.1 Development Views of the Parts 1612LSC Speed Increaser Type...

  • Page 128: Figure 7-3 Assembly Sectional View (Vertical)

    2202L5JE-DA-C5-N_2015.05. 7 Related Documents Figure 7-3 Assembly Sectional View (Vertical) Compound 2-stage Screw Compressor 7.1 Cross-section Views of the Parts 1612LSC Speed Increaser Type...

  • Page 129: Figure 7-4 Assembly Sectional View (Horizontal)

    2202L5JE-DA-C5-N_2015.05. 7 Related Documents Figure 7-4 Assembly Sectional View (Horizontal) Compound 2-stage Screw Compressor 7.1 Cross-section Views of the Parts 1612LSC Speed Increaser Type...

  • Page 130: Parts Configuration Table

    2202L5JE-DA-C5-N_2015.05. 7 Related Documents Parts Configuration Table Table 7-1 Configuration table of the parts Quantity Part name Part code No. Remarks 52/62 53/63 Main Rotor Casing (1) CS00100-160L 160L** Main Rotor Casing (2) CS00100-1612C 1612*SC Hexagon Socket Head Cap Screw NB35412-040 M12×40 Hexagon Socket Head Cap Screw...
  • Page 131 2202L5JE-DA-C5-N_2015.05. 7 Related Documents Quantity Part name Part code No. Remarks 52/62 53/63 Key, Balance Piston CS03100-125 125*** Snap Ring C type External NG12-040 Sleeve, Balance Piston CS03300-160 160*** Hexagon Socket Head Cap Screw NB35406-015 M6×15 O-ring PA12-095 JIS B 2401 G95 Snap Ring C type Internal NG11-102 H102...
  • Page 132 2202L5JE-DA-C5-N_2015.05. 7 Related Documents Quantity Part name Part code No. Remarks 52/62 53/63 O-ring PA12-085 JIS B 2401 G85 Hexagon Socket Head Cap Screw NB35406-035 M6×35 Indicator Cam CS07700-1610C 1610SLC Ball Bearing CS07800-200 #6000 Snap Ring C type External NG12-010 Bearing Gland CS08000-200 200***...
  • Page 133 2202L5JE-DA-C5-N_2015.05. 7 Related Documents Quantity Part name Part code No. Remarks 52/62 53/63 53-3610rpm 174-2 Speed Increaser Drive Gear (2P) CS17400-1612153 63-4350rpm 174-3 Speed Increaser Drive Gear (2P) CS17400-1612154 54-4350rpm Key, Speed Increaser Gear Shaft CS18000-1610CD 1610C Gland, Speed Increaser Gear CS18100-1610CD 1610C, 4P 52-2610rpm...

  • Page 134: Tightening Torques For Bolts And Nuts

    2202L5JE-DA-C5-N_2015.05. 7 Related Documents Tightening Torques for Bolts and Nuts Table 7-2 List of Tightening Torques  Hexagon socket head cap screw Tightening torque Tightening point Qty. Size N·m kgf·cm Main Rotor Casing (1) to M12×40 Suction Cover (1) and Bearing Head (1) Main Rotor Casing (2) to 1400 M14×40...
  • Page 135 2202L5JE-DA-C5-N_2015.05. 7 Related Documents  Locknut Tightening torque N·m Tightening point Qty. Size Regular Maxi- 39-1A Thrust bearing (1) M AN14 39-1B Thrust bearing (1) F AN12 Speed increaser driven gear 39-2 Thrust bearing (2) AN09 Unloader piston — AN05 Unloader slide valve AN06 Intermediate gear coupling, drive hub...

