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mycom UD Series Instruction Manual

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UD-series
Instruction Manual
Read this manual carefully and thoroughly before operating, maintaining or inspecting this
product. It is important to fully comprehend the contents of this manual. Keep the operation
manual in a safe, designated place for future reference whenever the need arises.
Specifications of this product are subject to change without prior notice.
Screw Compressor
125SUD/125LUD
160SUD/160MUD/160LUD
200SUD/200MUD/200LUD
250SUD/250MUD/250LUD
320SUD/320MUD/320LUD/320LLUD
400SUD/400MUD/400LUD/400LLUD/
400XLUD
CAUTION
2200X2JE-MY-S2-N_2020.09.

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  • Page 1 2200X2JE-MY-S2-N_2020.09. UD-series Screw Compressor Instruction Manual 125SUD/125LUD 160SUD/160MUD/160LUD 200SUD/200MUD/200LUD 250SUD/250MUD/250LUD 320SUD/320MUD/320LUD/320LLUD 400SUD/400MUD/400LUD/400LLUD/ 400XLUD CAUTION Read this manual carefully and thoroughly before operating, maintaining or inspecting this product. It is important to fully comprehend the contents of this manual. Keep the operation manual in a safe, designated place for future reference whenever the need arises.

  • Page 2: Preface

    Keep this manual in a safe place near this product for quick reference whenever needed. Revision History Title of Instruction Manual Document No. Date of Initial Issue UD series Instruction Manual 2200X2JE-MY-S2-N_2020.09. September, 2020 Issue Date Revision Details Prepared/Approved by Rev.

  • Page 3: Warranty And Disclaimer

    Warranty and Disclaimer Warranty and Disclaimer Warranty Clauses If malfunctions or damages occur under proper usage and conditions following documents such as specifications or instruction manual of this product, or, if MAYEKAWA judges that malfunctions or damages are related to design or manufacture of the product, and if the malfunctions or damages are within the warranty period, MAEKAWA will repair this product or replace parts without any charges.

  • Page 4: Important Information

    Important Information Important Information Intended Use of this Product This product is a screw compressor intended use for freezing and refrigeration. Do not use this product for any other purposes for which it is not intended or deviate from the specifications which are described in Chapter 2, Article 2.3 “Compressor Specifications”.

  • Page 5: Construction Of This Manual

    Important Information prohibited. The sole purpose of the tag plates such as prohibition of operation or commissioning is to warn others that it is prohibited to operate the locked out product. It should always be accompanied by a suitable lockout device to make operation impossible. Observe the following precautions when performing maintenance work on electrical control.
  • Page 6 Important Information T i t l e o f s e c t i o n a n d D e s c r i p t i o n d e t a i l s c h a p t e r Describes sections and period for inspecting, disassembly and 5.

  • Page 7: Table Of Contents

    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: Table Of Contents

    Table of Contents 2.4.5 Shaft Seal ......................2-17 2.4.6 Capacity Control ....................2-17 2.4.7 Oil Supply Route ....................2-17 Chapter 3 Installation General Installation Precautions ............... 3-1 Installation Works..................3-1 3.2.1 Unpacking ......................3-1 3.2.2 Storage ....................... 3-1 3.2.3 Transportation ..................... 3-1 3.2.4 Preparation for Installation ..................
  • Page 9 Table of Contents 5.4.1 Unloader Indicator Block ................... 5-14 5.4.2 Shaft Seal Block....................5-17 5.4.3 Shaft Seal ......................5-19 5.4.4 Unloader Cover ....................5-20 5.4.5 Unloader Piston and Unloader Cylinder ............5-23 5.4.6 Removal of Bearing Cover ................5-24 5.4.7 Thrust Bearings....................
  • Page 10 Table of Contents Table 7-4 Parts Configuration Table of 250*UD models ..........7-20 Table 7-5 Parts Configuration Table of 320*UD models ..........7-24 Table 7-6 Parts Configuration Table of 400*UD models ..........7-29 Maintenance Data ..................7-33 Lock Nuts ....................7-35 Thrust Bearing Gland ................

  • Page 11: Chapter 1 Safety

    Chapter 1 Safety Chapter 1 Safety Observation/Prevention 1.1.1 Observance (Do's) Do’s on Operation  The controller protects this product based on the sensor output values.  Make sure that all necessary safety devices are installed and that their control values are set correctly to assure proper and safe operation.
  • Page 12 Chapter 1 Safety Do's on Lockout/Tagout after Shutting off the Power  Prepare lockout / tag-out devices for the main breakers in the power lines to the main motor and control cabinet.  By applying the lockout/tag-out procedure after turning off the power, you can prevent any other personnel from restoring the power inadvertently.

  • Page 13: Prohibitions (Don'ts)

    Chapter 1 Safety Other Do’s  Keep the floor around the freezing, refrigeration, and/or air conditioning packages clean and provide a safety aisle.  Use the safety aisle only to move around the equipment. Keep the safety aisle free under all circumstances to ensure safe passage when required.

  • Page 14: Warnings

    Chapter 1 Safety Warnings To alert workers about possible dangers, the following information is always provided with the compressor.  Warnings described in this manual  Safety labels on the compressor 1.2.1 Types and Meanings of Warnings This manual uses the following four types of warnings to emphasize potential hazards during operation or maintenance of the compressor: Neglecting the warnings may cause damage to the compressor or its auxiliary equipment.
  • Page 15 Chapter 1 Safety  Types of Safety Labels Table 1-2 Safety Label S af et y l ab el Re ma r ks UD-series Screw Compressors 1.2 Warnings...

  • Page 16: Residual Risks

    Chapter 1 Safety Residual Risks The following information is provided on the assumption that this product is operated, inspected, and maintained while being used in freezing, refrigeration, and air conditioning packages. Note that all hazardous sources cannot be predicted for the applications mentioned. Foresee appropriate countermeasures for hazardous sources applicable to your systems.
  • Page 17 Chapter 1 Safety Measures to be taken Measures to be taken when cleaning, Danger source Predicted hazard in operation inspecting, and replacing parts I Oil drains from Contact with hazard- Sufficient ventilation Sufficient ventilation compressor unit ous substances 7) Avoid contact Wear protective gear caused by leakage Keep away and do not...
  • Page 18 Chapter 1 Safety Figure 1-1 Hazardous Sources (Compressor: V*D type i.e. discharge port facing sideways) Figure 1-2 Hazardous Sources (Compressor: V*D type) UD-series Screw Compressors 1.3 Residual Risks...

  • Page 19: Safety Devices

    Chapter 1 Safety Safety Devices For safe use and protection of the compressor, make sure to foresee and install safety devices to the compressor that comply with the regulations and the following descriptions. Safety devices must be properly and periodically maintained and inspected. It is important to include maintenance and inspection of safety devices in the periodical maintenance/inspection schedule.

  • Page 20: Compressor Protection Devices

    Chapter 1 Safety 1.4.3 Compressor Protection Devices  Overview/Function/Purpose To protect the compressor, the following safety functions of the controller are used.  Protection against High discharge temperature This function stops the compressor when the discharge temperature exceeds the set value. A temperature sensor is installed in the oil separator.
  • Page 21 Chapter 1 Safety  Sensor positions and settings Consult the package instruction manual for the positions and sensor settings for compressor protection. Make sure that the set values of the sensors do not exceed the operating limits indicated in Chapter 2, section 2.3.2 and Table 2-6 in this manual. ...

  • Page 22: Chapter 2 Compressor Specifications And Structure

    Chapter 2 Compressor Specifications and Structure Chapter 2 Compressor Specifications and Structure 2.1 Features of UD-series Screw Compressors UD-series Screw is a single-stage screw compressor classified into a rotary displacement pump type, and it consists of the following features.  High Efficiency The UD-series has achieved high efficiency by applying "...

