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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.

2201Q4JE-MY-C9-N_2018.01.

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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Table of Contents

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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Table of Contents

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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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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2.6 Gas and Oil Flow

The compression process of the screw compressor is as described in the preceding paragraphs. Gas of the compound 2-stage screw compressor 4032**C is sent from the evaporator, and passes

through the suction strainer and check valve. It is drawn in from the upper central area (1) of the compressor, compressed at the low-stage side (2), and then discharged at (3).

(3) and (4) are connected with a pipe. At the mid point of the pipe, that gas is mixed with the gas from liquid cooler which was used for supercooling.

Gas compressed at the low-stage is, while kept mixed with lubricating oil, suctioned from (4) into the high-stage. After being further compressed at (5), the gas with lubricating oil is discharged from (6), and is sent to the condenser via an oil separator. Even if without intermediate gas cooling, oil provides cooling effect. So, the high-stage discharge temperature is maintained at a temperature not higher than 90 °C.

Figure 2-11 Gas Flow

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 Oil Supply Route

As shown in Figure 2-12, oil supply route for the low-stage is split into six flows including the flow to the shaft seal block lubrication. After completing each role, the oil flows to the high-stage via the low-stage rotor messing part.

Oil supply system in the high-stage is split into three flows. Eventually, the oil mixed with compressed gas and the oil from the low-stage are discharged from the compressor via the high-stage rotor messing part.

In standard configuration, oil injection is not performed at the high-stage.

Figure 2-12 4032**C Oil Supply Route

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Chapter 3 Installation

3.1 General Precautions for Installation

 This chapter (Installation) assumes that the compressor is installed to a standard refrigeration/

cold storage/gas compression package unit. If the package unit you are actually using is not the standard type refrigeration/cold storage/gas compression 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. If there are any questions, please contact our local sales offices or service centers.

 In some cases, it may be required that installation is performed by qualified personnel. Make

sure that the work is performed by qualified personnel in compliance with local laws, ordinances and other regulations/requirements.

 Before installing the compressor, please read this chapter and related documents attentively

and fully understand their contents.

 Electrical works should be performed only by electrical engineers.

3.2 Installation Works

3.2.1 Unpacking

Confirm whether a compressor does not have abnormality including the damage.

 If there are abnormalities or deficient parts on the compressor, please contact our sales offices

or service centers immediately.

 Unnecessary packing materials should be discarded according to the laws and ordinances, or

your company's rules.

3.2.2 Storage

If you need to store the compressor before installation, perform the followings.

 Store it indoors.  Infuse nitrogen gas into the compressor and seal it. (Pressure: Approximately 0.15 Mpa )

3.2.3 Transportation

 Dropping of the lifted compressor may cause death or serious injury to the worker.

Do not allow anyone to be under the lifted compressor.

1. For lifting the compressor within the safety limit, use lifting equipment and tools appropriate for the

mass of compressor.

2. Secure sufficient space for safe lifting.

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3. 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.

4. To lift the compressor, attach the wire ropes to the appended eye bolts by using appropriate

shackles and hooks. Refer to Figure 3-1in next page. Use the eye bolts only for lifting the compressor. Do not use the eye bolts when lifting the compressor together with additive equipment.

 The compressor eye bolts must not be used for lifting the package unit. To lift the

unit, use the lifting chains provided around the base or other lifting means provided on the base.

5. Check the transportation route to make sure it is free of obstacles in consideration of the

compressor size.

6. Before lifting, check that the hook is located above the gravity center of the compressor.

7. Direct all the workers to stay clear of the work site before lifting.

8. Before lifting the compressor, alert all workers in area of dangers during lifting process by signal

(such as calling at the beginning of the work or making a signal by hand). Do not lift the compressor unless the signals (such as calling out or hand signals) are completely understood by the workers at site.

9. Slowly reel up the wire ropes until immediately before the compressor leaves the ground.

10. Then, reel up the wire ropes a little further until the compressor is slightly up away from the ground.

Check that the compressor is not tilted. If the compressor is tilted, return the compressor to the ground and correct the tilt by adjusting the wire ropes. After that, restart the lifting operation.

11. Be sure to lift up the compressor slowly. If it is lifted rapidly, it may damage the lifting tools such as

wire ropes or a part of the compressor.

12. When the lifting work starts, observe to see if wire ropes and lifting tools are normal. Be sure that

the compressor is not tilted.

13. When moving the lifted compressor, always use guiding ropes.

14. When moving the compressor, turn away workers from the movement direction and check safety.

15. Do not lift the compressor above the safety passage unless absolutely necessary.

16. Do not lower the compressor on the safety passage. Always keep the safety passage free of

obstacles.

