mycom 4032LLLLC, 4032LLMC, 4032XLLLC, 4032LLLC, 4032LLSC Instruction Manual

...

2201Q4JE-MY-C9-N_2018.01.

Compound 2-stage Screw Compressor

4032 * * C Instruction Manual

4032XLLLC/4032LLLLC/4032LLLC/4032LLMC/4032LLSC

4032LLC/4032LMC/4032LSC/4032MLC/4032MMC/4032MSC

4032SLC/4032SMC/4032SSC

CAUTION

Before operating, servicing, or inspecting this product, read this manual thoroughly to fully understand the contents. Keep this Instruction Manual in a safe, designated place for future reference whenever the manual is needed.

Specifications of this product and contents of this manual are subject to change without

prior notice due to technical improvements, and the like.

2201Q4JE-MY-C9-N_2018.01.

Preface

Compound 2-stage Screw Compressor 4032**C

Preface

Thank you for purchasing the C-series compound 2-stage screw compressor 4032**C (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. This manual is applicable to the following models:

4032XLLLC-*B*-51

4032LLLLC-*B*-51

4032LLLC-*B*-51

4032LLMC-*B*-51

4032LLSC-*B*-51

4032XLLLC-*B*-61

4032LLLLC-*B*-61

4032LLLC-*B*-61

4032LLMC-*B*-61

4032LLSC-*B*-61

4032LLC-*B*-51

4032LLC-*B*-61

4032LMC-*B*-51

4032LMC-*B*-61

4032LSC-*B*-51

4032LSC-*B*-61

4032MLC-*B*-51

4032MLC-*B*-61

4032MMC-*B*-51

4032MMC-*B*-61

4032MSC-*B*-51

4032MSC-*B*-61

4032SLC-*B*-51

4032SLC-*B*-61

4032SMC-*B*-51

4032SMC-*B*-61

4032SSC-*B*-51

4032SSC-*B*-61

* -51 (-61) may not be written. For more information, see 2.2 "Model designation of the compressor" in this manual Chapter 2.

Before installing or using this product, make sure you read this manual. Keep this manual in a safe place near this product for quick reference.

Revision History

Title

Document No.

First edition issue date

4032**C Instruction Manual

2201Q4JE-MY-C9-N_2018.01.

Apr. 30, 2015

Revision

No.

Issue date

Major Contents of revisions

Created/approved by:

Apr. 30, 2015

Newly issued as a electronic edition manual.

Ikehara / Muta

Jan. 31, 2018

Corrected errors. Deleted Contact Information.

Takenouchi・Ito/Kato

2201Q4JE-MY-C9-N_2018.01.

Warranty and Disclaimer

Compound 2-stage Screw Compressor 4032**C

Warranty and Disclaimer

Warranty

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.

The warranty period is "12 months from factory shipment of this product". However, if any separate agreement has been concluded, such an agreement will have the priority in principle.

MAYEKAWA is not liable for production or man-made disaster compensation due to malfunction or damage of this product.

Disclaimer of Warranty

Although MAYEKAWA warrants the clauses mentioned above, the following clauses are exempted.

 Malfunction or damage of this product caused by natural disaster, or other accidental forces

(such as fire, thunderbolt, windstorm, intense rainfall, flood, tidal wave, earthquake, land subsidence, etc.).

 Malfunction or damage caused by misusage described below.

 Malfunctions, damage, or deterioration of this product due to abnormal or improper use

(including improperly storing this product outdoors or under too hot/humid conditions, unexpected inspections, tests, operations, too frequent liquid flow-back operation*, and too frequent start-stop cycles, etc.).

 Malfunction or damage caused by devices or equipments not provided by MAYEKAWA

including operation control methods of those devices.

 Malfunction or damage caused by refrigerants, gases, or refrigerant oils, and operating

conditions (design conditions) not approved for this product.

 Malfunction or damage caused by maintenance or inspection not recommended by

MAYEKAWA.

 Malfunction or damage caused by parts that are not genuine.  Malfunction or damage caused by remodeling the product without approval of

MAYEKAWA.

 Malfunction or damage caused by unexpected misusage

"Liquid flow-back operation" is ･･･ Normally, while the compressor sucks in the refrigerant liquid only after vaporizing it in the

evaporator, it may directly sucks it in because of the faulty adjustment or failure of the expansion valve. We call this state of compressor operation "liquid flow-back operation".

No compressor can compress a liquid. The compressor may be damaged should the liquid be sucked in.

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Important Information

Compound 2-stage Screw Compressor 4032**C

iii

Important Information

Intended Use of This Product

This product is a general-purpose screw compressor for refrigeration, cold storage and various gases compression. 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 Section 2.3 "Compressor Specifications" in this manual Chapter 2.

Please perform the maintenance items described in this manual by using safe and assured procedures.

Important Information for Safe Use of This Product

Although MAYEKAWA has paid a lot of attention to safety measures for this product, all hazards including potential hazards caused by human errors, or due to environmental conditions can not be anticipated.

As there are too many items to be strictly observed or prohibited when using this product, it is impossible to inform all of them through this manual. Therefore, when operating this product, pay extreme caution on personnel safety as well as on items described in this manual.

Important rules for safety work with this product that apply to all workers including managers and supervisors are listed below.

Please read this manual before using this product. Fully understand the instructions provided there, and be sure to perform the safety procedures described in this manual.

 Operation, maintenance, and inspection of this product should be performed by qualified

personnel educated about the fundamentals of this product and trained about hazards involved and measures to avoid danger.

 Do not allow any person other than those educated on the fundamental expertise of this

product and trained about hazards involved and measures to avoid dangers to approach this product while it is operating or during maintenance.

 Observe all related federal/national and local codes and regulations.  To prevent accidents, do not carry out any operation or maintenance other than those

described in this manual. Do not use this product for any purpose other than intended.

 Replace the parts with genuine parts.  Not only workers but also managers should actively participate safety and health activities in

the workplace to prevent accidents.

 When closing or opening a valve during work, make sure to apply lockout/tagout to prevent

the valve from being accidentally closed or opened during the work.

[Lockout] To lock with a key in order to keep people, except the workers involved, from

operating the product.

Lockout means disconnecting or keeping disconnected machines and devices by locking their

energy (power) sources. Lockout is not just simply turning off the power switches to stop the supply of power, but includes immobilizing them with a key or similar device to keep any blocked switches from being operated. Lockout devices are devices such as keys, covers, and latches, to immobilize switches, valves, opening and closing levers, etc., with a state of being locked.