  • Page 23: Model Designation Of The Compressor

    Chapter 2 Compressor Specifications and Structure Model Designation of the Compressor The meaning of the type designation, which is engraved on the MODEL column of the compressor nameplate, is as follows. [1] Working fluid , R134a, R404A, R507A Propane, propylene, CO2 R407C, R407F, R410A [2] Rotor diameter Symbol...
  • Page 24 Chapter 2 Compressor Specifications and Structure 3) Systems that use Economizer and Sideload have an extremely high risk of reduced capacity. 4) When used with Liquid injection, the capacity may be reduced. 5) The notation for no symbol is left-justified. [6] Discharge port Symbol Supplement...

  • Page 25: Compressor Specifications

    Chapter 2 Compressor Specifications and Structure Compressor Specifications 2.3.1 Standard Specifications Table 2-1 UD-Series 125 1 2 5 1 6 0 2 0 0 Items L U D S U D L U D M U D S U D L U D M U D S U D...

  • Page 26: Operation Limits

    Chapter 2 Compressor Specifications and Structure 2.3.2 Operation Limits Table 2-4 Operation Limits of UD-series Screw Compressors I t e m O p e r a t i o n L i m i t Maximum discharge pressure 1.96 (Other than 320LL, 400LL, 400XL) 1.37（320LL,400LL,）...
  • Page 27 Chapter 2 Compressor Specifications and Structure  If operation at partial load, which is not greater than 30% of the indicated load, is continued for a long time except when starting up the machine, abnormal noises or vibration may be generated. So avoid such operation. ...

  • Page 28: Outer Dimensions And Weight

    Chapter 2 Compressor Specifications and Structure 2.3.3 Outer Dimensions and Weight Figure 2-1 Outer Dimensions UD-Series Table 2-5 Outer Dimensions (1/2) (mm) MODEL 125SUD 286.5 240.5 125LUD 310.5 160SUD 40.5 160MUD 160LUD 200SUD 40.5 300.5 200MUD 200LUD 250SUD 80.5 366.5 250MUD 250LUD 320SUD...
  • Page 29 Chapter 2 Compressor Specifications and Structure 200LUD 1275 φ23 250SUD 1297 33.5 250MUD 1404 250LUD 1518 φ33 320SUD 1619 320MUD 1755 320LUD 1891 φ39 400S 200(S) 2107 1050 304(D) 400M 2273 400L 2489 400LL 2611 400XL MODEL φ38 125SUD 162.5 33.5 +0.022 125LUD...
  • Page 30 Chapter 2 Compressor Specifications and Structure Table 2-6 Weight （kg） FC300 MODEL Current weight Actual weight 125SUD 125LUD 160SUD 160MUD 160LUD 200SUD 200MUD 200LUD 250SUD 1060 1170 250MUD 1140 1260 250LUD 1200 1320 320SUD 2030 2240 320MUD 2250 2480 320LUD 2400 2640 320LLUD...

  • Page 31: Compressor Structure And Mechanism

    Chapter 2 Compressor Specifications and Structure Compressor Structure and Mechanism 2.4.1 Overview of UD-series Screw Compressor UD-series Screw Compressors are rotary compressors falling into the category of the positive displacement compressor. The compressor sucks refrigerant gas into a cavity, gradually reduces the volume of the cavity, and discharge the refrigerant as a high-pressure gas.

  • Page 32: Refrigerant Gas Compression Mechanism

    Chapter 2 Compressor Specifications and Structure 2.4.2 Refrigerant Gas Compression Mechanism Inside the main rotor casing, there are the M rotor (number of screw lobes: 4) and F rotor (number of screw lobes: 6), intermeshing and rotating in the opposing directions each other. Together with the rotor casing, these two rotors constitute the essential elements of the compressor for sucking and compressing the refrigerant gas.
  • Page 33 Chapter 2 Compressor Specifications and Structure Compression Phase As the rotors rotate further, the volume between the rotor lobes and grooves decreases while the sealing line moves toward the discharge side, which compresses the trapped refrigerant gas. Figure 2-7 Compression Phase Discharge Phase The volume between the rotor lobes and grooves decreases to a level predetermined by the discharge port.

  • Page 34: Internal Volume Ratio Vi

    Chapter 2 Compressor Specifications and Structure 2.4.3 Internal Volume Ratio Vi What is the Internal Volume Ratio Vi ? In the case of reciprocating compressors, the refrigerant compression capacity is controlled by setting the pressure attained by piston displacement to an optimum level for the intended application. With screw compressors, on the other hand, the compression capacity is controlled by setting the extent to which the volume of the sucked refrigerant gas is to be reduced.
  • Page 35 Chapter 2 Compressor Specifications and Structure Why the Vi Needs to Be Chosen? [1] You ca set the Vi that is suitable for use refrigerant. Internal volume ratio Vi is expressed as follows with the compression ratio. Pd: discharge pressure, Ps: suction pressure, κ...
  • Page 36 Chapter 2 Compressor Specifications and Structure Figure 2-12 Refrigeration Capacity of Screw Compressor UD-series Screw Compressor 2.4 Compressor Structure and Mechanism 2-15...
  • Page 37 Chapter 2 Compressor Specifications and Structure Figure 2-13 Proper and Improper Adaptation of Vi to Load Condition UD-series Screw Compressor 2.4 Compressor Structure and Mechanism 2-16...

  • Page 38: Bearings And Balance Piston

    Chapter 2 Compressor Specifications and Structure 2.4.4 Bearings and Balance Piston The M rotor and F rotor are supported at their both ends by the side bearings in the suction cover and the main bearings in the bearing head. These bearings use sleeve type white metal lined bearings. In addition, the thrust bearings located outside the main bearings support the thrust loads working on the rotors, which result from both the rotation of the rotors and the difference in refrigerant gas pressure that takes place during the compression process.
  • Page 39 Chapter 2 Compressor Specifications and Structure Oil supply header ① Oil injection Unloader Push Rod Slide valve Injection hole ② Oil supply pipe (for lubrication) Main Bearing Thrust Bearing Mechanical Seal Balance Piston Rotor chamber Side Bearing ③ Unloader operation（Solenoid valve） Unloader piston Discharge port Figure 2-14 Oil Supply Route of Forced Oil Supply System...
  • Page 40 Chapter 2 Compressor Specifications and Structure Figure 2-16 Oil Supply Route UD-series Screw Compressor 2.4 Compressor Structure and Mechanism 2-19...

  • Page 41: Chapter 3 Installation

    Chapter 3 Installation Chapter 3 Installation General Installation Precautions  This chapter (Installation) assumes that the compressor is installed to a standard refrigeration / cold storage package unit. If the unit you are actually using is not the standard type refrigeration/cold storage package unit, prepare a proper installation manual by referring to the description in this chapter and paying due consideration to safety, before installing the compressor.
  • Page 42 Chapter 3 Installation Always check the wire ropes before using them. Thoroughly check the wire ropes for problems such as kinks, knots and broken strands. Do not perform lifting before confirming the safety of the wire ropes. If you cannot make a correct evaluation or judgment, entrust an expert to check. To lift the compressor, attach the wire ropes to the appended eye bolts by using appropriate shackles and hooks.

  • Page 43: Preparation For Installation

    Chapter 3 Installation 3.2.4 Preparation for Installation  Installation Space Secure sufficient working space for easy operation, cleaning, maintenance, and inspection.  Illumination Prepare illumination devices which allow easy operation, cleaning, maintenance, and inspection.  Ventilation If natural ventilation is insufficient, install ventilation fans according to the relevant regulations. ...
  • Page 44 Chapter 3 Installation Figure 3-2 Dimensions of the MYK Flange Joint Part (Compressor) φg φC 2-M12×P1.75 2-M12×P1.75 2-M12×P1.75 □ 25A 4-M12×P1.75 □ 32A 4-M12×P1.75 □ 40A 4-M12×P1.75 □ 50A 4-M16×P2 □ 65CD 4-M16×P2 □ 80A 4-M20×P2.5 □ 100A 4-M22×P2.5 □ 100CD 4-M22×P2.5 125A 8-M20×P2.5...
  • Page 45 Chapter 3 Installation Table 3-2 Connecting Port of Compressor (125 – 320, Cast steel case) Rotor diameter Item Connecting port for liquid injection 1 Connecting port for liquid injection 2 ANSI #300 ANSI #300 ANSI #300 ANSI #300 ANSI #300 Discharge gas outlet（type D）...
  • Page 46 Chapter 3 Installation Table 3-3 Connecting Port of Compressor (400) Item Size Oil injection port ANSI #300 2 1/2” Lubricating oil main supply port（Side, ANSI #300 2” Balance piston） Lubricating oil main supply port（TPTB） ANSI #300 2” Discharge gas outlet ANSI #300 12”...