17. Remove any obstacles before lowering the compressor onto the ground. The compressor should

not be tilted or unstable.

18. Before lowering the compressor, announce to the workers around the working area in advance.

19. When lowering the compressor onto two or more blocks, align the tops of blocks so that the

compressor becomes stable horizontally on them.

20. Slowly lower the lifted compressor so that it is not damaged by shock.

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 Outer Dimensions, Mass and Lifting Position

Figure 3-1 Outer Dimensions, Mass and Lifting Position of Compressor

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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.

 Piping

Table 3-1 List of Connecting Pipes (Compressor)

Item

Size

Φ A Φ B Φ C Φ

UNC Bolt

Size

Qty

(Bolt)

Suction gas inlet

ANSI #300 16”

650

571.5

470

400

1-1/4-7

High-stage gas inlet

ANSI #300 12”

521

451

381

300

1-1/8-7

Low-stage gas outlet

ANSI #300 12”

521

451

381

320

1-1/8-7

High-stage discharge gas outlet

ANSI #300 8”

381

330

270

200

7/8-9

Lubricating oil inlet for low-stage TPTB

ANSI #300 2”

165

127

5/8-11

Lubricating oil inlet for low-stage main bearing

ANSI #300 2”

170

127

5/8-11

Lubricating oil inlet for low-stage side bearing

ANSI #300 1”

156

5/8-11

Oil inlet for oil injection

ANSI #300 2-1/2”

190

149

105

3/4-10

Lubricating oil inlet for high-stage bearing

ANSI #300 2”

165

127

5/8-11

Oil outlet of low-stage suction cover

ANSI #300 1/2”

66.5

1/2-13

Oil outlet of low-stage bearing head

ANSI #300 1”

124

23.5

5/8-11

Oil outlet of high-stage suction cover

ANSI #300 1/2”

66.5

1/2-13

Lubricating oil inlet for low-stage capacity control (load)

NPT 3/4 - - - -

Lubricating oil inlet for low-stage capacity control (unload)

NPT 3/4 - - - -

Lubricating oil inlet for high-stage capacity control (load)

NPT 1/2 - - - -

Lubricating oil inlet for high-stage capacity control (unload)

NPT 3/8 - - - -

Figure 3-2 Dimensions of the Joint (Compressor)

for the ANSI #300 Flange

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3.2.5 Installation

3.2.5.1 Installation

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.

3.2.5.2 Shaft Alignment between the Compressor and Driving Machine

 Turn off the main power and control power of the driving machine before shaft

alignment work between the compressor and the driving machine. Be careful so that the power of instruments does not turn on during shaft alignment work. If the power turns on during shaft alignment work, the driving machine starts moving and there is a risk of being entangled with the rotating shaft.

 At the time of turning ON/OFF each electric power breaker, make sure to prevent

electric shock.

 For shaft alignment work between the compressor and driving machine, use

designated tools in normal condition. If a worn or damaged tool or a tool unsuitable for the work is used, there is a risk of being injured.

In the case shaft alignment between this product and the driving machine, be sure that the deviations within the range shown in the Table 3–2. However, if alignment tolerance of the driving machine side is more stringent than Table 3-2, please adjust to the request within the allowable value of the driving machine side.

Table 3–2 Tolerance of Misalignment

Tolerance

Offset

6/100 mm

Angularity

3/100 mm (reference: Φ100 mm)

The Figure 3–3 and 3–4 show how to measure offset and angularity when performing the centering of the shafts of the driving machine and this product using a dedicated hub, a dial gauge and a magnet stand.

Figure 3-3 Measurement of Offset Figure 3-4 Measurement of Angularity

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3.2.5.3 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.). Therefore, when connecting the piping, do not allow any of such foreign substances to enter inside.

 Some compressors (mainly those for export) are charged with nitrogen gas to prevent rust. Be

sure to release the pressure before starting piping work.

 Be sure not to allow moisture to enter the piping. There is a high probability that it will cause

trouble after the start of operation. Be sure to assemble piping when it is dry.

 Cover flanges are attached to the compressor's low-stage gas outlet and high-stage gas inlet.

After installation, be sure to attach piping (intermediate piping) that links the both connection ports.

 Improper piping may cause operating problems such as oil not returning to the compressor or

liquid flow-backs.

 When connecting the piping to the compressor, use piping that is the same size as the

compressor connection port. If the pipe size of the piping is smaller than the compressor connection port, the flow of lubricating oil or refrigerant will be obstructed leading to problems.