[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.

2201Q4JE-MY-C9-N_2018.01.

Important Information

Compound 2-stage Screw Compressor 4032**C

Observe the following precautions when performing maintenance work on electrical control.

 Electrical maintenance of the product must be performed by certified/qualified personnel and

only those educated about the electrical control of the product.

 Before servicing or inspecting the electrical equipment or devices, turn "OFF" the motor main

power and control power, and perform lockout/tagout to prevent the power from being turned on during work.

Even when the motor main power and control power are turned "OFF", this product may be turned on if the power is supplied from outside the package unit. Make sure the power supply on the power source side is shut off, and perform lockout/tagout to prevent the product from being turned on during work.

About This Manual

 This product may be modified without prior notice. Therefore, the appearance of actual

machine may differ from the descriptions in this manual. If you have any questions, contact our sales offices or service centers. For each sight of MAYEKAWA, refer to following URL. http://www.mayekawa.com/about/network/

 This manual is in English. If any other language is required, it is the customers’ responsibility

to prepare a manual for safety education and operation instructions.

 This manual is copyrighted. Drawings and technical references including this manual shall not,

in whole or part, be copied, photocopied, or reproduced into any electronic medium or machine-readable form without prior permission from MAYEKAWA.

 Photographs or drawings included in this manual may differ from the appearance of actual

product.

 If this manual is lost or damaged, immediately request our local sales offices or service

centers for a new manual. Using this product without the manual may result in safety issues.

 If you resell this product, never fail to attach this manual to this product.

Construction of This Manual

Title of section and chapter

Description details

Preface

Describes the outline of this manual and how to read this manual.

Warranty and Disclaimer

Describes what MAYEKAWA warrants and what are covered by the warranties. Warranty exemption is stated as disclaimer.

Important Information

Describes important information related to this product and this manual.

1. Safety

Describes safety information for the worker, safety rules for this product, and management details regarding the work safety that is required for handling this product.

2. Compressor Specifications and Structure

Describes the main components of this product, functional information, specification, and operating limits.

3. Installation

Describes the installation procedure of this product.

4. Compressor and Package Unit Operation

Describes the precautions for operating this product.

5. Maintenance and Inspection

Describes sections and period for inspecting, and assembly and disassembly of this product.

6. Troubleshooting

Describes troubleshooting methods for this product in case problems occur during operation of this product.

7. Related Documents

Describes documents such as Exploded views and parts list.

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Table of Contents

Compound 2-stage Screw Compressor 4032**C

Table of Contents

Preface .................................................................................................................... ⅰ

Revision History ..................................................................................................... ⅰ

Warranty and Disclaimer ....................................................................................... ⅱ

Important Information ............................................................................................ ⅲ

Intended Use of This Product ........................................................................................... ⅲ

Important Information for Safe Use of This Product .......................................................... ⅲ

About This Manual ............................................................................................................. ⅳ

Construction of This Manual .............................................................................................. ⅳ

Table of Contents ................................................................................................... ⅴ

Chapter 1 Safety

1.1 Strict Requirements and Prohibitions ........................................................ 1-1

1.1.1 Strict Requirements (Do’s)................................................................................... 1-1

1.1.1.1 Do’s on Operation ........................................................................................ 1-1

1.1.1.2 Do’s on Maintenance ................................................................................... 1-1

1.1.1.3 Do’s on Lockout/Tagout after Shutting Off the Power ................................. 1-1

1.1.1.4 Do’s about Personal Protective Gear .......................................................... 1-2

1.1.1.5 Do’s about Handling of Hazardous and Toxic Substances .......................... 1-2

1.1.1.6 Do’s about Handling Emergency Situations ................................................ 1-2

1.1.1.7 Do’s about Waste Oil, Fluid, and Materials ................................................. 1-2

1.1.1.8 Other Do’s .................................................................................................... 1-2

1.1.2 Prohibitions (Don’ts) ......................................................................................... 1-3

1.2 Warnings ....................................................................................................... 1-3

1.3 Residual Risks ............................................................................................. 1-4

1.4 Safety Devices .............................................................................................. 1-6

1.4.1 Emergency Stop Button ....................................................................................... 1-6

1.4.2 Breakers of Motor Main Power and Control Power

(with Lockout/Tagout Mechanism) ...................................................................... 1-6

1.4.3 Compressor Protective Devices .......................................................................... 1-7

Chapter 2 Compressor Specifications and Structure

2.1 Overview of 4032**C .................................................................. 2-1

2.2 Model Designation of the Compressor ................................................... 2-1

2.3 Compressor Specifications ........................................................................ 2-2

2.3.1 Specifications ....................................................................................................... 2-2

2.3.2 Operation Limits ................................................................................................... 2-3

2.3.3 Outer Dimensions ................................................................................................ 2-4

2.4 Compressor Structure ................................................................................. 2-8

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Compound 2-stage Screw Compressor 4032**C

2.5 Mechanisms ................................................................................................. 2-9

2.5.1 Basics of the Screw Compressor ........................................................................ 2-9

2.5.2 Suction Process ................................................................................................... 2-9

2.5.3 Compression Process ........................................................................................ 2-10

2.5.4 Discharge Process ............................................................................................. 2-10

2.5.5 About Volume Ratio (Vi) .................................................................................... 2-10

2.5.6 Capacity Control Mechanism ............................................................................. 2-12

2.5.7 Bearing and Balance Piston .............................................................................. 2-12

2.5.8 Shaft Seal .......................................................................................................... 2-12

2.6 Gas and Oil Flow ........................................................................................ 2-13

Chapter 3 Installation

3.1 General Precautions for Installation .......................................................... 3-1

3.2 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 ................................................................................... 3-4

3.2.5 Installation ............................................................................................................ 3-5

3.2.5.1 Installation .................................................................................................... 3-5

3.2.5.2 Shaft Alignment between the Compressor and Driving Machine ................ 3-5

3.2.5.3 Piping Connection ....................................................................................... 3-6

3.2.5.4 Equipment and Devices for Protection of the Compressor ......................... 3-6

3.2.6 Airtightness Test .................................................................................................. 3-7

3.2.7 Lubricating Oil Charge ......................................................................................... 3-7

3.2.7.1 Initial Charge of Lubricating Oil ................................................................... 3-7

3.2.7.2 Additional Charge of Lubricating Oil ............................................................ 3-7

3.2.8 Charge of Refrigerant .......................................................................................... 3-7

