mycom i125S Instruction Manual
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mycom i125S Instruction Manual

Screw compressor
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i-Series Screw Compressor
Instruction Manual
This manual is applied to each compressor after the serial number
shown below.
i125S: 8750303
i160S: 8710055
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 is subject to change without prior notice.
i160S / i160M / i160L
:
i125L
8770301
i160M: 8720018
CAUTION
2200M4JE-HO-iS2-N_2014.04.
i125S / i125L
i160L: 8730030

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  • Page 1 2200M4JE-HO-iS2-N_2014.04. i-Series Screw Compressor Instruction Manual i125S / i125L i160S / i160M / i160L This manual is applied to each compressor after the serial number shown below. i125S: 8750303 i125L 8770301 i160S: 8710055 i160M: 8720018 i160L: 8730030 CAUTION Before operating, servicing, or inspecting this product, read this manual thoroughly to fully understand the contents.
  • Page 2 2200M4JE-DA-iS2-N_2014.04. Preface Preface Thank you for purchasing our i-series screw compressor (hereinafter referred to as "this product"). This instruction manual (hereinafter referred to as "this manual") provides safety information and operation and maintenance procedures, so that users correctly understand how to handle this product and, as a result, can use it safely and efficiently.
  • Page 3 2200M4JE-DA-iS2-N_2014.04. 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 2200M4JE-DA-iS2-N_2014.04. Important Information Important Information Intended Use of this Product This product is a general-purpose screw compressor for refrigeration and cold storage. Do not use this product for any other purposes that are not intended for or which depart from the specifications. For specifications of this product, refer to "2.3 Compressor Specifications".
  • Page 5 2200M4JE-DA-iS2-N_2014.04. Important Information [Tagout] To prevent any inappropriate work by hanging tag plates indicating "work in progress". “Tagout” means to clearly indicate, by hanging tag plates, that a device is in lockout and that operation of the device is prohibited. Tag plates forbidding operation, starting, opening, etc. are warnings clearly stating to not operate energy (power) sources, and are not for stopping blocking devices.
  • Page 6 2200M4JE-DA-iS2-N_2014.04. Important Information Structure of This Manual Chapter/Section Title Description Preface Describes the outline of this manual and how to read this manual. Describes what MAYEKAWA warrants and what are covered by the Warranty and Disclaimer warranties. Warranty exemption is stated as disclaimer. Describes important information related to this product and this Important Information manual.

  • Page 7: Table Of Contents

    2200M4JE-DA-iS2-N_2014.04. Table of Contents Table of Contents Preface ････････････････････････････････････････････････････････ⅰ Revision History ･･････････････････････････････････････････････････････････････ⅰ Warranty and Disclaimer･･･････････････････････････････････････ⅱ Warranty Clauses ....................ⅱ Disclaimer Clauses (Exclusion of Warranty Clauses) ........ⅱ Important Information･･････････････････････････････････････････ⅲ Intended Use of this Product ................. ⅲ Important Information for Safe Use of this Product ..........ⅲ About This Manual ....................
  • Page 8 2200M4JE-DA-iS2-N_2014.04. Table of Contents Compressor Specifications ................ 2-2 2.3.1 Specifications ....................... 2-2 2.3.2 Operation Limits ....................2-3 2.3.3 Alarm Set Values ....................2-4 2.3.4 Outer Dimensions ....................2-5 Configuration of Compressor ..............2-10 2.4.1 Sectional View ....................2-10 2.4.2 Development View of Parts ................2-16 2.4.3 Parts Configuration Table ..................
  • Page 9 2200M4JE-DA-iS2-N_2014.04. Table of Contents 4.2.2 Purging of Non-Condensable Gases ..............4-4 4.2.3 Action for Stopping the Compressor for Long Period of Time ......4-5 Chapter 5 Maintenance and Inspection Precautions for Maintenance and Inspection ..........5-1 Maintenance and Inspection List..............5-2 5.2.1 Daily Management ....................
  • Page 10 2200M4JE-DA-iS2-N_2014.04. Table of Contents 5.5.9.1a Disassembly (i125) ..................5-17 5.5.9.1b Disassembly (i160) ..................5-17 5.5.9.2 Inspection ....................5-18 5.5.10 Unloader ......................5-18 5.5.10.1 Disassembly ....................5-18 5.5.10.2 Inspection ....................5-18 Reassembly ....................5-19 5.6.1 Unloader ......................5-20 5.6.2 Rotor and Inner Ring of Radial Bearing ............. 5-20 5.6.3 Bearing Head .....................

  • Page 11: Chapter 1 Safety

    2200M4JE-HO-iS2-N_2014.04. Chapter 1 Safety Chapter 1 Safety Observation/Prevention (DOs and DON'Ts) 1.1.1 1.1.1.1 DOs on Operation  Make sure to attach safety and protective devices to the package unit.  The safety devices and protection systems must be regularly checked for their normal operation.

  • Page 12: Dos On Lockout/Tagout After Shutting Off The Power

    2200M4JE-HO-iS2-N_2014.04. Chapter 1 Safety 1.1.1.3 DOs on Lockout/Tagout after Shutting Off the Power  A lock-out/tag-out mechanism must be installed for the main circuit breakers that supply power to the motor and power to the control system. The lock-out/tag-out after power down is a very effective means to ensure the safety when two or more workers are working on the system at the same time, as it can prevent possible injury of workers that may be caused by accidental power-on of the driving source by one of the workers.