 Do not let the mass of the piping connected to the compressor applied onto flanges or joints.

Be sure to prepare proper supports for piping.

3.2.5.4 Equipment and Devices for Protection of the Compressor

 Oil Filter

According to the requirements of the use of the package unit or the standard to apply, install an oil filter of appropriate filtration precision in the lubrication system of the compressor.

In case of general applications such as closed-cycle refrigeration systems, we recommend to use an oil filter with beta ratio in the range of β

≥ 150 that conforms to requirements of NAS 1638

class 8 or ISO 4406 17/15/13. When the package unit requires API 619 4th/5th edition conformity, use an oil filter with beta ratio in

the range of β

≥200.

The oil filter may be clogged just after test operation. We recommend installing two oil filters in parallel. This will enable replacement of either filter during operation.

 Oil Heater for Oil Separator

To preserve the temperature of the lubricating oil before starting the compressor, install an oil heater on the oil separator. Make sure to install a protection function (thermostat, etc.) to prevent overheating.

 Suction Strainer

When compatible (inter-soluble) oil is used, the mesh size of suction strainer should be not less than 200 meshes. When incompatible (non- inter-soluble) oil is used, it should be not less than 100 meshes.

For details about compatible and incompatible oils, refer to Section 4.1 "Lubricating Oil (Refrigerant Oil)" in this manual Chapter 4.

During the commissioning, small particles and scale may come from the system. We recommend installing a finer filter temporarily.

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 Compressor Protective Devices (Safety Devices)

To protect the compressor, install the necessary protective devices as described in Section 1.4.3 "Compressor Protective Devices" in this manual Chapter 1.

3.2.6 Airtightness Test

Perform an airtightness test on the package unit before starting commissioning. To prevent water entry in the package unit, use nitrogen gas or dry air for the airtightness test.

3.2.7 Lubricating Oil Charge

 TO select the lubricating oil to be used, refer to Section 4.1 "Lubricating Oil

(Refrigerant Oil)" in this manual Chapter 4.

 When refilling lubricating oil, ensure that it is clean and does not contain foreign

matters.

 Be careful that air and water are not mixed in when refilling.  To ensure that the lubricating oil does not absorb air moisture, keep it indoors in an

airtight container until use.

3.2.7.1 Initial Charge of Lubricating Oil

Depending on the package unit configuration and operating condition, specify the procedure, method and amount of the initial charge of lubricating oil, and make sure to provide users of this product with such information.

In determining the procedure and work procedure, please care oil is to be filled in the oil filter and oil cooler always.

3.2.7.2 Additional Charge of Lubricating Oil

Specify the procedure of the additional filling of lubricating oil based on the configuration of the package unit, and make sure to provide users of this product with the information.

3.2.8 Charge of Refrigerant

Depending on the use working fluid and equipment configuration of your package unit, specify the work procedure that considered safety enough, and conduct the refrigerant initial filling work accordingly.

In addition, specify the procedure of the additional filling of refrigerant, make sure to provide users of this product with the information.

3.2.9 Check after Installation

Depending on the package unit to which this product is installed, formulate the necessary confirmation items and methods for package unit after installation and conduct them accordingly before the commissioning. In addition, make sure to record and keep the results of your confirmation.

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Chapter 4 Compressor and Package Unit Operation

4.1 Lubricating Oil (Refrigerant Oil)

Lubricating oil (Refrigerant oil) management is very significant to keep the compressor in a good operating condition. Take the following notes when managing lubricating oil.

4.1.1 Precautions for Selecting the Lubricating Oil

 Selection of the lubricating oil should depend on the type of the refrigerant, the type of the

evaporator used with the compressor, and the conditions under which the compressor is operated. Also to be considered when selecting lubricating oil are the properties of the oil that include not only the viscosity but also such characteristics as solubility in refrigerant, separability from refrigerant, low temperature fluidity, high temperature thermal stability, etc. We therefore recommend contacting our sales offices or service centers for choice of a specified brand for your system.

 Lubricating oil used for compressors must have a viscosity appropriate for lubricating the

bearings and other components in the compressors. The viscosity to be considered in this case should be the viscosity the oil shows at the oil inlet of the compressor. The viscosity of the lubricating oil significantly changes depending on the type of the refrigerant used in combination with the oil. If the refrigerant dissolves in the oil (or the oil and refrigerant are inter-soluble), the viscosity of the oil drops to a level remarkably below the level required for operation of the compressor under some operating conditions. On the contrary, if the refrigerant does not dissolve in the oil (or the oil and refrigerant are non-inter-soluble), the viscosity may become too high when the supply oil temperature is low. For this reason, the lubricating oil must be selected such that it is supplied to the compressor with an appropriate viscosity (kinematic viscosity of 13

- 40 mm2/s) in the operating state.