3.2.9 Check after Installation ........................................................................................ 3-7

Chapter 4 Compressor and Package Unit Operation

4.1 Lubricating Oil (Refrigerant Oil) ................................................................. 4-1

4.1.1 Precautions for Selecting the Lubricating Oil....................................................... 4-1

4.1.2 Change of Lubricating Oil Brand ......................................................................... 4-1

4.1.3 Precautions for Handling lubricating Oil .............................................................. 4-2

4.1.3.1 Precautions for Handling Polyalkylene Glycol (PAG) .................................. 4-2

4.1.3.2 Precautions for Handling Polyolester (POE) Oil .......................................... 4-2

4.1.4 Lubricating Oil Management Criteria ................................................................... 4-3

4.1.5 Lubricating Oil Replacement Timing .................................................................... 4-4

4.1.5.1 After Starting the Initial Operation ............................................................... 4-4

4.1.5.2 During Normal Operation............................................................................. 4-4

4.2 Precautions for Operation ........................................................................... 4-5

4.2.1 Prevention of Liquid Flow-back Operation ........................................................... 4-5

4.2.2 Purging of Non-Condensable Gases ................................................................... 4-5

4.3 When Stopping the Compressor for a Long Time .................................... 4-6

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Compound 2-stage Screw Compressor 4032**C

vii

Chapter 5 Maintenance and Inspection

5.1 Precautions for Maintenance and Inspection ............................................ 5-1

5.2 Maintenance and Inspection List................................................................ 5-3

5.2.1 Daily Management ............................................................................................... 5-3

5.2.2 Periodic Inspection .............................................................................................. 5-5

5.2.3 Guidelines for the Timing of Compressor Overhaul ............................................ 5-6

5.3 Compressor Disassembly Preparation ...................................................... 5-7

5.3.1 Disassembly Tools and Workplace ..................................................................... 5-7

5.3.2 Replacement Parts .............................................................................................. 5-7

5.3.3 Refrigerant Gas Recovery ................................................................................. 5-10

5.3.4 Removal of Connections to the Package Unit ................................................... 5-11

5.3.5 Removal and Lifting the Compressor ................................................................ 5-12

5.4 Disassembly and Inspection ..................................................................... 5-13

5.4.1 Unloader Indicator ............................................................................................. 5-14

5.4.1.1 Disassembly .............................................................................................. 5-15

5.4.1.2 Inspection .................................................................................................. 5-15

5.4.2 Unloader Cover .................................................................................................. 5-16

5.4.2.1 Disassembly .............................................................................................. 5-16

5.4.2.2 Inspection .................................................................................................. 5-17

5.4.3 Unloader Piston and Unloader Cylinder ............................................................ 5-18

5.4.3.1 Disassembly .............................................................................................. 5-18

5.4.3.2 Inspection .................................................................................................. 5-19

5.4.4 Shaft Seal Block ................................................................................................ 5-20

5.4.4.1 Disassembly .............................................................................................. 5-20

5.4.4.2 Inspection .................................................................................................. 5-20

5.4.5 Bearing Cover .................................................................................................... 5-21

5.4.5.1 Disassembly .............................................................................................. 5-21

5.4.6 Separating High-stage and Low-stage Blocks................................................... 5-22

5.4.6.1 Disassembly .............................................................................................. 5-22

5.4.7 Gear Coupling .................................................................................................... 5-22

5.4.7.1 Disassembly .............................................................................................. 5-22

5.4.7.2 Inspection .................................................................................................. 5-22

5.4.8 Balance Piston ................................................................................................... 5-23

5.4.8.1 Disassembly .............................................................................................. 5-23

5.4.8.2 Inspection .................................................................................................. 5-23

5.4.9 Low-stage Suction Cover and Side Bearings .................................................... 5-24

5.4.9.1 Disassembly .............................................................................................. 5-24

5.4.9.2 Inspection .................................................................................................. 5-25

5.4.10 High-stage Suction Cover and Side Bearings ................................................... 5-26

5.4.10.1 Disassembly .............................................................................................. 5-26

5.4.10.2 Inspection .................................................................................................. 5-26

5.4.11 Thrust Bearing Block ......................................................................................... 5-27

5.4.1 1.1 Disassembly of the High-stage Thrust Bearing Block ............................... 5-27

5.4.1 1.2 Disassembly of the Low-stage Thrust Bearing Block ................................ 5-28

5.4.1 1.3 Inspection .................................................................................................. 5-28

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Compound 2-stage Screw Compressor 4032**C

viii

5.4.12 Rotors and Main Rotor Casing (Low-stage/High-stage) .................................... 5-30

5.4.12.1 Disassembly .............................................................................................. 5-30

5.4.12.2 Inspection .................................................................................................. 5-30

5.4.13 High-stage Bearing Head and Main Bearings ................................................... 5-31

5.4.13.1 Disassembly .............................................................................................. 5-31

5.4.13.2 Inspection .................................................................................................. 5-31

5.4.14 Low-stage Bearing Head and Main Bearings .................................................... 5-32

5.4.14.1 Disassembly .............................................................................................. 5-32

5.4.14.2 Inspection .................................................................................................. 5-32

5.5 Reassembly ................................................................................................ 5-33

5.5.1 Unloader Slide Valve ......................................................................................... 5-35

5.5.2 Bearing Head and Main Bearings ...................................................................... 5-36

5.5.3 Bearing Head and Rotor Casing ........................................................................ 5-37

5.5.4 Installing the Rotors ........................................................................................... 5-39

5.5.5 Suction Cover and Side Bearings ...................................................................... 5-40

5.5.6 Installing the Suction Cover ............................................................................... 5-41

5.5.7 Balance Piston and Balance Piston Sleeve ....................................................... 5-42

5.5.8 Thrust Bearing Block ......................................................................................... 5-43

5.5.8.1 High-stage Block ....................................................................................... 5-44

5.5.8.2 Low-stage Block ........................................................................................ 5-45

5.5.8.3 End Clearance Measurement .................................................................... 5-46

5.5.8.4 End Clearance Adjustment Procedure ...................................................... 5-47

5.5.8.5 Tightening after Finishing the End Clearance Adjustment ........................ 5-47

5.5.9 Balance Piston Cover and High-stage Unloader Cylinder ................................. 5-48

5.5.10 Bearing Cover .................................................................................................... 5-49

5.5.11 Shaft Seal Block ................................................................................................ 5-49

5.5.12 Low-stage Unloader Cylinder ............................................................................ 5-50

5.5.13 Unloader Cover .................................................................................................. 5-51