  • Page 13: Don'ts

    2200M4JE-HO-iS2-N_2014.04. Chapter 1 Safety 1.1.2 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

    2200M4JE-HO-iS2-N_2014.04. Chapter 1 Safety Residual Risks The following information assumes that this product is operated or inspected/maintained as part of a general package unit for refrigeration/cold storage. It is impossible to predict all the risk sources involved in actual use of the package unit. Devise appropriate countermeasures for hazardous sources in your systems.
  • Page 15 2200M4JE-HO-iS2-N_2014.04. Chapter 1 Safety Measures to be taken Hazardous Measures to be taken during cleaning, Predicted hazard sources in operation inspection or parts replacement  Electric shock caused  Install protective cover  Turn off each breaker Package Unit Electric by contact with live on terminals, and and the control power,...

  • Page 16: Safety Devices

    2200M4JE-HO-iS2-N_2014.04. Chapter 1 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.

  • Page 17: Compressor Protective Devices

    2200M4JE-HO-iS2-N_2014.04. Chapter 1 Safety 1.4.3 Compressor Protective Devices  Be sure to adjust the set values and check operation of the protective devices when commissioning. Also, after that, the regular operation confirmation is necessary. Install necessary protection devices shown in section 2.3.3 "Alarm Set Values" in this manual chapter 2. Also, install the following protection devices that are not indicate in section 2.3.3, as occasion demands.

  • Page 18: Features Of I-Series Compressor

    2200M4-JE-HO-iS2-N_2014.04. Chapter 2 Compressor Specifications and Configuration Chapter 2 Compressor Specifications and Configuration Features of i-Series Compressor i-series compressor enables designers to design highly reliable and most compact refrigerating unit. It has a lot of features.  Centering is made unnecessary by mounting the motor using a flange. By mounting the motor using a flange eliminates the need of the troublesome motor centering before starting the equipment.

  • Page 19: Compressor Specifications

    (Applies to i-series compressors manufactured *Note 2 and shipped in May 2014 or after.) Capacity control 3-step (100%, 75%, 50%) unloader ANSI ＃300 5" Suction flange MYCOM 100A (4") MYCOM 65A ANSI ＃300 3" Discharge flange (2-1/2") Connected Oil inlet port...

  • Page 20: Operation Limits

    2200M4-JE-HO-iS2-N_2014.04. Chapter 2 Compressor Specifications and Configuration 2.3.2 Operation Limits Table 2-2 Operation Limits of i-Series Compressor Items Operation limits Permissible limit *Note 1 2950@50Hz 125S, 160S: Max. 4500 *Note 2 Speed 3550@60Hz 125L, 160M, 160L : Max. 3550 Discharge pressure 1.0 - 1.9 Max.

  • Page 21: Alarm Set Values

    To protect the compressor, please set the alarm shown in the table below. Table 2-3 Application Limits of i-series Compressor * Note 1 Item Unit Alarm Stop i125S, i160S: 4550 (0 sec.) High — i125L, i160M, i160L: 3650 (0 sec.) Rotation speed 1450 (0 sec.) —...

  • Page 22: Outer Dimensions

    2200M4-JE-HO-iS2-N_2014.04. Chapter 2 Compressor Specifications and Configuration 2.3.4 Outer Dimensions Figure 2-1 i125S Outer Dimensions Diagram Screw Compressor i-series 2.3 Compressor Specifications...
  • Page 23 2200M4-JE-HO-iS2-N_2014.04. Chapter 2 Compressor Specifications and Configuration Figure 2-2 i125L Outer Dimensions Diagram Screw Compressor i-series 2.3 Compressor Specifications...
  • Page 24 2200M4-JE-HO-iS2-N_2014.04. Chapter 2 Compressor Specifications and Configuration Figure 2-3 i160S Outer Dimensions Diagram Screw Compressor i-series 2.3 Compressor Specifications...
  • Page 25 2200M4-JE-HO-iS2-N_2014.04. Chapter 2 Compressor Specifications and Configuration Figure 2-4 i160M Outer Dimensions Diagram Screw Compressor i-series 2.3 Compressor Specifications...
  • Page 26 2200M4-JE-HO-iS2-N_2014.04. Chapter 2 Compressor Specifications and Configuration Figure 2-5 i160L Outer Dimensions Diagram Screw Compressor i-series 2.3 Compressor Specifications...