 The circulation of the lubricating oil for the entire system must be considered. After lubricating

and cooling each part of the compressor, the lubricating oil is discharged with refrigerant gas. Most of the oil which is discharged from this compressor is trapped by the oil separator and is cycled to the compressor. A small quantity of refrigerant oil goes to the condenser and the evaporator. The lubricating oil is required to have sufficient fluidity and stability inside parts with different temperatures.

 Note that some lubricating oils are incompatible with a certain type of refrigerant.

The caution below is an example case that is required especially attention.

 Be careful since polyolester synthetic oil (POE) cannot be used with ammonia

refrigerant.

4.1.2 Change of Lubricating Oil Brand

When changing the lubricating oil brand in currently use due to some reason, attention must be paid to the following points.

 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.

 Package unit composition differs depending on the characteristics of lubricating oil

(inter-soluble/non-inter-soluble with refrigerant). As a general rule, changing inter-soluble oil to non-inter-soluble oil or vice versa is not allowed.

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 Lubricating oil contains various additives to fulfill necessary lubricating conditions. Types of

additives and their mixing ratio depend on each oil brand. We, therefore, recommend to avoid mixed use of different brands of lubricating oil. If mixed brands of lubricating oil are used, the different additives in the lubricating oil may react with each other and produce foreign substances like slurry.

 If it is necessary to change the brand of lubricating oil, collect as much as oil as possible from

the compressor as well as from the condenser, evaporator, and all other refrigerating unit components before charging the new lubricating oil. After 100 to 200 hours of operation, replace the oil again.

 If lubricating oil manufacturers differ, contact both of them and inquire whether the changing is

appropriate. The same confirmation is required for changing the brand even if it is of the same manufacturer.

 There is no problem in changing the viscosity level within the same brand. However, make sure

that the viscosity grade will not cause problems during operation. (Example ： SUNISO 3GS→SUNISO 4GS)

4.1.3 Precautions for Handling lubricating oil

 When refilling lubricating oil, ensure that it is clean and does not contain foreign matters.  Be careful that air and water are not mixed in when refilling.  To ensure that the lubricating oil does not absorb air moisture, keep it indoors in an airtight

container until use.

4.1.3.1 Precautions for Handling Polyalkylene Glycol (PAG)

PAG oil is much more hygroscopic than mineral oils and any moisture mixed in the oil may lead to rust, corrosion and wear within the package. When handling PAG oil, pay special attention to the following points.

 Do not perform oil charging in rainy weather or at a place with high humidity to prevent

absorbing moisture.

 Before charging, remove as much moisture as possible from the system by exhausting it with

a vacuum pump for a sufficient length of time and leaving the system in vacuum condition overnight.

 Do not open the lid of pail (oil container) until just before charging. Once the can is opened,

finish the oil charge as quickly as possible. (Finish the charge of a single can of oil within 15 minutes.)

 Cover any gaps between the pail opening and the charge hose so that foreign substances or

moisture cannot enter. A more effective way is to substitute any space inside the pail with nitrogen gas .

 Always charge all oil from the pail. Even if some oil remains, do not use it subsequently.  If any oil drops on a painted surface, wipe it away as soon as possible. Otherwise the paint

may come off.

4.1.3.2 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.

 Finish the charging in as short a time as possible after opening the pail to minimize exposure

to air.

 Make sure that all oil in a pail is used in a single charging. Any remaining oil must be stored

indoors with the can lid closed tightly. Do not attempt to store it for a long time.

 Because POE can hydrolyze, make sure to perform an oil analysis regularly in the package to

see if any abnormal conditions are present.

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4.1.4 Lubricating Oil Management Criteria

Lubricating oils that are managed by the criteria are classified into the following categories: (1) Synthetic oils: Polyalkylene glycols (PAG)

(2) Mineral oils: Naphthenic base oils and paraffinic base oils (3) Synthetic oils: Alkylbenzene (AB) and Polyalphaolefine (PAO) (4) Synthetic oils: Polyolesters (POE)

 Oil sampling and analysis is recommended every six months.  If the following control criteria are not satisfied, replace the oil.

◆ Note that the water content of PAG shall be excluded from the above oil replacement criteria. Refer to the Note *1 in the table below.

The analysis items and the criteria are shown in the following tables. Please note that these management criteria may be changed without notice.