5.5.14 Coupling the High-stage and Low-stage Blocks ................................................ 5-52

5.5.15 Unloader Indicator ............................................................................................. 5-53

5.5.15.1 Potentiometer ............................................................................................ 5-53

5.5.15.2 Micro-switches and Micro-switch Cam ...................................................... 5-54

5.5.15.3 Reassembly ............................................................................................... 5-54

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Table of Contents

Compound 2-stage Screw Compressor 4032**C

Chapter 6 Troubleshooting

01: Compressor does not start up ............................................................................ 6-1

02: Compressor stops immediately after startup ................................................... 6-1

03: Unusually low pressure (decrease of suction pressure) ................................. 6-2

04: Low oil pressure (low lubricating oil supply pressure) ................................... 6-2

05: Intermediate pressure is unusually high ........................................................... 6-3

06: Unusually high pressure (abnormal discharge pressure) ............................... 6-4

07: Discharge temperature is abnormally high ....................................................... 6-5

08: Leak from mechanical seal ................................................................................. 6-6

09: Squeaking of mechanical seal ............................................................................ 6-7

10: Capacity control position is indicated incorrectly ........................................... 6-7

11: Capacity control malfunction.............................................................................. 6-8

12: Compressor generates abnormal vibration and/or sound .............................. 6-9

Chapter 7 Related Documents

7.1 Exploded Views, Assembly Sectional Views ............................................ 7-1

7.2 Parts Configuration Table ........................................................................... 7-6

7.3 Tightening Torques for Bolts and Nuts ................................................... 7-13

7.4 About the O-rings Used ............................................................................. 7-15

7.4.1 List of O-rings Used ........................................................................................... 7-15

7.4.2 O-ring Materials Used for Screw Compressor ................................................... 7-15

7.5 Tools for Disassembly............................................................................... 7-16

Contact Information

Sales 0ffices/Service Centers ..................................................................... Contact-1

Sales Offices in Japan ........................................................................................... Contact-1

Manufacturing Bases in Japan ............................................................................... Contact-1

Global Network ....................................................................................................... Contact-2

NORTH AMERICA ........................................................................................................ Contact-2

EUROPE and AFRICA .................................................................................................. Contact-2

ASIA PACIFIC ............................................................................................................... Contact-3

LATIN AMERICA ........................................................................................................... Contact-5

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Chapter 1 Safety

Compound 2-stage Screw Compressor 4032**C 1.1 Strict Requirements and Prohibitions

1-1

Chapter 1 Safety

1.1 Strict Requirements and Prohibitions

1.1.1 Strict Requirements (Do’s)

1.1.1.1 Do’s on Operation

 Make sure to install safety and protective devices on the package unit.  Regularly inspect the safety and protective devices if they function properly.  If the safety or protective devices do not work properly or if this product operates abnormally,

immediately stop the operation and report to your supervisor. Obtain his/her approval and direction before restarting the compressor.

 If this product stops for unknown reasons, immediately inform your supervisor of it. Obtain

his/her approval before restarting this product.

 Some types of refrigerants emit bad smell or toxic gases when they leak. Make sure to

ventilate the air during operation.

 For the properties of refrigerant and lubricating oil (corrosiveness, decomposability or toxicity),

be sure to obtain the Safety Data Sheet (SDS) and follow the relevant information.

 When stopping the operation of this product, close the suction and discharge side shut-off

valves and turn "OFF" the motor (main power), heater power, and control power.

1.1.1.2 Do’s on Maintenance

 Prepare work procedures based on a work schedule. Be sure to perform danger forecasting

before starting the work.

 Before performing the work together with at least one other person, thoroughly confirm each

other's work details and procedures to acknowledge the other worker's movement.

 When troubleshooting during operation or before performing setup, cleaning, maintenance or

inspection of this product, always turn OFF the main power to the motor and control power and other devices. Also, lock and tag out them to prevent the power from being supplied erroneously during operation.

 When troubleshooting during operation or before performing setup, cleaning, maintenance or

inspection of this product, confirm that the pressure inside this product and the package unit is at atmospheric pressure.

 Some refrigerants in use generate bad smell or toxic gases, or may cause deficiency of

oxygen. Before starting work, measure oxygen concentration in the work area as necessary. Ventilate the area well. Be sure to keep the area well ventilated until the work is finished.

 For the properties of refrigerant and lubricating oil (corrosiveness, decomposability or toxicity),

be sure to obtain the Safety Data Sheet (SDS) and follow the relevant information.

 After using tools always restore to designated place and never leave tools in the package unit.

1.1.1.3 Do’s on Lockout/Tagout after Shutting Off the Power

 Attach lockout/tagout mechanism to the main breakers of motor main power and control power.

Lockout/tagout after power off is a very effective means to secure safety. It can prevent the power source from being turned on by accident by two or more workers which may cause injury to other worker(s).

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Chapter 1 Safety

Compound 2-stage Screw Compressor 4032**C 1.1 Strict Requirements and Prohibitions

1-2

 If there are any possibilities of danger during works (especially during cleaning, maintenance

and inspection, and troubleshooting), turn "OFF" the motor main power and control power, and perform lockout/tagout.

 In the following situations, workers may neglect to perform power source shutoff or

lockout/tagout. Clearly notify the workers of the necessity of lockout/tagout.

 It is assumed that workers do not perform lockout/tagout before starting work because it is

troublesome, and only turn "OFF" the main motor and control power.

 It is assumed that workers only turn off the main motor and control power and do not

lockout/tagout the main motor and control power, because they judge that there is no danger.

1.1.1.4 Do’s about Personal Protective Gear

 Prepare and use protective gear complying with the safety standards of the regulations.  Check the function of each protective gear before using.  Wear designated clothes such as work outfits, with their cuffs tightly closed.  Do not wear any neckties or jewelry as there is a risk of being entangled by a movable part or

rotating part. Put on a helmet as your hair may get entangled.

 Do not have anything in your pocket to prevent objects from falling into the package unit.

1.1.1.5 Do’s about Handling of Hazardous and Toxic Substances

 Obtain the Safety Data Sheet (SDS) from manufacturers of hazardous and toxic substances.

Check the SDS and follow the handling instructions recommended by the manufacturers to handle and store those substances.

1.1.1.6 Do’s about Handling Emergency Situations

 Formulate an emergency action plan complying with the regulations, and post it on a safe

place.