  • Page 27: Configuration Of Compressor

    2200M4-JE-HO-iS2-N_2014.04. Chapter 2 Compressor Specifications and Configuration Configuration of Compressor 2.4.1 Sectional View Figure 2-6 i125L Longitudinal Sectional View Screw Compressor i-series 2.4 Configuration of Compressor 2-10...
  • Page 28 2200M4-JE-HO-iS2-N_2014.04. Chapter 2 Compressor Specifications and Configuration Figure 2-7 i125L Cross-Sectional View Screw Compressor i-series 2.4 Configuration of Compressor 2-11...
  • Page 29 2200M4-JE-HO-iS2-N_2014.04. Chapter 2 Compressor Specifications and Configuration Figure 2-8 i125 Longitudinal Sectional View of Suction/Capacity Control Section Screw Compressor i-series 2.4 Configuration of Compressor 2-12...
  • Page 30 2200M4-JE-HO-iS2-N_2014.04. Chapter 2 Compressor Specifications and Configuration Figure 2-9 i160S Longitudinal Sectional View Screw Compressor i-series 2.4 Configuration of Compressor 2-13...
  • Page 31 2200M4-JE-HO-iS2-N_2014.04. Chapter 2 Compressor Specifications and Configuration Figure 2-10 i160S Cross-Sectional View Screw Compressor i-series 2.4 Configuration of Compressor 2-14...
  • Page 32 2200M4-JE-HO-iS2-N_2014.04. Chapter 2 Compressor Specifications and Configuration Figure 2-11 i160 Longitudinal Sectional View of Suction/Capacity Control Section Screw Compressor i-series 2.4 Configuration of Compressor 2-15...

  • Page 33: Development View Of Parts

    2200M4-JE-HO-iS2-N_2014.04. Chapter 2 Compressor Specifications and Configuration 2.4.2 Development View of Parts Figure 2-12 Development View of i125S/L Parts with Motor Spacer Screw Compressor i-series 2.4 Configuration of Compressor 2-16...
  • Page 34 2200M4-JE-HO-iS2-N_2014.04. Chapter 2 Compressor Specifications and Configuration Figure 2-13 Development View of i160S/L Parts with Motor Spacer Screw Compressor i-series 2.4 Configuration of Compressor 2-17...

  • Page 35: Parts Configuration Table

    2200M4-JE-HO-iS2-N_2014.04. Chapter 2 Compressor Specifications and Configuration 2.4.3 Parts Configuration Table Table 2-4 i125S/L Parts Configuration Table Part name Code No. Remarks Main Rotor Casing CS00102-I125S* i125S-* port Main Rotor Casing CS00102-I125L* i125L-* port Hexagon Socket Head Cap Screw NB35412-050 M12×50 SCM435...
  • Page 36 2200M4-JE-HO-iS2-N_2014.04. Chapter 2 Compressor Specifications and Configuration Part name Code No. Remarks 38-2 Thrust Bearing F CS03800-I125F i125F 39-1 Lock Nut NG31-008 39-2 Lock Nut NG31-009 40-1 Lock Washer NG32-008 40-2 Lock Washer NG32-009 41-1 Spacer, Thrust Bearing Outer Race M CS25000-FM11S FM11S Thrust Washer 41-2...
  • Page 37 2200M4-JE-HO-iS2-N_2014.04. Chapter 2 Compressor Specifications and Configuration Part name Code No. Remarks Nipple (High Pressure) NN410-080 R3/8 Sch40 80L Connection (L-type) NJ3-0803NE L-Φ8-R3/8 JO4060 Connection (L-type) NJ3-0802NE L-Φ8-R1/4 JO4050 Φ8 Piping QA11-08 Wave Washer ND91-016 FM125 BW16 Angle Valve NF042-0302N JO5820 R1/4×Rc1/4 Gland PK CR72200-NR94...
  • Page 38 2200M4-JE-HO-iS2-N_2014.04. Chapter 2 Compressor Specifications and Configuration Table 2-5 i160 Parts Configuration Table Part name Code No. Remarks Main Rotor Casing CS00102-I160S* i160S-* port Main Rotor Casing CS00102-I160M* i160M-* port Main Rotor Casing CS00102-I160L* i160L-* port Hexagon Socket Head Cap Screw NB35416-055 M16×55 SCM435 13×50L With internal thread...
  • Page 39 PA12-110 JIS B 2401 G110 150-2 O-ring, Thrust Bearing Gland F PA12-115 JIS B 2401 G115 216-2 Flange Gasket, Oil Inlet Port CR72000-025N MYCOM 25A Motor Spacer CS23500-I160N i160 235-1 Plate, Motor Spacer CS23510-FM160 FM160 235-2 Hexagon Socket Head Cap Screw NB35406-010 M6×10 SCM435...
  • Page 40 2200M4-JE-HO-iS2-N_2014.04. Chapter 2 Compressor Specifications and Configuration Part name Code No. Remarks i160 #150 Φ160×200 Strainer Element CS48000-I160 Retainer, Strainer Element CS48100-I160 i160 Check Valve Spring CS48500-I160 i160 Hexagon Nut NC622-10 FM160(U-NUT M10 Type 2) Plain Washer ND193-10 Small-sized SPCC1 M10 Seat Stopper CS48800-I160 i160...

  • Page 41: Mechanisms

    2200M4-JE-HO-iS2-N_2014.04. Chapter 2 Compressor Specifications and Configuration Mechanisms 2.5.1 Basics of the Screw Compressor The screw compressor is categorized as a positive displacement rotary compressor. It has features of both reciprocating and centrifugal compressors. As shown in Figure 2-14, the refrigerant (gas) is continuously compressed by the 3-dimensional spaces that are formed by a pair of male and female screw rotors (with different sectional profiles) and the casing, as the spaces change continuously.