  • Page 47: Installation

    Chapter 3 Installation 3.2.5 Installation Placement Check that the surface of the package unit, where the compressor is to be installed, is even and horizontal. If it is uneven and non-horizontal, tightening the bolts may lead to compressor deformation, which may prevent normal operation. Shaft Alignment between the Compressor and Driving Machine ...
  • Page 48 Chapter 3 Installation Piping Connection  Refrigerant Piping Observe the following when connecting the refrigerant piping to the compressor.  The compressor is one of the few devices installed within the package unit that have moving components. These moving components are adversely affected by foreign substances within the system (scale, dust, spatter, etc.).

  • Page 49: Airtightness Test

    Chapter 3 Installation 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. 3.2.7 Vacuuming  Do not turn the compressor rotor shaft during vacuuming. Vacuuming involves discharging the air in the unit before the refrigerant and oil are charged in the unit.

  • Page 50: Chapter 4 Compressor And Package Unit Operation

    Chapter 4 Compressor and Package Unit Operation Chapter 4 Compressor and Package Unit Operation Lubricating Oil (Refrigerant Oil) Selecting and managing lubricating oil (refrigerant oil) is very significant to keep the compressor in a good operating condition. Take the following notes when selecting and managing lubricating oil. 4.1.1 Precautions for Selecting the Lubricating Oil ...

  • Page 51: Change Of Lubricating Oil Brand

    Chapter 4 Compressor and Package Unit Operation 4.1.2 Change of Lubricating Oil Brand  The change of lubricating oil brand may cause problems in operating conditions and the compressor. When changing the lubricating oil brand in use, make sure to contact us because appropriate steps must be surely followed.

  • Page 52: Lubricating Oil Control Criteria

    Chapter 4 Compressor and Package Unit Operation Precautions for Handling Polyolester (POE) Oil This type of oil has high hygroscopicity as polyalkylene glycol, and also exhibits hydrolyzability under high temperature environments. Moisture entry must be avoided. Therefore, special attention must be paid as with PAG when handling POE.

  • Page 53: Lubricating Oil Replacement Timing

    Chapter 4 Compressor and Package Unit Operation (c) Kinematic viscosity Within ±10 % from that of fresh oil (d) Water content 200 mass ppm or less (e) Degree of contamination Degree of contamination measured by mass method (Millipore value) shall be 15 mg/100 mL or less Note 1: Synthetic oils (compatible with ammonia) are so highly hygroscopic that they can absorb moisture at the time of sampling.

  • Page 54: Precautions For Operation

    Chapter 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 Operation Liquid flow-back is a phenomenon where refrigerant that did not completely evaporate with the gas reaches the compressor.

  • Page 55: When Stopping The Compressor For A Long Time

    Chapter 4 Compressor and Package Unit Operation When Stopping the Compressor for a Long Time Before stopping the compressor for a long time, make sure to perform the following steps.  Turn off the motor main power.  Turn off the oil heater power and the control power. ...

  • Page 56: Chapter 5 Maintenance And Inspection

    Chapter 5 Maintenance and Inspection Chapter 5 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 57 Chapter 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 58: Maintenance And Inspection List

    Chapter 5 Maintenance and Inspection Maintenance and Inspection List 5.2.1 Daily Management For the purpose of daily maintenance, check the items listed in Table 5-1 "Daily Inspection Items" and record the results. These operation data should be recorded in an operating log book on a daily basis. This practice is significantly effective and helpful in finding out any abnormal condition of the compressor and prevents possible compressor failures.
  • Page 59 Chapter 5 Maintenance and Inspection Table 5-1 Daily Inspection Item (continued) Inspection item Inspection details Checkpoints and actions  Compressor failure Motor current Whether it is higher than the  Motor failure current at test run  Oil loss Oil level of oil separator Oil level ...

  • Page 60: Periodic Inspection

    Chapter 5 Maintenance and Inspection 5.2.2 Periodic Inspection Inspect the following points at specified intervals. Table 5-3 Periodic Inspection Items Item Inspection interval Remarks Pressure sensors Annually Temperature sensors Annually Protection devices and Annually safety valves Suction strainer Inspection after the first 500h of If the differential pressure between operation the front and back of the suction...
  • Page 61 Chapter 5 Maintenance and Inspection 5.2.3 Guidelines for Compressor Overhaul Frequency When servicing or overhauling the compressor, follow the instructions and guidelines described below. The compressor inspection frequency significantly differs depending on the operating conditions, refrigerant in use, type and condition of lubricant, and the system in which the compressor is operated. The table below indicates the overhaul frequency recommended by based on the operating conditions of the compressor.

  • Page 62: Compressor Disassembly Preparation

    Chapter 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.

  • Page 63: Replacement Parts

    Chapter 5 Maintenance and Inspection 5.3.2 Replacement Parts Prepare the genuine parts for replacement. Parts listed in Table 5-5, we recommend to be replaced on the occasion of each compressor overhaul. For each part size and code No. of each compressor model, refer to Section 7.2 "Parts Configuration Table"...
  • Page 64 Chapter 5 Maintenance and Inspection V-ring, Unloader Cylinder Gasket, Suction Flange Gasket, Discharge Flange (1) Mechanical Seal Assembly BBS-E as standard To be replaced if any abnormality is Micro Switch found. To be replaced if any abnormality is Potentiometer found. O-ring, Thrust Bearing Gland for 320V*D Gasket, Lubricating Oil Inlet...

  • Page 65: Refrigerant Gas Recovery

    Chapter 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 drop the pressure down to the atmospheric pressure before starting the disassembly process.
  • Page 66 Chapter 5 Maintenance and Inspection When removing the compressor from the mounting base frame, the following parts must be disconnected beforehand in numeric order. (1) Coupling to connect the compressor to the driving machine; (2) Suction piping of the compressor. If the suction strainer is directly connected to the compressor, also remove the strainer;...

  • Page 67: Removal Of The Compressor From Base Flame

    Chapter 5 Maintenance and Inspection 5.3.5 Removal of the Compressor from Base Frame  The work to lift up or move the compressor must be performed by a qualified operator. If the work is done by an unqualified operator, it may result in a dropping accident. ...

  • Page 68: Compressor Disassembly Order

    Chapter 5 Maintenance and Inspection Figure 5-2 5.3.6 Compressor Disassembly Order The disassembly order of the UD/G-series compressor is general as described below. Generally UD/G-series compressors are disassembled in the order described below. But this order is just an example and the actual order may differ according to individual situations. Depending on the situation, please complete the work in a safe and appropriate procedure.

  • Page 69: Disassembly And Inspection

    Chapter 5 Maintenance and Inspection Disassembly and Inspection 5.4.1 Unloader Indicator Block The UD/G-series unloader indicator has been changed to the new type indicator (right picture) with the protection grade IP66 by improving the performance of the dust and water proof from December 2014 Moriya factory production.
  • Page 70 Chapter 5 Maintenance and Inspection Disassembly ■ In the Case of Removing the Wiring only When removing the wiring of the unloader indicator upon removing the compressor, it is necessary to remove the cover as the indicator has a terminal block for the wiring. Perform the work according to the following procedure, and after removing the wires, attach the cover to them for protection.
  • Page 71 Chapter 5 Maintenance and Inspection ■ For Further Disassembly (In the case of Removing as Unloader Indicator Assembly) As the indicator is an assembly to be removed as a whole, no further disassembly should be made unless the purpose of the disassembly is to disassemble this part. a) As a result of the previous disassembly process, the micro switch base plate [121], which is mounting the potentiometer [129], micro switches [125], and micro switch cam [127], can be removed.