1.1.1.7 Do’s about Waste Oil, Fluid, and Materials

 Disposing of refrigerant and oil used for this product are subject to a number of regulations for

the environmental protection purposes. Follow the local, state, federal acts and regulations and your company's rules when disposing of such waste oil, fluid and materials.

1.1.1.8 Other Do’s

 Clean the floor around the entire package unit. Provide a safety passage.  Walk only on the areas set up as a work floor. Also, do not leave tools and cleaning solutions

in that area.

 If water or oil is spilled on this product or the floor, immediately wipe it off to prevent workers

from slipping and getting injured.

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1-3

1.1.2 Prohibitions (Don’ts)

 Do not remove or relocate any safety device, including electrical interfaces.  Do not disable any safety device by short-circuiting or bypassing without any permission.  Do not leave this product unsafe and unattended, by removing a safety cover or some other

measures.

 Do not touch, clean or lubricate any part of this product which is moving.  Do not touch relays or electric systems such as terminal block with bare hands when turning

on the power.

1.2 Warnings

The warning messages described in this manual warn dangerous situations that may arise during work by using the following four categories.

Neglecting such warnings may cause accidents, resulting in personal injury or even death. Also, this product or its auxiliary equipment may be heavily damaged. Therefore, be sure to always

observe the instructions of the warnings.

Table 1-1 Warning Symbols and their Meanings

Symbol

Meaning

Indicates a hazardous situation which, if not avoided, could very likely cause serious injury or death.

Indicates a potentially hazardous situation which, if not avoided, may cause serious injury or death.

Indicates a potentially hazardous situation which, if not avoided, may cause minor or moderate injury.

Indicates a potentially hazardous situation which, if not avoided, may result in property damage.

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1-4

1.3 Residual Risks

The following information assumes that this product is operated or inspected/maintained while being used in general refrigerating/cold storage/gas compression package units.

Note that all hazardous sources cannot be predicted for the applications mentioned. Devise appropriate countermeasures for hazardous sources in your systems.

Table 1-2 Hazardous Sources

Hazardous sources

Predicted hazard

Countermeasures in

operation

Countermeasures in

cleaning, inspecting,

and replacing parts

Motor and compressor coupling Refer to Figure 1-1

 Caught in due to contact

 Install coupling cover

and prohibit opening.

 Keep away.

 Turn off motor main

power and control power, and conduct lockout/tagout.

Motor terminals

 Electric shock caused by

contact with live wires or electrical leakage

 Keep away.  Do not open terminal

boxes.

 Do not touch terminal

boxes.

 Turn off motor main

power and control power, and conduct lockout/tagout.

Compressor low-stage side suction casing Refer to Figure 1-1

 Frostbite due to contact  Contact with or inhalation of

hazardous substances generated by leakage of refrigerant or the like

 Keep away and do not

touch.

 Wear protective gear.  Detect gas leakage.

 Wear protective gear.  Work under room

temperature.

Compressor intermediate piping (low-stage discharge port to high stage suction port) Refer to Figure 1-1

 Burn injury due to contact  Contact with or inhalation of

hazardous substances generated by leakage or spout of refrigerant or the like

 Keep away and do not

touch

 Wear protective gear  Gas leakage detection

 Wear protective gear  Work in temperatures

below 40 °C

Compressor high-stage side discharge casing and discharge piping Refer to Figure 1-1

 Burn injury due to contact  Contact with or inhalation of

hazardous substances generated by leakage or spout of refrigerant or the like

 Keep away and do not

touch.

 Wear protective gear.  Detect gas leakage.

 Wear protective gear.  Work at a temperature

of not higher than 40°C.

Check valves/service valves and joints on each section of the package unit

 Contact with or inhalation of

hazardous substances generated by mishandling or leakage

 Frostbite or burn due to contact

 Sufficient ventilation  Indicate valve

open/close state.

 Keep away and do not

touch.

 Wear protective gear.

 Sufficient ventilation  Wear protective gear.  Tagout for controlled

valve

Solenoid valves/ electric valves on each section of the package unit

 Electric shock caused by

contact with live wires or electrical leakage

 Pinched due to contact with

driving part

 Install protective cover

on terminals, and prohibit opening.

 Keep away and do not

touch.

 Wear protective gear.

 Turn off each breaker

and the control power, and conduct lockout/tagout.

 Wear protective gear.

Electric components in each section of the package unit (oil heater, protective switch, etc.)

 Electric shock caused by

contact with live wires or electrical leakage

 Pinched due to contact with

driving part

 Install protective cover

on terminals, and prohibit opening.

 Keep away and do not

touch.

 Wear protective gear.

 Turn off each breaker

and the control power, and conduct lockout/tagout.

 Wear protective gear.

Package unit oil drains

 Contact with hazardous

substances generated by leakage or spout

 Burn caused by contact with

high-temperature fluid

 Sufficient ventilation  Keep away and do not

touch.

 Wear protective gear.

 Sufficient ventilation  Wear protective gear.  Work at a temperature

of not higher than 40°C.

Noises

 Damage caused by noise

 Wear protective gear.

—

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Figure 1-1 Locations of Hazardous Sources (compressor)

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1-6

1.4 Safety Devices

For safe use and protection of this product, make sure to attach safety devices to this product in accordance with the regulations and the following instructions.

Safety devices cannot be kept in normal condition unless inspected and maintained at regular intervals. Their maintenance and inspection need to be performed as an important part of the maintenance/inspection work project. Provide users of this product with necessary information on the safety devices, for example, types of the safety devices, installation position, function, and inspection method of safety related devices.

 Check the safety devices after turning on the power and before operation of the

compressor. If they do not operate normally, immediately take repair or replace safeties before starting compressor.

1.4.1 Emergency Stop Button

 Overview/Function/Purpose

The emergency stop buttons are used to stop this product operation immediately if an emergency occurs in this product.

 Installation Positions

On the local control panel and in the operation control room

 Stop/Restoration Methods

The operating procedures for the emergency stop button, i.e., how to stop the operation and restore the normal operating condition, must be clearly defined and the information provided to the user of this product.

 Inspection Method/Cycle

The emergency stop buttons must be tested before commissioning and must also be periodically re-tested after that. The inspection procedures and the inspection interval for the emergency stop button must be clearly defined and the information provided to the user of this product.

1.4.2 Breakers of Motor Main Power and Control Power (with Lockout/Tagout Mechanism)

 Overview/Function/Purpose

Turn off the main motor and control power, and if there is any possibility of danger during work (especially during cleaning, maintenance, inspection, or troubleshooting), lockout/tagout devices must be used on the breakers of the main motor and control powers to prevent injuries to workers in case the power is turned on accidentally during work.