  • Page 42: Compression Process

    2200M4-JE-HO-iS2-N_2014.04. Chapter 2 Compressor Specifications and Configuration 2.5.3 Compression Process As the rotors rotate further, the volume between the rotor teeth and grooves decreases while the sealing line moves toward the discharge side, which compresses the trapped refrigerant gas. Figure 2-16 Compression Process Figure 2-17 Discharge Process 2.5.4 Discharge Process...
  • Page 43 2200M4-JE-HO-iS2-N_2014.04. Chapter 2 Compressor Specifications and Configuration (A) Properly adapted Vi to load condition Both the required compression ratio and Vi are low. Both the required compression ratio and Vi are high. (B) Improperly adapted Vi to load condition Too low Vi compared with necessary compression ratio. Too high Vi compared with necessary compression ratio Figure 2-19 Relationship between Volume ratio (Vi) and Operation Conditions Screw Compressor i-series...

  • Page 44: Chapter 3 Installation

    2200M4JE-HO-iS2-N_2014.04. Chapter 3 Installation Chapter 3 Installation General Precautions for Installation  The description in Chapter 3 “Installation” assumes that the compressor is installed to a package unit intended for standard type refrigeration/cold storage. If the package unit you are actually using is not the one for standard type refrigeration/cold storage, prepare a proper installation manual by referring to the description in this chapter and paying due consideration to safety, before installing the compressor.
  • Page 45 2200M4JE-HO-iS2-N_2014.04. Chapter 3 Installation 4. To lift the compressor, attach the wire ropes to the appended eye bolts by using appropriate shackles and hooks. Use the eye bolts only for lifting the compressor. Figure 3-1 Eye bolts for lifting the compressor (Arrows) ...

  • Page 46: Preparation For Installation

    2200M4JE-HO-iS2-N_2014.04. Chapter 3 Installation 3.2.4 Preparation for Installation  Installation Space Secure sufficient working space for easy operation, cleaning, maintenance, and inspection.  Lighting Provide sufficient lighting to allow easy operation, cleaning, maintenance, and inspection.  Ventilation If natural ventilation is insufficient, install ventilation fans according to the relevant regulations. ...

  • Page 47: Airtightness Test

    2200M4JE-HO-iS2-N_2014.04. Chapter 3 Installation  Suction Strainer When miscible oil is used, the mesh size of suction strainer should be not less than 200 meshes. When non-miscible oil is used, it should be not less than 100 meshes. For details about miscible and non-miscible oils, refer to section 4.1 "Lubricant (Refrigerant Oil)" in this manual.

  • Page 48: Additional Charge Of Lubricant

    2200M4JE-HO-iS2-N_2014.04. Chapter 3 Installation  Be sure to conduct the initial charge of lubricant in such a way that the oil cooler and oil filter are filled with lubricant.  For details about lubricant to be used, refer to section 4.1 "Lubricant (Refrigerant Oil)" in this manual.

  • Page 49: Chapter 4 Operation Of Compressor And Unit

    2200M4JE-HO-iS2-N_2014.04. Chapter 4 Operation of Compressor and Unit Chapter 4 Operation of Compressor and Unit Lubricant (Refrigerant Oil) Lubrication management is very significant to keep the compressor in a good operating condition. Take the following notes when managing lubricant. 4.1.1 Precautions for Selecting the Lubricant ...

  • Page 50: Recommended Lubricants

    2200M4JE-HO-iS2-N_2014.04. Chapter 4 Operation of Compressor and Unit 4.1.2 Recommended Lubricants When selecting lubricant, not only compatibility with refrigerant but also effects on O-rings must be considered. To prevent compressor malfunctions, we recommend the lubricant described below. 4.1.2.1 Recommended Lubricants for Ammonia Refrigerant ...

  • Page 51: Oils For Systems Using Hfc Refrigerants

    2200M4JE-HO-iS2-N_2014.04. Chapter 4 Operation of Compressor and Unit 4.1.2.2 Oils for Systems Using HFC Refrigerants Polyolester Synthetic Oil (POE) for R404A and R507A: Inter-soluble Synthetic Oil Kinematic Brand viscosity Manufacturer Type (40°C) mm SUNISO SL-68S Sun Oil EMKARATE RL68H Lubrizol ...

  • Page 52: Precautions For Operation

    2200M4JE-HO-iS2-N_2014.04. Chapter 4 Operation of Compressor and Unit Precautions for Operation 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. Liquid flow-back may cause insufficient lubrication of the compressor, abnormal vibrations and noises, and abnormal foaming of lubricant (too much entry of oil).

  • Page 53: Action For Stopping The Compressor For Long Period Of Time

    2200M4JE-HO-iS2-N_2014.04. Chapter 4 Operation of Compressor and Unit 4.2.3 Action for Stopping the Compressor for Long Period of Time When stopping the compressor for a long period of time, conduct the following:  Turn off the motor main power.  Turn off the heater power and control panel power. ...

  • Page 54: Chapter 5 Maintenance And Inspection

    2200M4JE-HO-iS2-N_2014.04. Chapter 5 Maintenance and Inspection Chapter 5 Maintenance and Inspection Precautions for Maintenance and Inspection  Before starting maintenance/inspection work after completely recovering the refrigerant from the unit, make sure that the main motor power, control power and power for instruments and valves are turned off and that the turned-off switches are protected from any unauthorized access.