  • Page 136: O-Rings For Use

    2202L5JE-DA-C5-N_2015.05. 7 Related Documents O-rings for Use 7.4.1 List of O-rings for Use Table 7-4 List of O-rings for Use Used locations JIS-B2401 (mm type) attached place description in function aspect Balance Piston Sleeve same as left Oil Seal Retainer same as left Oil Injection Pipe Guide Oil Injection Pipe...
  • Page 137 2202L5JE-DA-C5-N_2015.05. 7 Related Documents Disassembly Tools Table 7-6 List of Tools for Standard Disassembly Tool name size, etc.; Code No. Ratchet wrench 1/4” SG261-08 Adjustable wrench 250 mm SG231-250 Screwdriver Phillips SG112-075 Screwdriver Flat blade SG111-075 Snap ring pliers external for shaft ST-2N SG311-02N Snap ring pliers internal...

  • Page 138: Contact Information

    Contact Information_2015.04. Contact Information Sales Offices/Service Centers  Sales Offices in Japan (as of April 21, 2015) Description Location Phone/Fax Head Office 3–14–15 BOTAN KOTO-KU, TOKYO 135-8482 TEL: 03-3642-8181 FAX: 03-3643-7094 Hokkaido 2-5-1, 3-JYO NIJYUUYONKEN NISHI-KU, TEL: 011-631-2052 Branch SAPPORO-CITY, HOKKAIDO 063-0803 FAX: 011-631-2053 Tohoku 8-72, ROKUTYONO-MEMINAMI-MACHI,...

  • Page 139: Global Network

    Contact Information_2015.04.  Global Network (as of , 2015) April 21 Telephone and Description Location facsimile No. NORTH AMERICA MAYEKAWA CANADA INC. 12180 RIVERSIDE WAY, TEL: (1) 604-270-1544 (VANCOUVER OFFICE) RICHMOND, B.C., V6W 1K5, CANADA FAX: (1) 604-270-9870 MAYEKAWA CANADA INC. 1745 BONHILL ROAD, TEL: (1) 905-564-0664 (TORONTO OFFICE)

  • Page 140: Asia Pacific

    Contact Information_2015.04. Telephone and Description Location facsimile No. MAYEKAWA. S.L. CALLE MONTEVIDEO 5, NAVE 13 TEL: (34) 91-830-0392 POL. INDUSTRIAL CAMPORROSO FAX: (34) 91-830-0397 28806 ALCALA DE HENARES, MADRID, SPAIN MAYEKAWA FRANCAISE SARL 9, RUE MICHAEL FARADAY, 78180 TEL: (33) 1-30-58-26-00 MONTIGNY-LE-BRETONNEUX, FAX: (33) 1-30-58-19-37 FRANCE...
  • Page 141 Contact Information_2015.04. Telephone and Description Location facsimile No. P.T.MAYEKAWA INDONESIA GRAHA PRATAMA BUILDING, 9TH TEL: (62) 21-8370-9484 FLOOR JL. M.T. HARYONO KAV.15 FAX: (62) 21-8370-9483 JAKARTA 12810, INDONESIA P.T.MAYEKAWA INDONESIA JL. SUTRISNO No.274 MEDAN-20215, TEL: (62) 61-7323627 (MEDAN OFFICE) INDONESIA FAX: (62) 61-7358848 P.T.MAYEKAWA INDONESIA BUMI MANDIARI BUILDING, 7TH...

  • Page 142: Latin America

    MEMBER CO., LTD. 60A HOANG VAN THU, WARD 9, FAX: (84) 8-3997-5287 PHU NHUAN DIST., HO CHI MINH CITY, VIETNAM MYCOM KOREA CO., LTD. 2F, 345, CHEONGRA-RO , TEL: (82) 2-796-1766 (HEAD OFFICE) YONGSAN-KU, FAX: (82) 2-798-7715 SEOUL, 140-710, REP.OF KOREA MYCOM KOREA CO., LTD.
  • Page 143 FAX: (55) 21-2430-8882 LTDA. TRADE II, (RIO DE JANEIRO BRANCH) BARRA DA TIJUCA, RIO DE JANEIRO-RJ CEP:22775-055, BRASIL MYCOM CENTROAMERICA S.A BODEGA #63, CONDOMINIO TEL: (506) 2441-4464 COMERCIAL TIERRA DOS, EL FAX: (506) 2441-4465 CACIQUE DE RIO SEGUNDO, ALAJUELA, COSTA RICA...
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