 Methods of Performing and Releasing Lockout/Tagout

Make sure to clearly notify methods of performing and releasing lockout/tagout referring to the regulations created by Occupational Safety & Health Administration (OSHA) or local governing body.

 Inspection Method/Cycle

The inspection procedures and the inspection interval for the lockout/tagout devices, must be clearly defined and the information provided to the user of this product.

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1.4.3 Compressor Protective Devices

 Be sure to adjust the set values and check operation of the protective devices at the

commissioning.

 Overview/Function/Purpose

These protective devices are used to protect this product.

 Protecting from discharge temperature rise (DT)

This device activates and stops the compressor operation when the compressor discharge temperature gets equal to or higher than the set value. Install a temperature sensing port to the discharge pipe.

 Protecting from oil temperature rise (OT)

This device activates and stops the compressor operation when the compressor oil temperature gets equal to or higher than the set value. Install a temperature sensing port to the oil supply pipe of the package unit (after the oil cooler).

 Protecting from high pressure (HP)

This device activates and stops the compressor operation when the compressor discharge pressure gets abnormally high due to mishandling of the compressor or suspension of water supply to the condenser. This device prevents explosion of the equipment and components. Install a pressure sensing port to the discharge pipe.

 Protecting from intermediate pressure (IP)

This device activates when the intermediate pressure of the compressor gets equal to or higher than the set value and properly controls the compressor. In some cases, this device stops the compressor operation. Install a pressure output port to the package unit's intermediate gas pipe (or compressor's intermediate gas pressure output port).

 Protecting from suction pressure drop (LP)

This device activates and stops the compressor operation when the compressor suction pressure gets equal to or lower than the set value. Install a pressure sensing port to the suction pipe.

 Protecting from oil pressure (OP)

This device activates and stops the compressor operation when the differential pressure to supply oil to the compressor (= lubrication oil supply pipe pressure − compressor discharge pressure) gets equal to or lower than the set value, due to insufficient lubricant, clogged filter or mixture of refrigerant into the lubrication oil. This device prevents the sliding portion from being abnormally worn or seized. Install a pressure sensing port to the package unit's oil supply pump (after the oil pump) and the discharge pipe.

 Protecting from motor over-current (OCR)

This device activates and applies appropriate control when the current gets equal to or higher than the set level flows. In some cases, this device stops the compressor operation. This device is normally installed inside the control panel.

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1-8

 Connection Positions and Settings

Specify the connection position and setting for each compressor protective device, and make sure to provide users of this product with them.

Make sure that the set values do not exceed the operating limits shown in Section 2.3.2 and Table 2-2 in this manual Chapter 2.

 Inspection Method/Cycle

Compressor protective devices require operation tests and confirmation of the settings calibration before commissioning as well as at regular intervals. Specify the inspection methods/intervals of the compressor protection devices, and make sure to provide users of this product with such information.

 In the operation test, check that alarms and protective devices operate normally by

using devices such as pressure tester. Do not operate the compressor with all the valves closed, or in any other dangerous conditions.

 If the protection from low oil pressure (OP), high pressure (HP) activates, do not

restart operation until the cause of activation is removed.

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Compound 2-stage Screw Compressor 4032**C 2.1 Overview of MYCOM 4032**C

2-1

Chapter 2 Compressor Specifications and Structure

2.1 Overview of 4032**C

The 2-stage compression system, which has hitherto required two units of standard-type screw compressor for its embodiment, can now be realized by a single unit of compound 2-stage screw compressor.

Generally, screw compressors use oil injection to keep discharge temperature at a low level during operation without loss of volumetric efficiency even at high compression ratios. It can, therefore, be operated with a single-stage compression system even at evaporative temperatures near -40 °C.

However, for normal use at low temperatures, a 2-stage compression system is applied in order to improve kW/RT (ratio of power consumption versus refrigerating capacity). If the 2-stage compression system is configured with standard-type screw compressors, at least two screw compressor units need to be installed, one on the high-stage and the other on the low-stage, which inevitably requires double installation of the entire system including machinery, motors, utilities, etc.

This 2-stage screw compressor is produced to solve this problem. It is a single unit that has two single-stage compressor units combined into one.

The 4032**C model is currently the biggest size compressor in the compound 2-stage compressor C-series. In addition to general refrigeration systems and air conditioning systems, the 4032**C model has been used in variety process gas compression systems due to the ability to meet various requirements specifications, i.e., temperature conditions, pressure conditions, power conditions, etc. As a result, most of the products which have been manufactured and shipped until now, are special specification products.

If there are different points of specifications between your purchased compressor and the standard specification compressor described in this manual, refer to the document showing specifications of your purchased compressor.

2.2 Model Designation of the Compressor

This manual describes 4032**C-*B*-51 and 4032**C-*B*-61 models. The meaning of the type designation, which is engraved on the MODEL column of the compressor

nameplate, is as follows.

*4032**C-*B*-51/61

5: Power frequency (6: 60Hz)

1: Indicates that it is a motor directly connected type. * Unless specifically specified, machines manufactured in

September, 2010 or after do not have this indication engraved on their nameplate.

Vi (volume ratio) specified for the high-stage discharge port,

standard value of which is L or M

Means a booster (low-stage machine) Vi (volume ratio) specified for the low-stage discharge port, standard

value of which is L or M

Stands for Compound (compound 2-stage machine) Specifications of high-stage rotor length, which is LL, L, M or S Specifications of low-stage rotor length, which is XL, LL, L, M or S High-stage rotor diameter of 320 Low-stage rotor diameter of 400 Indicates working fluid (Example: N = Ammonia, F= Fluorocarbon, P = Propane, HE = Helium)

There are cases that the symbol indicating the special specification is engraved other than these. In such a case, refer to the specifications of each compressor.

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2.3 Compressor Specifications

2.3.1 Specifications

Table 2-1 4032**C Screw Compressor Specifications (1/2)

Items

Model

XLLLC

LLLLC

LLLC

LLMC

LLSC

LLC

Product mass

12320

*Note1

11250

10500

10350

10150

9700

Low-stage swept volume @3550 min-1 /2950 min-1

m3/h

15600

/12900

13800

/11500

13800 /11500

13800

/11500

13800

/11500

11700

/9700

High-stage swept volume @3550 min-1 /2950 min-1

m3/h

6740

/5600

6740

/5600

5700

/4740

4760

/3960

3820

/3170

5700

/4740

Working fluid

Ammonia, Hydrofluorocarbon, Hydrocarbons, Other.