  • Page 55: Maintenance And Inspection List

    2200M4JE-HO-iS2-N_2014.04. Chapter 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. By regularly recording the daily operational data in an operation log, it should be able to detect any significant change in the system.
  • Page 56 2200M4JE-HO-iS2-N_2014.04. Chapter 5 Maintenance and Inspection Inspection Item Inspection Details Check Items/Actions  Mechanical seal failure Leak from Leak per hour mechanical seal  Compressor failure Noise and Abnormal vibration noise/vibration  Compressor failure Motor current Whether it is higher than at test run ...

  • Page 57: Periodical Inspection

    2200M4JE-HO-iS2-N_2014.04. Chapter 5 Maintenance and Inspection 5.2.2 Periodic Inspection Check the following items at specified intervals. In addition, regarding other related items such as any safety devices, gas leak detectors, or other utility (gas/electricity) protection devices that constitute the cooling system together with the compressor, even if they are not directly connected to the compressor, any regulatory requirements that require inspection and recording of the results must be observed according to the instructions provided.
  • Page 58 2200M4JE-HO-iS2-N_2014.04. Chapter 5 Maintenance and Inspection 5.2.3 Guidelines for Compressor Overhaul Interval When servicing or overhauling the compressor, follow the instructions and guidelines described below. 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 lists overhaul intervals recommended by MAYEKAWA which are categorized based on the compressor operating conditions.

  • Page 59: Management Of Lubricant

    2200M4JE-HO-iS2-N_2014.04. Chapter 5 Maintenance and Inspection Management of Lubricant 5.3.1 Management Criteria Lubricants, to which the management criteria applies, are classified as follows: (1) Mineral oils: Naphthenic base and paraffinic base (2) Synthetic oils: Alkyl benzene (AB) and Polyalphaolefine (PAO) (3) Synthetic oils: Polyolesters (POE) ...

  • Page 60: Compressor Disassembly Preparation

    2200M4JE-HO-iS2-N_2014.04. Chapter 5 Maintenance and Inspection Compressor Disassembly Preparation Screw compressors are very reliable compressors. However, it is necessary to disassemble and inspect parts after a certain period of operation. This chapter describes the order and method of disassembly, and locations of and methods for inspecting parts. As a general rule, periodic inspections where the compressor is completely disassembled should be done at the manufacturing factory.

  • Page 61: Replacement Parts

    2200M4JE-HO-iS2-N_2014.04. Chapter 5 Maintenance and Inspection 5.4.2 Replacement Parts Prepare genuine replacement parts. Table 5-7 and table 5-8 are lists of standard parts to be replaced when i-series compressor overhauled. When purchasing any part, inform its (a) model, (b) serial number, (c) part name, (d) part code and to our sales offices or service centers.
  • Page 62 PA12-110 JIS B 2401 G110 150-2 O-ring see Note 1 PA12-115 JIS B 2401 G115 216-2 Flange Gasket, Oil Inlet Port CR72000-025N MYCOM 25A 237-1 Torsional Slip Washer M CS23700-FM160M FM160 237-2 Torsional Slip Washer F CS23700-160 160*** Gasket, Unloader Cover CS39500-I160 i160 t=1.0...

  • Page 63: Refrigerant Gas Treatment

    2200M4JE-HO-iS2-N_2014.04. Chapter 5 Maintenance and Inspection 5.4.3 Refrigerant Gas Treatment 5.4.3.1 Valves Used Before removing the compressor or when performing air tightness test or evacuation, refrigerant gas is recovered and charged. As the i-series compressor has a built-in check valve, care should be taken. Work procedures differ between the i125 and i160.

  • Page 64: Removing Parts Connected To The Unit

    2200M4JE-HO-iS2-N_2014.04. Chapter 5 Maintenance and Inspection 5.4.4 Removing Parts Connected to the Unit  If refrigerant gas or a mixture of refrigerant and oil remains in the compressor, refrigerant gas may blow off when the closed circuit is opened. This may result in injury such as frostbite or loss of vision.

  • Page 65: Disassembly And Inspection

    2200M4JE-HO-iS2-N_2014.04. Chapter 5 Maintenance and Inspection Disassembly and Inspection  When handling heavy objects, exercise extreme care and use apparatus such as crane as necessary. There is a risk that the compressor's main body or parts may drop on human body. Be careful with handling of the parts during disassembly and inspection.

  • Page 66: Inspection

    2200M4JE-HO-iS2-N_2014.04. Chapter 5 Maintenance and Inspection g) Loosen the set screws 【111】 of the seal collar 【109】 by turning them approximately three times (Photo 003). Do not remove the set screws completely, but leave them so that their ends are below the surface of the seal collar.

  • Page 67: Bearing Cover

    2200M4JE-HO-iS2-N_2014.04. Chapter 5 Maintenance and Inspection Photo 005 Part Name Mating ring Insert lock pin Stationary rings O-ring Seal collar Seal collar set screw Rotating rings O-ring Figure 5-1 Details of BBSE Mechanical Seal Assembly 5.5.2 Bearing Cover 5.5.2.1 Disassembly a) Remove two threaded alignment pins 【3】...

  • Page 68: Balance Piston

    2200M4JE-HO-iS2-N_2014.04. Chapter 5 Maintenance and Inspection 5.5.3 Balance Piston 5.5.3.1 Disassembly a) The balance piston sleeve 【33】 and the balance piston 【30】 can be removed just by removing the snap ring 【32】. Photo 008 Removing the Stop Ring Photo 009 Removing the Balance Piston Sleeve Photo 010 Removing the Balance Piston 5.5.3.2 Inspection...