Table 4-1 Synthetic Oil (PAG)

Item

Criteria

(a) Color phase

ASTM color scale: 4.0 or less

(b) Total acid number (TAN)

0.1 mg KOH/g or less

Within ±10% from that of fresh oil

(d) Water content

2000 mass ppm or less Note1

(e) Degree of contamination

Degree of contamination measured by mass method (Millipore value) shall be 15 mg/100 mL or less

Table 4-2 Mineral Oil and Synthetic Oil (AB, PAO)

Item

Criteria

(a) Color phase

ASTM color scale: 6.0 or less

(b) Total acid number (TAN)

0.3 mg KOH/g or less

Within ±15% from that of fresh oil

(d) Water content

100 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

Table 4-3 Synthetic Oil (POE)

Item

Criteria

(a) Color phase

ASTM color scale: 4.0 or less

(b) Total acid number (TAN)

0.2 mg KOH/g or less

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 (inter-soluble with ammonia) are so highly hygroscopic that they can absorb

moisture at the time of sampling. In addition, the ammonia content they have absorbed may be detected as the water content at the time of the analysis, making it difficult to precisely measure the water content. Thus, use the criterion value only as a reference.

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4.1.5 Lubricating Oil Replacement Timing

4.1.5.1 After Starting the Initial Operation

As the oil can easily be contaminated and degraded relatively quickly during the initial operation due to scales and deposits remaining in piping and vessels, be sure to sample and analyze the oil after 500 hours of operation.

If it is found as a result of the analysis that the criteria given in Tables 4-1 to 4-3 are not satisfied, the oil must be replaced.

4.1.5.2 During Normal Operation

Lubricating oils will degrade gradually as the system is operated over time. The rate of degradation depends on the operating condition, type of oil and amount of foreign matters

and moisture contained in the oil. The lubricating oil must be sampled and analyzed every six months. If it is found as a result of the analysis that the control criteria given in Tables 4-1 to 4-3 are not satisfied, the oil must be replaced.

If the oil filters are frequently clogged or the oil color quickly becomes darker and unclear, replace the oil after removing the cause of the problem.

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4.2 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. Liquid flow-back may cause insufficient lubrication of the compressor, abnormal vibrations and noises, and abnormal foaming of lubricating oil (too much oil loss).

To prevent liquid flow-back, appropriately adjust the expansion valve to the evaporator and/or liquid cooler. In addition, special attention must be paid to the suction pipe line connection way to the system and means of starting up the compressor after a long time of stoppage.

4.2.2 Purging of Non Condensable Gases

Any non condensable gas in the system may cause the compressor discharge pressure to rise higher than the refrigerant saturation pressure that depends on cooling water temperature of condenser. This is caused by the non condensable gas staying in the condenser which deteriorates the heat exchange performance.

If the vacuum pumping performed upon initial installation or maintenance is insufficient or the suction pressure is lower than the atmospheric pressure to suck air if the suction pipe had a leak, non condensable gases accumulate in the condenser.

When a considerable amount of non condensable gases accumulate in the condenser, the compressor load increases and finally the motor overcurrent alarm may occur.

In such a case, purge any non condensable gas from the condenser.

 Some types of refrigerants may have bad smell, toxicity, and/or flammability.

In a airtight space such as a machine room, oxygen shortage may occur due to high concentration of the refrigerant gas. Maintain sufficient ventilation while working.

 When handling fluorocarbon refrigerants, remember that they are prohibited from

being purged into air by law.

1. When the compressor is stopped, allow the cooling water to flow to the condenser and check that

there is no difference in water temperature between the inlet and outlet. If any difference is present between the inlet and outlet water temperatures, keep the cooling water flowing until the temperature difference is eliminated.

2. Measure the pressure of the condenser and compare it with the refrigerant saturation pressure

depending on the cooling water temperature.

3. If the condenser pressure is higher than the refrigerant saturation pressure by 0.05 MPa or more,

purge any non condensable gases.

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Chapter 4 Compressor and Package Unit Operation

Compound 2-stage Screw Compressor 4032**C 4.3 When Stopping the Compressor for a Long Time

4-6

4.3 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.  Close the suction stop valve and discharge stop valve.  If an economizer or liquid injection is used, close the stop valve located at the compressor

inlet.

If the operation stop period is 1 month or longer, perform the following checks every month.

 Operate the oil pump for 10 seconds per week.

After that, rotate the compressor shaft (10 rotations or more).

 Measure the system pressure once per month.  Check for refrigerant leak once per month.

When restarting the compressor after an operation stop period of 1 year or longer, check the system for refrigerant leak and analyze the lubricating oil. If it is found as a result of the analysis that the control criteria given in Section 4.1.4 Tables 4-1 to 4-3 are not satisfied, the oil must be replaced.