  • Page 72: Shaft Seal Block

    Chapter 5 Maintenance and Inspection 5.4.2 Shaft Seal Block (125～320) Part Name Mating ring Stationary Insert lock pin rings O-ring Seal collar Rotating Seal collar set screw rings O-ring Oil seal sleeve Note Set screw for oil seal sleeve Note O-ring Note Retainer, oil seal...
  • Page 73 Chapter 5 Maintenance and Inspection f) After the seal cover has been removed, wipe clean the shaft and then check its surface. If any flaw is found, use a fine sandpaper to smoothen the surface. This correction is intended to prevent possible damage of the internal O-ring when the mechanical seal is pulled out.

  • Page 74: Shaft Seal

    Chapter 5 Maintenance and Inspection 5.4.3 Shaft Seal (400) UD models use the double balanced mechanical seal assembly as the shaft seal. According to the system applications and working fluids (refrigerants), UD applies an appropriate one from appropriate three types of mechanical seal assemblies, i.e., BOD (balanced, O-ring, double) type, BBD (balanced, bellows, double) type, and BBDE (balanced, bellows, double, E* made) type.

  • Page 75: Unloader Cover

    Chapter 5 Maintenance and Inspection 5.4.4 Unloader Cover The unloader cover [74] is mounted with the indicator cam [77] which converts the linear motion of the unloader slide valve to a rotational motion, and their mounting parts. The indicator cam is supported by the ball bearing [78] and fixed to the cover with a bearing gland [80].
  • Page 76 Chapter 5 Maintenance and Inspection Indicator Cam and Pushrod Unloader Cover Removing the Unloader Cover Unloader Push Rod and Indicator Cam Unloader Cover Inspection a) Check the packing of the indicator cam shaft for any flaw. If the refrigerant leaks without any flaw observed in this part, it should be due to a defect of the V-ring or installing the V-ring without sufficient oil.
  • Page 77 Chapter 5 Maintenance and Inspection Figure 5-8 Unloader Cover Block(125～320 Type) Figure 5-9 Unloader Cover Block (400 Type) UD-series Screw Compressor 5.4 Disassembly and Inspection 5-22...

  • Page 78: Unloader Piston And Unloader Cylinder

    Chapter 5 Maintenance and Inspection Shaft seal parts of indicator cam Teflon V ring 5.4.5 Unloader Piston and Unloader Cylinder Disassembly a） Screw the eyebolts of the disassembly tool into the two screw holes on the unloader piston, and move the unloader piston to the unloader indicator side to the full load (100 % load) position.

  • Page 79: Removal Of Bearing Cover

    Chapter 5 Maintenance and Inspection or more) and wash the surface thoroughly. c） Replace the "O" ring (part number 73) on the unloader piston mating part of the unloader pushrod. Inspection of cap seal Unloader Push Rod "O" Ring 5.4.6 Removal of Bearing Cover If it is less than 320, the discharge flange is in an asymmetrical position, so the left and right balance is poor in terms of weight, so remove it carefully.

  • Page 80: Thrust Bearings

    Chapter 5 Maintenance and Inspection Disassembly a) Among the bolts "Part No. 18-1 and 18-2" tightening the bearing cover, replace the two bolts at the upper position without head "safety bolts" and remove all other bolts. b） There are two screw holes for the service holes at the 2 o'clock and 8 o'clock positions on the bearing cover.
  • Page 81 Chapter 5 Maintenance and Inspection Thrust bearing (1 set) Figure 5-11 Conical Spring Washer Figure 5-12 Development view of the 125-250 thrust bearing * 250 does not have thrust bearing outer race spacer (41). Figure 5-13 Development view of the 320 Thrust Bearing UD-series Screw Compressor 5.4 Disassembly and Inspection 5-26...
  • Page 82 Chapter 5 Maintenance and Inspection Disassembly “For 125, 160, 200, 250, 320” a) Remove the hexagon head screw “part number 45” that tightens the thrust bearing gland “part number 43”. Be careful not to lose the disc spring lock washer “part number 46” when removing the bolt, as it will come off at the same time.
  • Page 83 Chapter 5 Maintenance and Inspection Thrust bearing (1 set) Pulling out the Thrust bearing d） The thrust bearing inner ring and rotor shaft have a clearance fit. Prepare a slightly bent wire tip with a diameter (φ) of 2 to 3mm flattened, insert it between the outer ring of the bearing and the retainer, hook it, and pull it out toward you “see arrow e）...
  • Page 84 Chapter 5 Maintenance and Inspection Inspection a) After thoroughly cleaning the thrust bearings, remove the cleaning solution with compressed air. First, make sure that the surface of the ball is evenly shiny and that there are no scratches or flaking. Next, inspect the corners of the retainer (thrust bearing retainer) ball hole for blisters and wear.
  • Page 85 Chapter 5 Maintenance and Inspection Thrust Bearing Gland (2) Lock Nut (1) (The photograph used is 400 VMD) VMD and MUD have different points. TPTB assembly a) Use the lock nut wrench of the special disassembly tool to loosen the lock nut and remove the lock nut and lock washer.
  • Page 86 Chapter 5 Maintenance and Inspection Thrust Bearing (1) Thrust Bearing (2) e) Remove the thrust bearing alignment spacers from the rotor. Thrust bearing alignment spacer（1） Thrust bearing alignment spacer（2） Lock pin Cut-out part for Shaft Key Tilting pad thrust bearing (TPTB) UD-series Screw Compressor 5.4 Disassembly and Inspection 5-31...

  • Page 87: Balance Piston Cover

    Chapter 5 Maintenance and Inspection 5.4.8 Balance Piston Cover The balance piston cover (part number 22) can be easily reassembled by removing it together with the unloader cylinder as described in Section 5.4.5 “Unloader piston and cylinder”. Pay attention to the following points when removing only the balance piston cover after removing the unloader cylinder.

  • Page 88: Balance Piston

    Chapter 5 Maintenance and Inspection 5.4.9 Balance Piston The screw compressor is structurally of the two rotors M and F, and the M rotor rotates 1.5 times more than the F rotor because the thrust caused by the drive revolution of the M rotor and the thrust caused by the difference in the gas pressure are applied.
  • Page 89 Chapter 5 Maintenance and Inspection c) The balance piston sleeve is not attached to 125. There are two types of locking methods for 160 and above depending on the model. Type 1: How to fasten the cut out part of the balance piston sleeve with a screw (160 ~ 250 *** type) Type 2: Drive the spring pin into the sleeve and fit it into the groove of the suction cover (320, 400 *** type)
  • Page 90 Chapter 5 Maintenance and Inspection Balance piston sleeve locking Removing the Retaining ring for the balance spring pin(320，400Type) piston sleeve The balance piston sleeve (part number 33) has a cutout and is fixed by matching two hexagon socket set screws to the screw holes on the suction cover side. Pull out the M side or loosen the F side and let the head part of the M side into it.

  • Page 91: Oil Injection Pipe

    Chapter 5 Maintenance and Inspection 5.4.10 Oil Injection Pipe Oil injection pipe insertion part Figure 5-17 Development view of the Oil Injection Pipe section The unloader push rod protrudes from the location where the unloader cylinder of the suction cover is removed, and the injection pipe is attached to the outer periphery of the unloader push rod.

  • Page 92: Suction Cover And Side Bearing

    Chapter 5 Maintenance and Inspection c) The oil injection pipe retainer and the oil injection pipe (part number 85) are connected by spring pins so they can be pulled out at the same time. Oil injection pipe retainer Oil hole for oil injection Inspection a) Replace the "O"...