  • Page 69: Thrust Bearings

    2200M4JE-HO-iS2-N_2014.04. Chapter 5 Maintenance and Inspection 5.5.5 Thrust Bearings The thrust bearings 【38-1】 【38-2】 are face-to-face angular contact ball bearings. 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. Apart from receiving the thrust load, the bearing has the important role of securing the position of the gap between the rotor and the discharge side of the bearing head.

  • Page 70: Bearing Head

    2200M4JE-HO-iS2-N_2014.04. Chapter 5 Maintenance and Inspection 5.5.6 Bearing Head Though the case dividing method differs between i125 and i160, the work flow is the same. 5.5.6.1 Disassembly a) Attach lifting tools, remove all bolts 【2-1】 that hold the part to the main rotor casing, and separate the part from the main rotor casing.

  • Page 71: Radial Bearing

    2200M4JE-HO-iS2-N_2014.04. Chapter 5 Maintenance and Inspection 5.5.8 Radial Bearing Two pairs of large and small radial bearings are used. Put the disassembled parts in order to distinguish which bearing has been used where. 5.5.8.1 Disassembly a) Put the radial bearing with the side containing the bearing for bearing head 【11】 faced upward. b) Remove stop rings 【29-1】...

  • Page 72: Inspection

    2200M4JE-HO-iS2-N_2014.04. Chapter 5 Maintenance and Inspection d) Observe the main body of the check valve from the strainer cover side. Check that it moves smoothly. e) Remove Φ10 piping 【557】. f) Remove the R1/2 plug from check valve cover 【8】, and pull out check valve spring 【485】. g) Remove the check valve cover.

  • Page 73: Reassembly

    2200M4JE-HO-iS2-N_2014.04. Chapter 5 Maintenance Reassembly  When turning on/off electric tools, take care to avoid electric shocks.  When handling heavy objects, exercise extreme care and use apparatus such as crane as necessary. There is a risk that the compressor's main body or parts may drop on human body.

  • Page 74: Unloader

    2200M4JE-HO-iS2-N_2014.04. Chapter 5 Maintenance 5.6.1 Unloader a) In the same way as for disassembly, lay main rotor casing 【1】 on its side (horizontally). b) Set unloader cover gasket 【395】, unloader piston 【391】 and spring 【392】 to unloader cover 【393】. You can install the unloader piston and spring first. c) Insert this into the main rotor casing, and tighten the unloader cover.

  • Page 75: Bearing Head

    2200M4JE-HO-iS2-N_2014.04. Chapter 5 Maintenance d) By following the same procedure as for the M rotor, push the F rotor into the main rotor casing. At this moment, engage the M rotor tooth, which has stamped mark 1, between the F rotor teeth having stamped marks 1 and 2.

  • Page 76: Suction Strainer And Check Valve

    2200M4JE-HO-iS2-N_2014.04. Chapter 5 Maintenance 5.6.5 Suction Strainer and Check Valve The structure differs between the i125 series and i160 series. 5.6.5.1 i 125 Series a) Set O-ring 【495】 and check valve spring 【485】 to check valve shaft 【491】, and insert it to suction adapter 【5-1】. b) While holding the check valve shaft with a hand to prevent it from coming off, insert seat stoppers 【488-1】...

  • Page 77: Adjustment Of Thrust Bearing And End Clearance

    2200M4JE-HO-iS2-N_2014.04. Chapter 5 Maintenance 5.6.6 Adjustment of Thrust Bearing and End Clearance Figure 5-3 Thrust Bearings Section Table 5-12 Thrust Bearing Components Part name i125 i160 38-1 Thrust Bearing M 1 set 1 set 38-2 Thrust Bearing F 1 set 1 set 39-1 Lock Nut...
  • Page 78 2200M4JE-HO-iS2-N_2014.04. Chapter 5 Maintenance  When assembling the disassembled thrust bearing without replacing any parts, check the M and F stamp marks on the thrust bearing outer race spacer and thrust bearing alignment spacer, and reassemble them in the same way as before disassembly.

  • Page 79: End Clearance Measurement

    2200M4JE-HO-iS2-N_2014.04. Chapter 5 Maintenance 5.6.6.1 End Clearance Measurement At this moment, measure the end clearance on the discharge side of the fully assembled rotor. In particular, when the thrust bearing has been replaced, the end clearance must be measured. Even when the same bearing is used, measure the end clearance for confirmation.

  • Page 80: End Clearance Adjustment

    2200M4JE-HO-iS2-N_2014.04. Chapter 5 Maintenance 5.6.6.2 End Clearance Adjustment  When 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 81: Balance Piston

    2200M4JE-HO-iS2-N_2014.04. Chapter 5 Maintenance 5.6.7 Balance Piston a) With the notch of balance piston 【30】 aligned with the slotted set screw of M rotor shaft 【31】, install the balance piston. b) With the notch of the balance piston sleeve 【33】 aligned with the spring pin, install the balance piston sleeve.