Also check the motor insulation resistance. Supply power to the oil heater at least 1 day before operation start. Before starting the operation,

confirm that the refrigerant is not condensed in the package by checking the package temperature and pressure.

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Chapter 5 Maintenance and Inspection

Compound 2-stage Screw Compressor 4032**C 5.1 Precautions for Maintenance and Inspection

5-1

Chapter 5 Maintenance and Inspection

5.1 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. The ventilation must be continued steadily until the work is completed.

 For performing the inspection work, be sure to prepare safety shoes, protective

glasses, gas mask and other proper protective equipment and do not fail to use them whenever they are required.

 After stopping the machine and before working on a regular inspection or overhaul,

be sure to shut off the main motor power, control power, and other power to each equipment and valve. After they are shut off, be sure to make the switches inoperable by others. Also, be sure to attach notification tags to prohibit operation (lock-out/tag-out).

 When any manual stop valve has been closed, be sure to make the valve

inoperable by others and put a notification tag to prohibit the operation (tag-out).

 When the compressor is to be overhauled, check that the internal pressure of this

product is at the atmospheric pressure before starting the work.

 When using lifting devices, e.g. a crane, etc. and/or lifting tools, ensure that they

can sufficiently withstand the load.

 When lifting a heavy load object, do not allow anyone’s body to put under it.  The work to turn each power supply ON/OFF or operate a lifting unit must be

exclusively performed by qualified personnel.

 When using electric tools, ensure that they are properly managed in accordance

with each instruction manual. Especially before using and while using, be sure to follow the care instructions on the safety of each instruction manual.

 Be sure to use only genuine parts for replacement. Using parts that are

not genuine can cause damage to this product or other devices during operation.

 Do not convert or modify this product or its components without prior permission

from MAYEKAWA. Otherwise, it can lead to an unexpected accident.

 Exercise sufficient care for handling a heavy load, and use such a lifting device as a

crane or work with an adequate number of personnel commensurate with the magnitude of the weight. Also, be sure to use stud bolts (safety retention bolts) and other support tools for the work. Neglecting the above warning can lead to low back pain of the worker or injury due to dropping of the parts.

 If two or more people are to work together, be sure to clearly define the work

procedures to

 share a common understanding among all workers before performing the work.  Not only the work to turn each power supply ON/OFF or operate a lifting device, but

also any type of work requiring qualification must be exclusively performed by qualified personnel.

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Chapter 5 Maintenance and Inspection

Compound 2-stage Screw Compressor 4032**C 5.1 Precautions for Maintenance and Inspection

5-2

 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.

 In the disassembly/inspection workplace, secure a sufficient space for temporary

storage of the removed parts and tools, replacement parts, and for the disassembling work as well as safety passages, and then put up necessary off-limit signs.

 In the workplace, secure a sufficient space and refrain from putting tools directly on

the floor or from haphazardly laying wires.

 Keep the floor clean all the time. Leaving the floor smeared with oil and the like

causes it to be slippery and may result in the fall and injury of personnel. Thus, do not leave it but wipe it off right away.

 Make sure that the temperature of the high temperature sections such as

bearinghead and discharge lines has been cooled down to normal ambient temperature, before working on them.

 When disassembling and reassembling the compressor, use the specified tools

properly. Before starting to use those tools, gain the full understanding of their characteristics and the method for use.

 During the maintenance service, keep the tools clean all the time. Using those tools

smeared with oil increases the risk of slip and fall, leading to an injury. Also during the service, there is a risk of foreign matters intruding inside the compressor to cause its damage.

 Parts are slippery with oil. Fully watch out for the risk of any object falling down.

Pay attention to any parts falling down, which could lead to personal injury.

 Before disassembly, inspections, and handling of the compressor, sufficiently

understand the disassembly and assembly procedures. This manual is not intended to provide complete disassembly and assembly procedures for the compressor. Instead, it describes only the important points in relation to the maintenance service of the compressor.

 If complete disassembly and assembly of the compressor are required, please

contact your nearest sales office or service center of MAYEKAWA.

 When removing a part, be careful not to damage it.  Place the removed parts on a clean workbench in an orderly manner.  For cleaning parts, use kerosene and/or machine parts cleaner.  Washed parts shall be dried by compressed air or wiped up using clean cloth. Do

not use synthetic textiles or woolen textiles to prevent fibers from attaching the parts.