  • Page 93: Rotor And Rotor Casing

    Chapter 5 Maintenance and Inspection d）Once the suction cover has been separated, for 320 and 400, remove the hexagon socket head cap screws (part number 166) at the section where the unloader push rod was incorporated and remove the "O" ring retainer (part number 326). Replace the “O” ring inside the “O”...
  • Page 94 Chapter 5 Maintenance and Inspection does not touch the floor. c）Take out the other rotor in the same way as in a) and support the shaft with a V block (wooden) and hold it. After removing the suction cover Pull out the M rotor After pull out the M rotor Rotor casing and Bearing Head Inspection...

  • Page 95: Bearing Head And Main Bearing

    Chapter 5 Maintenance and Inspection 5.4.13 Bearing Head and Main Bearing On the side where the rotor of the bearing head (part number 11) is installed, a gas discharge port that is determined by the operating conditions of the compressor is machined. This discharge port affects the performance of the compressor.

  • Page 96: Unloader Slide Valve And Guide Block

    Chapter 5 Maintenance and Inspection 5.4.14 Unloader Slide Valve and Guide Block The guide block consists of a guide block stem (part number 88), a guide block (part number 87), and two "O" rings. The guide block meshes with the slot in the bottom of the slide valve. The length of this unloader slide valve assembly varies depending on the compressor model.

  • Page 97: Reassembly

    Chapter 5 Maintenance and Inspection List of O-rings used Install position Suction Cover P42(2) P42(2) G55(2) G60(2) P58(1) G95(1) Balance Piston Sleeve G95(1) P120(1) P150(1) G190(1) G240(1) Seal Retainer G85(1) G90(1) G115(1) G135(1) G160(1) G160(1) Oil Injection Pipe P30(2) P30(2) P40(2) P46(2) P32(1)

  • Page 98: Bearing Head And Main Bearing

    Chapter 5 Maintenance and Inspection 400UD slide valve and bearing head Figure 5-19 Adjustment of Slide Value b）Insert the slide valve into the casing, making sure the groove of the slide valve is aligned with the guide block. After insertion, move the slide valve back and forth to check the overall movement.

  • Page 99: Rotor

    Chapter 5 Maintenance and Inspection Cut-out part of the main bearing b） Cut the bearing head gasket along the inner edge (important for thrust adjustment). Bearing head gaskets are asymmetrical, so check if they are in the correct position. c） Insert the parallel pin through the flange before tightening the hexagon socket head cap screw (part number 2).

  • Page 100: Suction Cover, Side Bearing And Oil Injection Pipe

    Chapter 5 Maintenance and Inspection ① ② Install the F Rotor(200S) Install the M Rotor (400M) b）Of the robes of the F rotor, check the position of the groove between the robes of the robe tip marks ① and ②. c）Combine the teeth of the M rotor robe tip mark ①...
  • Page 101 Chapter 5 Maintenance and Inspection Side bearing positioning Setting Bearing Spring pin of Side Bearing Setting Retaining Ring of Side Bearing b） After checking that the positioning spring pins and side bearings are in the correct position, secure the side bearings with the stop ring. c）...
  • Page 102 Chapter 5 Maintenance and Inspection Suction cover tightening bolts Inside of suction cover Suction Cover Gasket left-right asymmetric Install Suction Cover (125-320) Fitting the unloader push rod Figure 5-21 Setting Suction Cover UD-series Screw Compressor 5.5 Reassembly 5-47...
  • Page 103 Chapter 5 Maintenance and Inspection On the surface plate with suction cover Use a crane to assemble the suction cover assembled For large models, it is difficult to slide the suction cover on the work bench during the above work, so place the rotor casing side on the end of the work table and hang the suction cover with a crane to combine.
  • Page 104 Chapter 5 Maintenance and Inspection Use of a bolt tightening torque wrench Using a hydraulic torque wrench (for large machines) Setting of Suction Cover（400UD） Completion of suction cover setting Precautions when tightening the bolts at the lower part of the rotor casing with a screw compressor The lower part of the rotor casing of the screw compressor is fixed to the bearing head and the suction cover with bolts, but do not attempt to hang the rotor casing and tighten this bolt.

  • Page 105: Balance Piston Sleeve

    Chapter 5 Maintenance and Inspection Tightening the bolts at the bottom of the rotor Tightening the upper bolt casing Bolt tightening with a hydraulic wrench (320-400UD) i） Check the movement of the unloader slide valve, and check that the M rotor shaft can be turned by hand.
  • Page 106 Chapter 5 Maintenance and Inspection b） Assemble the balance piston sleeve (part number 33). Make sure that the shaped edge side of the outer periphery of the balanced piston sleeve is on the "O" ring side and the side with the locking cut out is on the outside. Align the cut out position with the hexagon socket set screw.

  • Page 107: Balance Piston Cover

    Chapter 5 Maintenance and Inspection 5.5.6 Balance Piston Cover Balance piston cover and unloader cylinder When reassembling, if the balance piston cover and unloader cylinder are joined in advance and then attached to the suction cover, the unloader push rod and unloader piston can be easily adjusted.
  • Page 108 Chapter 5 Maintenance and Inspection Clearance of thrust bearing Install Thrust Bearing Spacer e) At this time, measure and confirm the end clearance of the rotor. The tolerances must fall within the following ranges: Use the methods described below to measure the end clearance. Install the Thrust Bearing Alignment spacer Bearing assembly Table 7 End clearance...
  • Page 109 Chapter 5 Maintenance and Inspection Install the Lock Washer Tighten the Lock Nut （400*UD） Setting Thrust Bearing Alignment Spacer Install the Thrust Bearing Gland （400*UD）Setting Bearing * For the 400 UD, insert the thrust bearing key in the direction of the shaft key. Install the lock washer and lock nut and tighten the lock nut using the lock nut spanner.
  • Page 110 Chapter 5 Maintenance and Inspection (400) Tightening Lock Nut Figure 5-23 Thrust adjustment g) Set the end clearance of the F rotor in the same way. Note that the screwdriver is pushed in as shown in Figure 5-23 to position the F-rotor on the discharge side. h) Install the thrust bearing gland and tightening bolt.
  • Page 111 Chapter 5 Maintenance and Inspection Figure 5-24 End Clearance adjustment (II) Tightening torque Model N・m Kg・cm Ft・lb 21.70 28.93 36.17 43.40 1200 86.78 65.10 Figure 5-25 UD-series Screw Compressor 5.5 Reassembly 5-56...
  • Page 112 Chapter 5 Maintenance and Inspection How to adjust if the end clearance is outside the specified value (1) If the end clearance is greater than the specified value, if the clearance measured from the discharge side of the bearing head at the end of the rotor is too large, the thrust bearing must be tightened with a lock nut to narrow the end clearance.
  • Page 113 Chapter 5 Maintenance and Inspection between the parts, the vibration value will increase. When the adjustment is completed, the thrust bearing is completely tightened. Note: (125-320 type) (1) Use new lock washers. (2) Set a torsional slip washer between the lock nut and lock washer. (3) Be careful not to break the claws of the lock washer.
  • Page 114 Chapter 5 Maintenance and Inspection n） For the 400 type, the inner ring of the tilting pad has a locking key. After inserting the tilting pad assembly, install the key in the keyway of the inner ring, and align the tilting pad with the stepped side of the key.

  • Page 115: Bearing Cover

    Chapter 5 Maintenance and Inspection 400*UD Tightening of thrust bearing gland with hexagon socket head cap screw 5.5.8 Bearing Cover Screw a long safety bolt into the bearing head and press the gasket and the bearing cover, taking care not to damage the mechanical seal. Adjust the parallel pin (part number 19) while taking care to keep it parallel, and press the bearing cover against the bearing head.
  • Page 116 Chapter 5 Maintenance and Inspection Push the piston into the unloader cylinder b) Make sure the cap seal is in the correct position. Push the unloader push rod to the end (no load position), pull out the unloader piston, and assemble the unloader cylinder and balance piston cover to the suction cover.