  • Page 82: Mechanical Seal

    2200M4JE-HO-iS2-N_2014.04. Chapter 5 Maintenance 5.6.9 Mechanical seal The standard mechanical seal assemblies used in the current standard screw compressors are of the BBSE (balance bellows single) type. a) Before assembly, clean the portion where the rotor shaft seal will be installed. b) In particular, recheck immediately before assembly that the stepped portion where the axial seal will be mounted is free of damage.
  • Page 83 2200M4JE-HO-iS2-N_2014.04. Chapter 5 Maintenance g) By using two seal collar set screws 【111】, tighten the seal collar against the countersunk holes in the rotor shaft. Tightening the seal collar at other places than the countersunk holes can cause damage to the rotor shaft which can lead to leakage. h) Assemble O-ring 【103】...

  • Page 84: End Cover

    2200M4JE-HO-iS2-N_2014.04. Chapter 5 Maintenance k) When the seal tightening allowance is proper, push the seal cover firmly into the bearing cover. Since there is repulsion force of the seal bellows, keep it pushed firmly and tighten the two hexagon socket head cap screws (for tightening the seal cover) evenly at positions 180 degrees apart.

  • Page 85: Chapter 6 Troubleshooting

    2200M4JE-HO-iS2-N_2014.04. Chapter 6 Troubleshooting Chapter 6 Troubleshooting Table 6-1 describes typical trouble symptoms of compressors, their causes and actions to be taken. For information about troubleshooting for the unit or the whole refrigeration cycle, refer to the instruction manual of the unit. Table 6-1 Troubleshooting Symptom Direct cause...
  • Page 86 2200M4JE-HO-iS2-N_2014.04. Chapter 6 Troubleshooting Symptom Direct cause Root cause Action Compressor Motor overload Motor overload that occurs just after startup is mostly stops caused not by the refrigeration cycle but by the motor. immediately Refer to the instruction manual of the motor. after startup.
  • Page 87 2200M4JE-HO-iS2-N_2014.04. Chapter 6 Troubleshooting Symptom Direct cause Root cause Action Abnormally Heat exchange Heat transmission Clean and wash. failure in condenser tubes and/or fins Depending on the contamination high pressure (heat exchanger) are contaminated level, use chemical cleaning. (Abnormal or blocked. discharge Failure or water Identify defective devices,...
  • Page 88 2200M4JE-HO-iS2-N_2014.04. Chapter 6 Troubleshooting Symptom Direct cause Root cause Action Abnormally Refrigerant is In some cases, Properly adjust the refrigerant high excessive. insufficient cooling charge. pressure is judged as (Abnormal caused by discharge insufficient pressure) refrigerant and, as a result, refrigerant is charged repeatedly.
  • Page 89 2200M4JE-HO-iS2-N_2014.04. Chapter 6 Troubleshooting Symptom Direct cause Root cause Action Discharge Defective discharge Failure of Identify defective devices, temperature temperature temperature investigate causes of failure and is abnormally detection/protection protection switch, take necessary actions. high. feature. pressure sensor, Then, replace failed device(s). relay, etc.
  • Page 90 2200M4JE-HO-iS2-N_2014.04. Chapter 6 Troubleshooting Symptom Direct cause Root cause Action Leak from Deteriorated part(s) Deteriorated seal If deteriorated over time, replace. mechanical ring/mating ring For other specific causes, see the seal causes/action for symptom "Overheating of sliding surface". Incompatibility of Unsuitable If possible, review the operating lubricant and...
  • Page 91 2200M4JE-HO-iS2-N_2014.04. Chapter 6 Troubleshooting Symptom Direct cause Root cause Action Compressor M rotor shaft Rotor dynamic If no other causes are found for generates vibrates balance is abnormal vibration, or if on-site abnormal excessively. disturbed. overhaul only has been repeatedly vibration performed for a long time, this and/or...
  • Page 92 2200M4JE-HO-iS2-N_2014.04. Chapter 6 Troubleshooting Symptom Direct cause Root cause Action Compressor Liquid flow-back Heat exchange In case of frosting (icing), conduct generates manual defrosting. during operation failure in heat Set defrosting interval shorter. abnormal * Notable frosting exchanger on load vibration on the suction side...
  • Page 93 2200M4JE-HO-iS2-N_2014.04. Chapter 6 Troubleshooting Symptom Direct cause Root cause Action Compressor Damaged thrust Excessive thrust Re-examine operating conditions, generates bearings. stress other than and improve if possible. abnormal above If difficult to improve, review ・High suction vibration maintenance interval and/or management.

  • Page 94: Chapter 7 Related Documents

    2200M4JE-HO-iS2-N_2014.04. Chapter 7 Related Documents Chapter 7 Related Documents Tightening Angles for Lock Nuts On June 14, 2010, the "Lock Nut Tightening Angle Range Control Standard" has been introduced to our compressor manufacturing division, to control the specified tightening torque for rotor shaft lock nuts as follows.