Design pressure

MPa

2.6

Capacity control (Actual load)

10 to 100

Rotation direction

Counterclockwise viewed from motor

*Note1: Product mass of 4032XLLLC is a data of the specifications for cast steel casings.

Table 2-2 4032**C Screw Compressor Specifications (2/2)

Items

Model

LSC

MLC

MMC

MSC

SLC

SMC

SSC

Product mass

9350

8900

8750

8550

8050

7900

7700

Low-stage swept volume @3550 min-1 /2950 min-1

m3/h

11700

/9700

9800

/8140

9800

/8140

9800

/8140

7800

/6480

7800

/6480

7800

/6480

High-stage swept volume @3550 min-1 /2950 min-1

m3/h

3820

/3170

5700

/4740

4760

/3960

3820

/3170

5700

/4740

4760

/3960

3820

/3170

Working fluid

Ammonia, Hydrofluorocarbon, Hydrocarbons, Other.

Design pressure

MPa

2.6

Capacity control (Actual load)

10 to 100

Rotation direction

Counterclockwise viewed from motor

 Unless otherwise noted, the pressure unit MPa represents the gauge pressure in this manual.  For limits of working temperature and pressure, refer to Section2.3.2 "Operation Limits" in this

Chapter.

 For sizes of connecting piping, refer to Section 2.3.2 "Outer Dimensions" or Section 3..2.4 Table

3-1 " List of Connecting Pipes (Compressor)" in this manual.

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2.3.2 Operation Limits

Table 2-3 Operation Limits of 4032**C

Items

Operation Limits

Maximum discharge pressure

MPa

1.96

Minimum suction pressure

MPa

−0.080

Maximum intermediate pressure

MPa

0.588

Minimum intermediate pressure

> Suction pressure

Oil supply pressure

･ Maximum journal lubrication pressure

MPa

Discharge pressure + 0.39

･ Minimum journal lubrication pressure

MPa

Discharge pressure +0.049 and Suction pressure +0.49

･ Minimum oil injection lubrication pressure

MPa

Suction pressure +0.49

Maximum Suction temperature

°C

Minimum suction temperature

°C

−60

Maximum low-stage discharge temperature

°C

Maximum high-stage discharge temperature

°C

100

Maximum oil supply temperature

°C

Minimum oil supply temperature

°C

Maximum male rotor rotation speed

min-1

3600

Minimum male rotor rotation speed

min-1

1450

Note: Unless otherwise noted, the pressure unit MPa represents the gauge pressure in this manual.

 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.

 Repeated startup and stop in a short period is harmful not for the startup devices

and electric machinery but also for the compressor itself. For information on the start/stop limitations, refer to each instruction manual. Wait at least 15 minutes after stopping the compressor before restarting it.

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2.3.3 Outer Dimensions

Figure 2-1 Outer Dimensions 4032**C

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2-5

Table 2-4 4032**C Outer Diameter of Low-stage M Rotor and Shaft Key Size

Symbol in Figure 2-1

Location

Qty

Size

（Length unit：mm）

Shaft-D

Outer diameter of low-stage M rotor shaft

Φ 110 ±0.01

Key-W

Shaft key width of low-stage M rotor shaft

-0.062

Shaft +Key

Shaft key groove height of low-stage M rotor shaft

117

Table2-5 4032**C Connecting Port Size

Symbol in Figure 2-1

Location

Qty

Size

Low-stage gas inlet port

ANSI #300 16”

High-stage gas inlet port

ANSI #300 12”

Low-stage gas outlet port

ANSI #300 12”

High-stage gas outlet port

ANSI #300 8”

Low-stage TPTB lubricating oil inlet port

ANSI #300 2”

Low-stage Main bearing lubricating oil inlet port

ANSI #300 2”

Low-stage Side bearing lubricating oil inlet port

ANSI #300 1”

Oil injection inlet port

ANSI #300 2-1/2”

High-stage journal lubricating oil inlet port

ANSI #300 2”

F10

Oil outlet port of low-stage suction cover

ANSI #300 1/2”

F11

Oil outlet port of low-stage bearing head

ANSI #300 1”

F12

Oil outlet port of high-stage suction cover

ANSI #300 1/2”

NPT1

Low-stage capacity control hydraulic pressure connecting port (Loading)

NPT 3/4

NPT2

Low-stage capacity control hydraulic pressure connecting port (Unloading)

NPT 3/4

NPT3

High-stage capacity control hydraulic pressure connecting port (Loading)

NPT 1/2

NPT4

High-stage capacity control hydraulic pressure connecting port (Unloading)

NPT 3/8

Cable1

Low-stage electric wires for unloader indicator connecting port (EPB-102)

PF 3/4

Cable2

High-stage electric wires for unloader indicator connecting port (EPB-102)

PF 3/4

Bolt-hole 1

Bolt hole for low-stage compressor leg

Φ39

Bolt-hole 2

Bolt hole for high-stage compressor leg

Φ33

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2-6

Table 2-6 4032**C Outer Dimensions

Unit： mm

Symbol

Figure

2-1

Compressor Model

LLC

LMC

LSC

MLC

MMC

MSC

SLC

SMC

SSC

1792.5

1684.5

1569.5

1336.5

1228.5

1113.5

354

1229

1121

1006

1364

1256

1141

1855

1747

1632

456

3126

2990

2854

3018

2882

2746

2903

2767

2631

759

664

L10

2426

2339

2251

2318

2231

2143

2203

2116

2028

L11

145

L12

2616

2529

2441

2508

2421

2333

2393

2306

2218

L13

190

L14

205

L15

1254

1146

1031

L16

1279

1171

1056

L17

1336.5

1228.5

1113.5

L18

1785.5

1677.5

1562.5

L19

L20

2576

2489

2401

2468

2381

2293

2353

2266

2178

L21

2586

2499

2411

2478

2391

2303

2363

2276

2188

L22

540

491

443

540

491

443

540

491

443

L23

3885

3749

3613

3777

3641

3505

3567

3431

3295

L24

2426

2339

2251

2318

2231

2143

2203

2116

2028

L25

1279.5

1192.5

1104.5

1279.5

1192.5

1104.5

1279.5

1192.5

1104.5

L26

1146.5

1038.5

923.5

L27

176

L28

L29

456

L30

3000

2864

2728

2892

2756

2620

2777

2641

2505

L31

598

503

1305

1150

360

440

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Symbol

Figure

2-1

Compressor Model

LLC

LMC

LSC

MLC

MMC

MSC

SLC

SMC

SSC

W10

W11

260

W12

W13

W14

W15

W16

360

W17

360

W18

650

W19

500

W20

110

W21

W22

160

W23

700

W24

605

550

240

348

550

1055

348

H10

550

H11

1030

H12

H13

240

H14

550

H15

1050

H16

1120

H17

1180.5

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2-8

2.4 Compressor Structure

 For names of each part of the compressor, refer to Section 7.1 "Exploded Views, Sectional

Views ", and Section 7.2 "Parts Configuration Table".