  • Page 117: Unloader Cover

    Chapter 5 Maintenance and Inspection e) Screw two eye bolts into the unloader piston to check if the piston and slide valve are working properly. f) Keep the unloader piston in the no-load position. Setting the cylinder and balance piston cover Setting Lock Washer and Lock Nut Tigten the Lock Nut to the specified torque Bend the claws of the lock washer...
  • Page 118 Chapter 5 Maintenance and Inspection shaft, push the inner ring of the bearing. Otherwise, the bearing may be damaged. Push into the stepped part of the indicator cam and use the stop ring to prevent it from coming off. If the outer diameter of the indicator cam is larger than the inner diameter of the bearing retainer, install the bearing retainer before installing the bearing.

  • Page 119: Shaft Seal Block

    Chapter 5 Maintenance and Inspection Figure 5-28 Development view of the Unloader cover (400 type) Indicator CAM Mounting parts Setting Unloader Cover 5.5.11 Shaft Seal Block The assembly procedure of the shaft seal block is the reverse sequence described in Section 5.4.3 as shown in the order of the colored number of each sectional view drawing.

  • Page 120: Disassembly And Assembly Of The Unloader Indicator

    Chapter 5 Maintenance and Inspection Note that to confirm the sliding surface pressure of the mechanical seal is proper or not, measure the clearance between the surfaces of the seal cover gasket and the bearing cover flange. This clearance is called " fastening margin of the seal", it should be measured by using a taper gauge. The proper value guide line (reference) of this "...
  • Page 121 Chapter 5 Maintenance and Inspection Micro-switch（For signals at slide valve full load (100 %) position） Micro-switch （Slide valve partial load position signal, for 50 % load） Micro-switch（Slide valve partial load position signal, for special specifications） Micro-switch Cam（For 0-100 % operation） Micro-switch Cam（For 0-50 % or 50-100 % operation）...
  • Page 122 Chapter 5 Maintenance and Inspection Figure 5-30 Development View of the Unloader Indicator(160～400 type) UD-series Screw Compressor 5.5 Reassembly 5-67...
  • Page 123 Chapter 5 Maintenance and Inspection Figure 5-31 Sectional View of UD-series Unloader Indicator (Traditional standard type) UD-series Screw Compressor 5.5 Reassembly 5-68...
  • Page 124 Chapter 5 Maintenance and Inspection Figure 5-32 Unloder Indicator for 125LUD Component Parts of the Unloader Indicator ( The number in () is the 125 type) Part Name Q'ty Part Name Q'ty Part Name Q'ty Phillips Screw Indicator glass 3(4) Micro-switch base plate Hexagon socket head Terminal block...
  • Page 125 Chapter 5 Maintenance and Inspection Disassembly Remove the Phillips screw (part number 140) that fixes the indicator pointer (part number 139) to the shaft. Remove the Phillips screw (part number 138) that fixes the dial plate (part number 137) to the dial plate support.
  • Page 126 Chapter 5 Maintenance and Inspection Micro-switch cam Potentiometer Potentiometer positioning mark 1 micro switch Fix the dial with the indicator needle aligned to the no-load position. The full-loadmicroswitch will eventually pneumatically move the unloader piston to the full-load position and adjust it to operate with the mounting screw.

  • Page 127: Chapter 6 Troubleshooting

    Chapter 6 Troubleshooting Chapter 6 Troubleshooting Table 6-1 Troubleshooting Trouble Direct causes Factors Actions Compressor Power source is off. Power source not Prevent oversight by checking a does not turned on after check sheet after inspection. start up inspection. Main motor Most cases are due Refer to the motor instruction malfunction...
  • Page 128 Chapter 6 Troubleshooting Trouble Direct causes Factors Actions Compressor Low pressure Insufficient refriger- If any heat exchange failures as stops imme- protection circuit ant circulation typified by poor defrost diately after activated volume performance, investigate the cause startup. and take measures. For malfunction in pressure regulating valve operation, replace pressure regulating valve, or...
  • Page 129 Chapter 6 Troubleshooting Trouble Direct causes Factors Actions Defect in hydraulic Malfunction in Identify malfunctioning devices, oil-supply pressure detection hydraulic pressure examine their causes, and take pressure divices. protection measures. device(switch), Then, replace malfunctioning pressure sensor, devices. relays, etc. Clogging in the Remove clogging.
  • Page 130 Chapter 6 Troubleshooting Trouble Direct causes Factors Actions Abnormally Excessive Repetitive Adjust refrigerant to proper amount. high refrigerant charge refrigerant charge pressure by mistaking (abnormal insufficient cooking discharge as a lack of pressure) refrigerant in the system. Insufficient capacity If the trouble is caused by change in of heat exchanger operating conditions, re-examine the conditions to improve.
  • Page 131 Chapter 6 Troubleshooting Trouble Direct causes Factors Actions Abnormally High oil supply Heat exchange For water-cooled oil cooling, refer to high temperature failure in oil cooler “Heat exchange failure at discharge condenser (heat exchanger)” in temperature item 05. For liquid-injection oil cooling, inspect liquid supply expansion valve, temperature sensor, related relays, wiring, terminals, etc., and...
  • Page 132 Chapter 6 Troubleshooting Trouble Direct causes Factors Actions Leak from Long stoppage Due to user’s If stoppage period becomes more mechanical period (no oil film specific conditions, than one week, manually operate oil seal on sliding surfaces) such as heat load pump as well as manually turn being intermittent.
  • Page 133 Chapter 6 Troubleshooting Trouble Direct causes Factors Actions Faulty Imprecision in Loose screws for Manually tighten screws to the 0% indication of compressor indicator indication position of compressor capacity indicator capacity control. control posi- Imprecision in Worn groove of Most cases are due to prolonged tion controller capacity compressor...

  • Page 134: 10: Capacity Control Malfunction

    Chapter 6 Troubleshooting Trouble Direct causes Factors Actions Capacity Capacity control Maladjustment of oil Readjust it. control hydraulic line defect flow controller valve malfunction Leak and clogging Remove factors. Check oil in solenoid valve contamination level and replace oil gland and oil pipes as necessary.
  • Page 135 Chapter 6 Troubleshooting Trouble Direct causes Factors Actions Abnormal Oil hammer Continuous low During low load operation, lubricant vibration load operation at is poorly discharged. Because of and/or below 30 % of this, the amount of oil that remains noise of capacity control inside rotor mesh increases and oil compressor...
  • Page 136 Chapter 6 Troubleshooting Trouble Direct causes Factors Actions Abnormal Expansion valve Avoid rapid changes in heat load. vibration opening control and/or cannot keep up with noise of rapid changes in compressor heat load on load side. Shortage in heat For frosting (icing), defrost exchanger capacity manually.
  • Page 137 Chapter 6 Troubleshooting Trouble Direct causes Factors Actions Abnormal Entering of foreign Refer to the Direct cause “Foreign vibration substances substances entering into and/or compressor” above. noise of Excessive thrust Re-examine operating conditions compressor stress and improve them if possible. High suction pres- If it is difficult to improve, sure exceeding...

  • Page 138: Chapter 7 Related Documents

    Chapter 7 Related Documents Chapter 7 Related Documents Exploded Views, Sectional Views Figure 7-1 Exploded View (125*UD model) UD-series Screw Compressor 7.1 Exploded Views, Sectional Views...
  • Page 139 Chapter 7 Related Documents Figure 7-2 Exploded View (160～250*UD model) UD-series Screw Compressor 7.1 Exploded Views, Sectional Views...
  • Page 140 Chapter 7 Related Documents Figure 7-3 Exploded View (320*UD model) UD-series Screw Compressor 7.1 Exploded Views, Sectional Views...
  • Page 141 Chapter 7 Related Documents Figure 7-4 Exploded View (400*UD model) UD-series Screw Compressor 7.1 Exploded Views, Sectional Views...
  • Page 142 Chapter 7 Related Documents Figure 7-5 Sectional View (125 to 250*UD model) UD-series Screw Compressor 7.1 Assembly Sectional Views...
  • Page 143 Chapter 7 Related Documents Figure 7-6 Sectional View (320*UD model) UD-series Screw Compressor 7.1 Assembly Sectional Views...
  • Page 144 Chapter 7 Related Documents Figure 7-7 Sectional View (400*UD model) UD-series Screw Compressor 7.1 Assembly Sectional Views...