 When separating the assembled compressor casings, sometimes it is difficult to

separate them due to the gasket stuck. In such a case, never hammer in a screw driver or flat chisel into the gap. Screw jack bolts using the screw holes to separate the casing each other. When some gap is observed between them, use a scraper to remove one side of the gasket from the surface.

 Removed bolts from each part should be classified into each used section to

prevent confusion.

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Chapter 5 Maintenance and Inspection

Compound 2-stage Screw Compressor 4032**C 5.2 Maintenance and Inspection List

5-3

5.2 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 Item" and record the results.

Regularly recording the daily operational data in an operation log makes it possible to detect any significant change in the system. This practice is particularly effective in preventing possible failures of the compressor.

It is particularly important to keep track of the records that indicate the relationship between the temperature and pressure, as it is closely related to the evaporation and condensation of the refrigerant, in quickly finding any abnormal condition of the compressor or the system.

Keeping an operation log in this way can facilitate the efforts to properly track down the cause of failure or accident that may occur in the compressor or the system, making it easier to quickly and accurately deal with the situation.

Table 5-1 Daily Inspection Item

Inspection item

Inspection details

Checkpoints and actions

Compressor

Hours of operation

Total hours of operation

 Used to determine the timing of

regular maintenance and inspection

Suction pressure

MPa

Difference from the pressure that corresponds to the specified evaporation temperature

 Cleanliness of the cooling pipe

surface

 Temperature and flow of the items

cooled

Intermediate pressure

MPa

Difference from the normal pressure during rated operation

 If the pressure is too high (or too

low), check the conditions of the high/low-stages.

Discharge pressure

MPa

Difference from the condensation pressure for the specified cooling water temperature

 Cleanliness of the condenser

cooling pipe

 Mixing of non-condensing gas  Amount and temperature of the

cooling water

Oil supply pressure

MPa

Difference from the discharge pressure

 Whether the differential pressure is

decreasing or not

 Liquid flow-back operation  Wear of compressor parts

Pressure loss of the oil filter

MPa

Pressure difference between the inlet and outlet ports of the oil filter

 Contamination of the lubricating oil  Clogged oil filter element

Suction temperature

°C

Whether upper or lower limit temperature is not exceeded

 Temperature and flow of the items

cooled

Suction degree of superheat

°C

Whether the degree of superheat is appropriate or not

 Adjustment of expansion valve  Insufficient refrigerant circulation

Intermediate temperature

°C

Whether upper or lower limit temperature is not exceeded

 Adjustment of the intermediate

expansion valve

Discharge temperature

°C

Whether it is within the upper limit temperature

 Mixing of non-condensing gas  Supply oil temperature, insufficient

amount of oil supply

 Compressor failure

Supply oil temperature

°C

Whether upper or lower limit temperature is not exceeded

 Cleanliness of the cooling pipe of

the oil cooler

Capacity control loading

Normally operation

 Damaged coil of the solenoid valve  Improper manual valve adjustment

of the solenoid assembly

Leak at the mechanical seal

mL/hr

Amount of leak per hour

 Mechanical seal failure

Noise and vibration

Abnormal noise or vibration

 Compressor failure

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Chapter 5 Maintenance and Inspection

Compound 2-stage Screw Compressor 4032**C 5.2 Maintenance and Inspection List

5-4

Table 5-1 Daily Inspection Item (continued)

Inspection item

Inspection details

Checkpoints and actions

Others

Motor current

Whether it is increased from the time of the commissioning

 Compressor/motor failure

Oil level of the oil separator

- Oil level height

 Oil loss  Replenish oil

Liquid level of the liquid receiver

Liquid level height

 Replenish refrigerant

Refrigerant leak check

If any leak is found

 Inside the machine room and in the

facility on the load side

■ Unless otherwise specified, the pressure unit "MPa" represents the gauge pressure in this manual.

■ Daily Maintenance Items

1. Oil level height of the lubricating oil If the oil level of the oil separator has reached the lower limit, charge the lubricating oil.

2. Oil filer element replacement Replace the oil filter element if the pressure difference between the inlet and outlet ports of the oil filter is 0.1 MPa or more. During the period of initial operation, the pressure difference between the inlet and outlet ports of the oil filter can quickly become large.

3. Cleaning of suction strainer Inspect the suction strainer when the operating hours of the compressor from the initial operation starting has exceeded 500 hours.

If the filter used is a temporary filter for initial operation, remove the filter. Also, as it is common that the differential pressure across the suction strainer can become large

in a short period of time, inspect and clean the suction strainer if the differential pressure is large.