Figure 2-2 4032**C Screw Compressor Sectional View

The 4032**C model, a compound 2-stage compressor, consists of two compressors, (i) a low-stage compressor which suctions gas, working fluid, from the refrigerating unit and compresses (pressure-raises) the gas and (ii) a high-stage compressor which furthermore compresses the gas that has been pressure-raised by the low-stage compressor and sends the resulting gas to the equipment side.

In each casing (low-stage, high-stage), two screw rotors are supported on both ends by bearings. They are meshed with each other in a joint assembly. These two screw rotors are a set of a male rotor having 4 protruding lobe profiles (M rotor) and a female rotor having 6 concave lobe profiles (F rotor). They conduct compressing according to the mechanism explained below.

The standard compressor's M rotor is driven by a 2-pole motor; it operates at 3000 min-1 (50 Hz) or 3600 min-1 (60 Hz). F rotor operates at 2000 min-1 (50 Hz) or 2400 min-1 (60 Hz), conforming to the operation of M rotor.

* The actual speed of a motor is less than its calculated speed (synchronous speed). This difference is

caused by slipping of the motor rotor.

The shaft of the low-stage compressor's M rotor which is linked with the motor has a shaft seal block that keeps gas and lubricating oil from leaking from inside the compressor.

For high efficient operation, the 4032**C model has a capacity control mechanism for coping with load change on the low-stage, and a capacity control mechanism for reducing startup load on the high-stage.

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2-9

2.5 Mechanisms

2.5.1 Basics of the Screw Compressor

The screw compressor is categorized as a positive displacement rotary compressor. As shown in Figure 2-3, 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.

The rotor having 4 protruding lobe profiles is called a male rotor or M rotor, and the rotor having 6 concave lobe profiles is called a female rotor or F rotor. In this manual, they are referred to as M rotor and F rotor.

The compressor is driven by the motor connected to the shaft of the M rotor.

Figure 2-3 Compressor Mechanism

2.5.2 Suction Process

As shown in Figure 2-4, the rotors with different lobe profiles are engaged. As the rotors turn, the volume between the M and F rotor lobe profiles and the compressor casing gradually increases starting from the suction side.

As the rotation continues, at a certain point when the volume reaches its maximum, the rotors isolate the gas (volume), which is enclosed by the rotors and the compressor casing, from the suction port and then continues rotation.

Figure 2-4 Suction Process

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2.5.3 Compression Process

As the rotors rotate further, the volume between the rotor lobes decreases while the sealing line moves toward the discharge side, which compresses the trapped refrigerant gas.

2.5.4 Discharge Process

The volume between the rotor lobes decreases to a level predetermined by the discharge port. With the rotations of the rotors, the compressed refrigerant gas is pushed out to the discharge port.

2.5.5 About Volume Ratio (Vi)

Volume ratios (Vi) of C-series screw compressors are indicated in performance tables or catalogs by using port symbols L and M. The volume ratio represented by each symbol is as follows:

L=2.63, M=3.65

Which volume ratio (L or M) should be used is decided according to operating conditions. If the compressor is used with a volume ratio that does not match operating conditions, operation will go inefficiently wasting the power. The relationship between volume ratios and generally used compression ratios is as follows:

As Vi is affected by the constant of the refrigerant gas, its value that corresponds to the compression ratio will change depending on the refrigerant gas.

Figure 2-5 Compression Process

Figure 2-6 Discharge Process

Figure 2-7 Volume Ratio

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(A) Properly adapted Vi to load condition

(B) Improperly adapted Vi to load condition

Figure 2-8 Relationship between Volume ratio (Vi) and Operation Conditions

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Chapter 2 Compressor Specifications and Structure

Compound 2-stage Screw Compressor 4032**C 2.5 Mechanisms

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2.5.6 Capacity Control Mechanism

The capacity control mechanism, by moving a slide valve, lets suction gas (immediately before compressed) bypass and advance to the suction side, to help shorten the rotor portion used for compression. The slide valve is located at the bottom of the casing in which the rotors mesh together, and is constructed to move parallel to the rotor shaft. This movement is changed by a cam mechanism into rotation movement. Its position (namely, capacity control ratio) is indicated externally and, at the same time, fed back to the automatic control circuit by changing the electric resistance.

4032 ** C compressor, has a capacity control mechanism for reducing start-up load on the high-stage, and a capacity control mechanism for coping with load change on the low-stage.

Figure 2-9 Capacity Control Mechanism

2.5.7 Bearing and Balance Piston

For the load acting on the rotor perpendicular to the shaft, sleeve-type white metal-lined bearing is used. For the load acting along the shaft direction, the low-stage compressor uses tilting pad bearings while

the high-stage compressor uses angular ball bearings in the front combination. In case of API 619 compliance is required and/or special gas component is contained in the working

fluid, the high-stage compressor also uses tilting pad bearings for the load acting along the shaft direction.

Special care is taken to cope with the load acting along the shaft direction. Because the M rotor is a kind of helical gear and also because the thrust force produced by discharge pressure is larger than that for F rotor, the load applied onto the M rotor is reduced by using not only a thrust bearing but also a balance piston that applies pressure from the opposing direction.

2.5.8 Shaft Seal

A mechanical seal assembly, which has balance type double seal structure is used as a shaft seal. A mechanical seal assembly has two sliding seal blocks consisting of rotating rings and stationary rings

on inner machine side and atmosphere side. Those sliding seal blocks prevent leakage of working fluid (refrigerant) and oil from M rotor shaft.

For example, the BBDE (Balance Bellow Double Seal) which is currently used as standard seal, employs stationary ring (mating ring) made from carbon, rotating ring made from SiC, and O-rings for the packing.

Figure 2-10 Slide Valve in the

Rotor Casing

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