  • Page 95: List Of Tools For Disassembly Of I-Series

    2200M4JE-HO-iS2-N_2014.04. Chapter 7 Related Documents List of Tools for Disassembly of i-Series Table 7-2 List of Tools Tool i125 i160 Ratchet wrench 1/4” Adjustable wrench 250 mm Screwdriver (Phillips) Screwdriver (flat blade) Φ20 × L 300 (mm) Handle for hexagonal wrench key Φ15 ×...
  • Page 96 2200M4JE-HO-iS2-N_2014.04. Appendix: Basic Points of Design and Manufacturing for the Compressor Package This appendix describes the basic points of design and manufacturing for the packaging work using i-series compressor. In what is described here, there are overlapping explanations in chapter 1 to chapter 4 of this manual, but please refer to it as explanation to supplement them.
  • Page 97 2200M4JE-HO-iS2-N_2014.04.  Basic Flow of the Oil Cooler The supply of oil to the compressor must be in the range of 30 °C to 60 °C. Therefore, a cooler for lubricant cooling is necessary after an oil separator. Figure app.-2 is the reference flow of the water-cooled oil cooler.
  • Page 98 2200M4JE-HO-iS2-N_2014.04.  Oil Temperature Control Generally, in order to keep the lubricant temperature in the oil separator, install the oil heater at the bottom of the oil separator. In the cold district, the viscosity of lubricant at the compressor start-up is decreased;...
  • Page 99 2200M4JE-HO-iS2-N_2014.04.  Oil Separator In addition to the oil heater installation as described in the section of the oil temperature control, please also note the following points. 1) Installation of oil level gauge To manage the lubricant level, an oil level gauges that shows both the upper and lower level limit must be provided.
  • Page 100 Contact Information_2014.04. Contact Information How to Order Genuine Parts Confirm the target parts by referring to 2.4.3 "Parts Configuration Table" in Chapter 2 or 5.4.2 "Replacement Parts" in Chapter 5 of this manual. Please inform the Model Name and Serial Number, Part Name, Cord No., and required quantity to our local sales offices or service centers.
  • Page 101 Contact Information_2014.04.  Global Network (as of April 10, 2014) Telephone and Description Location facsimile No. NORTH AMERICA 12180 RIVERSIDE WAY, MAYEKAWA CANADA INC. TEL: (1) 604-270-1544 RICHMOND, B.C., V6W 1K5, CANADA (VANCOUVER OFFICE) FAX: (1) 604-270-9870 MAYEKAWA CANADA INC. 1745 BONHILL ROAD, TEL: (1) 905-564-0664 (TORONTO OFFICE)
  • Page 102 Contact Information_2014.04. Telephone and Description Location facsimile No. N.V.MAYEKAWA EUROPE 16 OAKHURST GARDENS, TEL: (44) 1322-433558 S.A.(UK) BEXLEYHEATH, FAX: (44) 1322-433164 KENT DA7 5JP, UNITED KINGDOM MAYEKAWA. S.L. CALLE MONTEVIDEO 5, NAVE 13 POL. TEL: (34) 91-830-0392 INDUSTRIAL CAMPORROSO 28806 FAX: (34) 91-830-0397 ALCALA DE HENARES, MADRID, SPAIN MAYEKAWA FRANCAISE SARL...
  • Page 103 Contact Information_2014.04. Telephone and Description Location facsimile No. MAYEKAWA INDIA PVT. LTD. SHOP NO. 3, OPP. TV TOWER, NIKODAR TEL: (91) 9711303865 (JALANDHAR OFFICE) ROAD, JALANDHAR, PUNJAB 144201, FAX: — INDIA TEL: (91) 89-5450-2937 MAYEKAWA INDIA PVT. LTD. CS-9 SECOND FLOOR, RASHMI FAX: (91) 97-1130-3865 (AGRA OFFICE) PALACE, SULTAN GANJ KI PULIA,...
  • Page 104 TEL: (84) 8-3997-5284 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, SEOUL, 140-710, FAX: (82) 2-798-7715 REP.OF KOREA...
  • Page 105 TEL: (54) 2965-475414 (PUERTO MADRYN OFFICE) LUGONES 45 FAX: (54) 2965-475414 (U9129KDA)-PUERTO MADRYN PCIA DE CHUBUT, REPUBLICA ARGENTINA MYCOM PERU S.A.C. CALLE LUIS PASTEUR 1490, TEL: (51) 1-205-5400 LINCE, LIMA, PERU FAX: (51) 1-222-1543 MAYEKAWA CHILE S.A.C.el. CORDILLERA No.331, MODULO D14,...
  • Page 106 313-EDIFICIO BARRA TRADE II, FAX: (55) 21-2430-8882 LTDA. BARRA DA TIJUCA, RIO DE JANEIRO-RJ (RIO DE JANEIRO BRANCH) CEP:22775-055, BRASIL MYCOM CENTROAMERICA S.A BODEGA #63, CONDOMINIO TEL: (506) 2441-4464 COMERCIAL TIERRA DOS, EL CACIQUE FAX: (506) 2441-4465 DE RIO SEGUNDO, ALAJUELA,...
  • Page 107 TEL: (58) 261-765-1059 SALES & SERVICE, C.A. LOCAL NRO.57, PLANTA ALTA, (BARCELONA OFFICE) MUNICIPIO SOTILLO, PUERTO LA CRUZ, VENEZUELA MYCOM CHEMICAL PROCESS CALLE 148,CENTRO EMPRESARIAL TEL: (58) 261-418-1760 CORP. DE VENEZUELA S.A. SAN FRANCISCO NIVEL 1 LOCAL 5 Y 6, FAX: -...
  • Page 108 2200M4JE-HO-iS2-N_2014.04. MAYEKAWA MFG. CO., LTD. 3-14-15 Botan, Koto-ku, Tokyo 135-8482, Japan 03-3642-8181 http://www.mayekawa.com...

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