  • Page 145: Parts Configuration Table

    Chapter 7 Related Documents Parts Configuration Table Table 7-1 Parts Configuration Table of 125*UD models Part Name Code No. Remarks Q’ty. Main Rotor Casing CS00100-125S 125S** 1 (S**) Main Rotor Casing CS00100-125L 125L** 1 (L**) Hexagon Socket Head Cap Screw NB35414-040 M14×40 φ16×40...
  • Page 146 Chapter 7 Related Documents Part Name Code No. Remarks Q’ty. Hexagon Head Bolt NB111008-025 M8×25 Spring Washer ND320-008 Retainer, Oil Seal CS04800-125 125*** O-ring PA12-085 JISB2401 1A G85 Oil Seal CS05000-125D 125*** Oil Seal CS05000-125HE HE125 1 (HE) Seal Cover CS051000-125BBS 125*** Seal Cover...
  • Page 147 Chapter 7 Related Documents Part Name Code No. Remarks Q’ty. Suction Cover Flange MYK100A without MYK100A(4") CS71400-P100 hole Male Gasket, Suction Flange CR72000-100N MYK100A Hexagon Head Bolt NB12022-055 M22×55 Discharge Cover Flange MYK65CD CS71400-P065CD MYK65CD Male 1 (*UD) Gasket, Discharge Flange CS72000-065N MYK65A 1 (*UD)
  • Page 148 Chapter 7 Related Documents  The part code of the O-ring is the one assigned to NBR which is standard material. When the material of the O-ring is other than NBR, a different part code is used for each material. If you are using O-rings made from other than the standard material, please contact MAYEKAWA when placing an order.
  • Page 149 Chapter 7 Related Documents Table 7-2 Parts Configuration Table of 160*UD models Part Name Code No. Remarks Q’ty. Main Rotor Casing CS00100-160S 160S** 1 (S**) Main Rotor Casing CS00100-160M 160M** 1 (M**) Main Rotor Casing CS00100-160L 160L** 1 (L**) Hexagon Socket Head Cap Screw NB35412-040 M12×40 φ13×40...
  • Page 150 Chapter 7 Related Documents Part Name Code No. Remarks Q’ty. O-ring PA12-095 JISB2401 1A G95 Spacer CS03600-160 160*** Stop Ring NG11-102 H102 Thrust Bearing CS03800-160P 7212B CSC3800-160 Ductile retainer CS03800-160N7 Lock Nut NG31-012 AN12 Lock Washer NG32-012 AW12 Spacer, Thrust Bearing Outer Race CS04100-160 160*** Spacer, Thrust Bearing Alignment...
  • Page 151 Chapter 7 Related Documents Part Name Code No. Remarks Q’ty. φ3×8 Guide Pin NE2503-008 Lock Nut NG31-005 AN05 Lock Washer NG32-005 AW05 O-ring PA11-021 JISB2401 1A P21 Unloader Cylinder Cover CS07400-160 160*** JISB2401 O-ring PA12-110 G110 Hexagon Socket Head Cap Screw NB35408-025 M8×25 Indicator Cam...
  • Page 152 Chapter 7 Related Documents Part Name Code No. Remarks Q’ty. Torsional Slip Washer CS23700-160 160*** Hexagon Socket Head Cap Screw NB35406-060 M6×60 Spring Washer for Hexagon Head Cap ND330-06 Screw φ6×50 Alignment Pin NE2006-050 Thrust Washer CS25000-160 160*** Gasket, Flange for Electromizer CR72000-025N MYK25A Hexagon Head Bolt...
  • Page 153 Chapter 7 Related Documents Table 7-3 Parts Configuration Table of 200*UD models Part Name Code No. Remarks Q’ty. Main Rotor Casing CS00100-200S 200S** 1 (S**) Main Rotor Casing CS00100-200M 200M** 1 (M**) Main Rotor Casing CS00100-200L 200L** 1 (L**) Hexagon Socket Head Cap Screw NB35416-050 M16X50 φ16X55...
  • Page 154 Chapter 7 Related Documents Part Name Code No. Remarks Q’ty. Set Screw NA83608-015 M8X15 O-ring PA11-120 JISB2401 1A P120 Spacer CS03600-200 200*** Stop Ring NG11-130 H130 Thrust Bearing CS03800-200P 7313PPS CS03800-200 NSK type Ductile retainer CS03800-200N NTN type Lock Nut NG31-013 AN13 Lock Washer...
  • Page 155 Chapter 7 Related Documents Part Name Code No. Remarks Q’ty. φ5X12 Guide Pin NE2505-012 Lock Nut NG31-007 AN07 Lock Washer NG32-007 AW07 O-ring PA12-030 JISB2401 1A G30 Unloader Cylinder Cover CS07400-200 200*** O-ring PA12-135 JISB2401 1A G135 Hexagon Socket Head Cap Screw NB35410-025 M10X25 Indicator Cam...
  • Page 156 Chapter 7 Related Documents Part Name Code No. Remarks Q’ty. Gasket, Lubrication Oil Supply Flange CR72000-020N MYK20A Hexagon Head Bolt NB111012-035 M12X35 Spacer, Discharge Flange FX101-200 Gasket, Discharge Flange Spacer CS23600-200N Torsional Slip Washer CS23700-200 200*** Guide, Unloader Slide Valve CS24600-200 200*** Hexagon Socket Head Cap Screw...
  • Page 157 Chapter 7 Related Documents Table 7-4 Parts Configuration Table of 250*UD models Part Name Code No. Remarks Q’ty. Main Rotor Casing CS00100-250S 250S** 1 (S**) Main Rotor Casing CS00100-250M 250M** 1 (M**) Main Rotor Casing CS00100-250L 250L** 1 (L**) Hexagon Socket Head Cap Screw NB35420-060 M20X60 φ16X70...
  • Page 158 Chapter 7 Related Documents Part Name Code No. Remarks Q’ty. Set Screw NA83608-020 M8X20 O-ring PA11-150 JISB2401 1A P150 Spacer CS03600-250 250*** Stop Ring NG11-160 H160 Thrust Bearing CS03800-250P 7317PPS Ductile retainer CS03800-250 Lock Nut NG31-017 AN17 Lock Washer NG32-017 AW17 Spacer, Thrust Bearing Alignment1 CS04200-250...
  • Page 159 Chapter 7 Related Documents Part Name Code No. Remarks Q’ty. Push Rod, Unloader Slide Valve CS0671-FL 250L** 1 (L**) φ5X12 Guide Pin NE2505-012 Lock Nut NG31-008 AN08 Lock Washer NG32-008 AW08 O-ring PA12-035 JISB2401 1A G35 Unloader Cylinder Cover CS07400-250S 250*** O-ring PA12-170...
  • Page 160 Chapter 7 Related Documents Part Name Code No. Remarks Q’ty. Gasket, Lubrication Oil Supply Flange CR72000-025N MYK25A Hexagon Head Bolt NB111012-035 M12X35 Spacer, Discharge Flange FX101-250 250*** 1 (*UD) Gasket, Discharge Flange Spacer CS23600-250N 250*** 1 (*UD) Torsional Slip Washer CS23700-250 250*** Guide, Unloader Slide Valve...
  • Page 161 Chapter 7 Related Documents Table 7-5 Parts Configuration Table of 320*UD models Part Name Code No. Remarks Q’ty. Main Rotor Casing CS00100-320S 320S** 1(SUD) Main Rotor Casing CS00100-320M 320M** 1(MUD) Main Rotor Casing CS00100-320L 320L** 1(LUD) Main Rotor Casing CS00100-320LL 320LL** 1 (LLUD) Hexagon Socket Head Cap Screw...
  • Page 162 Chapter 7 Related Documents Part Name Code No. Remarks Q’ty. Balance Piston CS03000-320 320*** Key, Balance Piston CS03100-320 320*** Stop Ring NG12-100 S100 Sleeve, Balance Piston CS03300-320 320*** φ6x14 Spring Pin NE3206-014 O-ring PA12-190 JISB2401 1A G190 Spacer CS03600-320 320*** Stop Ring NG11-200 H200...
  • Page 163 Chapter 7 Related Documents Part Name Code No. Remarks Q’ty. Hexagon Socket Head Cap Screw NB35416-050 M16X50 O-ring PA11-032 JISB2401 1A P32 Unloader Cylinder CS06000-320S 320S** 1 (SUD) Unloader Cylinder CS06000-320M 320M** 1 (MUD) Unloader Cylinder CS06000-320L 320L** 1 (LUD) Unloader Cylinder CS06000-320LL 320LL**...
  • Page 164 Chapter 7 Related Documents Part Name Code No. Remarks Q’ty. Hexagon Head Bolt NB12024-075 M24X75 Discharge Cover Flange CS71400-P200CD MYK200CD Male 1（*UD) Gasket, Discharge Flange CR72000-200N MYK200A Hexagon Head Bolt NB12020-055 M20X55 Hexagon Head Bolt NB12020-075 M20X75 Mechanical Seal Assembly (BOS) CS10000-320BE 320V** BOS Type Mechanical Seal Assembly (BBSE)
  • Page 165 Chapter 7 Related Documents  The part code of the O-ring is the one assigned to NBR which is standard material. When the material of the O-ring is other than NBR, a different part code is used for each material. If you are using O-rings made from other than the standard material, please contact MAYEKAWA when placing an order.
  • Page 166 Chapter 7 Related Documents Table 7-6 Parts Configuration Table of 400*UD models Part Name Code No. Remarks Q’ty. Main Rotor Casing CS00107-400S 400S** 1 (SUD) Main Rotor Casing CS00107-400M 400M** 1 (MUD) Main Rotor Casing CS00107-400L 400L** 1 (LUD) Main Rotor Casing CS00107-400LL 400LL** 1(LLUD)
  • Page 167 Chapter 7 Related Documents Part Name Code No. Remarks Q’ty. Stop Ring NG11-250 H250 Balance Piston CS03000-400 400V** Key, Balance Piston CS03100-400 400V** Stop Ring NG12-120 S120 Sleeve, Balance Piston CS03300-400 400V** φ10x25 Spring Pin NE3210-025 O-ring PA12-240 JISB2401 1A G240 Spacer CS03600-400 400V**...
  • Page 168 Chapter 7 Related Documents Part Name Code No. Remarks Q’ty. φ6x16 Guide Pin NE2506-016 Lock Nut NG31-010 AN10 Lock Washer NG32-010 AW10 O-ring PA12-045 JISB2401 1A G45 Unloader Cylinder Cover CS07400-400 400*** O-ring PA12-270 JISB2401 1A G270 Hexagon Socket Head Cap Screw NB35424-080 M24X80 Indicator Cam...
  • Page 169 Chapter 7 Related Documents Part Name Code No. Remarks Q’ty. NBU605/8-11UNC 5/8-11UNC X 75 mm Stud Bolt & Nut NCU1505/8-11UNC 5/8-11UNC NBU605/8-11UNC 5/8-11UNC X 75 mm Stud Bolt & Nut NCU1505/8-11UNC 5/8-11UNC Flange, Injection Oil Supply CZA01-300C0204B ANSI#300 2-1/2" Gasket, Injection Oil Supply PL300-065 ANSI#300 2-1/2"...
  • Page 170 Chapter 7 Related Documents UD-series Screw Compressor 7.2 Parts Configuration Table 400*UD 7-33...

  • Page 171: Maintenance Data

    Chapter 7 Related Documents Maintenance Data Table 7-7 End clearance For single stage (high stage) Model 0.03～0.05 0.04～0.06 0.05～0.07 0.08～0.11 0.17～0.21 0.20～0.24 0.23～0.27 0.26～0.30 0.24～0.30 For booster (low stage) Model 0.20～0.22 0.22～0.24 0.24～0.26 0.26～0.30 0.28～0.32 0.31～0.35 0.40～0.44 0.45～0.49 0.50～0.54 0.55～0.59 0.70～0.76 0.73～0.79 0.77～0.83...
  • Page 172 Chapter 7 Related Documents Table 7-11 Lock Nut Tightening Torque Standard Maximum N・m kgf・cm N・m kgf・cm AN 05 AN 06 AN 07 AN 08 1,130 AN 09 2,060 2,580 AN 10 2,380 2,970 AN 11 3,120 3,900 AN 12 4,080 5,100 AN 13 5,220...

  • Page 173: Lock Nuts

    Chapter 7 Related Documents Lock Nuts Table 7-14 Lock Nut Used and Each Tightening Torque Nominal Designation of Lock Nut（Qty） Tightening Torque N･m Location Thrust Bearing AN09(2) AN12 (2) AN13 (2) AN17 (2) AN21 (2) AN28(2) 206/258 408/510 522/653 1186/1483 2259/2824 5347/6683 Standard/Maximum...

  • Page 174: Thrust Bearing Gland

    Chapter 7 Related Documents Thrust Bearing Gland Standard tightening torque of thrust bearing gland bolt and its tightening method 1. Introduction Thrust bearing gland bolts for screw compressors are a very important task in assembling precision thrust bearings. In this work, excessive tightening or partial tightening exceeding the specified torque may affect the bearing life, so be sure to use the specified torque and tightening method below.

  • Page 175: O-Rings Used

    Chapter 7 Related Documents O-rings Used Table 7-17 List of O-ring Materials Used for Screw Compressor (excluding mechanical seal) Working fluid O-ring material Ammonia Hydrofluorocarbon (HFC) *Note HNBR Working Fluid Propane Propylene Natural gas City gas Helium ＊Note: Select FKM if you suspect that gases other than CO or impurities are mixed in.

  • Page 176: Gaskets Used

    Chapter 7 Related Documents Gaskets Used Figure 7-9 Gaskets Used （㎜） Table 7-19 Gasket Size Location Suction Cover Bearing Head Bearing Cover (D: Sideways discharge) ― Bearing Cover 332.5 ― (G: Downward discharge) Balance Piston Cover Φ Seal Cover Φ Suction Flange (125A) (150A)

  • Page 177: Tools For Disassembly

    Chapter 7 Related Documents Tools for Disassembly Table 7-20 List of Tools for Disassembly (example) Tool name Illustration size, etc.; Code No. Ratchet wrench 1/4” SG261-08 Adjustable wrench 250 mm SG231-250 75 mm SG112-075 Screwdriver Phillips 125 mm SG112-125 75 mm SG111-075 Screwdriver Flat blade...
  • Page 178 Chapter 7 Related Documents Tool name Illustration size, etc.; Code No. AN-21 SAS111-21 5-25 N･m Torque wrench 20-100 N･m SG132-0900 for assembly 60-420 N･m SG132-4200 CS70300-160 Assembly and CS70300-200 Disassembly Tool, Main/Side Bearing CS70300-250 CS70300-320 UD-series Screw Compressor 7.8 Tools for Disassembly 7-41...
  • Page 179 MAYEKAWA MFG. CO., LTD. 3-14-15 Botan Koto-ku, Tokyo 135-8482, JAPAN Phone : +81 (0)3-3642-8181 : http://www.mayekawa.com/...

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