4. Amount of oil leak from the mechanical seal If the amount of oil leak from the mechanical seal is considered excessive, check the amount of oil leak per hour. The table below shows the guideline on the acceptable amount of oil leak and the amount that requires inspection. If any damage is found on the mechanical seal in the inspection, be sure to replace it.

Table 5-2 Criteria of the Leakage from the Mechanical Seal

4032**C

Acceptable leakage amount (mL/hr)

≤ 12

Inspection is required (mL/hr)

≥ 36

Note: The values in the above table are only for guidance

purposes, and no guarantee is provided.

5. Contamination on the cooling water side of the condenser and oil cooler cooling pipe. The degree of contamination and clogging of the cooling pipe can significantly vary depending on the quality of the cooling water. If any gradual increase in the oil temperature and/or the discharge pressure is observed during the initial period of operation, check and clean the cooling water side of the oil cooler and the condenser regardless of the inspection schedule.

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Chapter 5 Maintenance and Inspection

Compound 2-stage Screw Compressor 4032**C 5.2 Maintenance and Inspection List

5-5

5.2.2 Periodic Inspection

Conduct inspection for the following items according to the specified schedule. In addition, observe relevant laws and regulations on the inspections and recording of the results that

are provided for other related items such as any safety devices (e.g. gas leak detectors), or other utility (gas/electricity) protection devices that constitute the package unit together with the compressor.

Table 5-3 Periodic Inspection Items

Item

Inspection interval

Remarks

Pressure gauge/pressure sensor

Yearly inspection

Thermometer/temperature sensor

Yearly inspection

Protection devices and safety valves

Yearly inspection

Suction strainer Inspection after 500 hours of

initial operation

Perform inspection and cleaning if the differential pressure across the suction strainer is high.

Yearly inspection and cleaning

Lubricating oil Analyze the oil after 500 hours of

initial operation

Replace the oil if the analysis result does not satisfy the control criteria given in Section 4.1.4 "Lubricating oil Management Criteria".

Analyze the Oil every six months

Oil filter element

Yearly replacement

Replace the oil filter element if the pressure difference between the inlet and outlet ports of the oil filter exceeds 0.1 MPa.

Cooling water side of the oil cooler

Yearly inspection

Clean it if it is heavily contaminated.

Cooling water side of the condenser

Yearly inspection

Clean it if it is heavily contaminated.

Mechanical seal

Inspection every year or every 8000 hours of operation Note*

To be replaced if any abnormality is found. If it is difficult to stop equipment except for scheduled inspections, replace the part at each inspection.

Coupling

Inspection every year or every 8000 hours of operation Note*

Note*: The inspection shall be performed according to the schedule or operating hours, whichever

comes first.

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Chapter 5 Maintenance and Inspection

Compound 2-stage Screw Compressor 4032**C 5.2 Maintenance and Inspection List

5-6

5.2.3 Guidelines for the Timing of Compressor Overhaul

While the overhaul interval for the compressor depends heavily on the conditions of use, type and condition of the refrigerant and oil, the package unit, and other factors, the table below shows the recommended interval of overhaul, as a guideline.

Table 5-4 Guidelines for the Timing of Overhaul Based on the Conditions of Use

(standard package)

Conditions of use

Example application

Guideline for the overhaul timing

Relatively stable operating conditions

Refrigeration

5 years or 40 000 hours

Relatively variable operating conditions

Ice making and chilling

4 years or 30 000 hours

Frequent start/stop and relatively variable operating conditions

Heat pump

3 years or 20 000 hours

Note 1: The above guideline is applicable only when the package unit is used under the standard

operating conditions separately defined. (Refer to Chapter 2, Section 2.3.2 "Operation Limits" in this manual.)

Note 2: The above guideline is applicable only when the routine and regular inspection services that

are separately defined are performed. (Refer to Section 5.2.1 "Daily Maintenance" of this chapter.)

Note 3: The inspection shall be performed according to the schedule or operating hours, whichever

comes first.

Note 4: The above guideline is for reference only, and not a warranty period.

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Compound 2-stage Screw Compressor 4032**C 5.3 Compressor Disassembly Preparation

5-7

5.3 Compressor Disassembly Preparation

Although screw compressors are very reliable machines, it is still necessary to perform overhaul to inspect internal parts after a certain period of operation.

This chapter 5 explains the essential points of disassembly methods, where to inspect on parts, and reassembly procedure of the compound 2-satge screw compressor 4032**C.

In principle, overhauling of the screw compressor that require complete disassembly should be performed in the maintenance factory. If you must do the overhaul work at the installation site due to unavoidable reasons, use the methods described in the following paragraphs.

However, please note that regular overhaul work requires removal of the compressor from the base frame. And then, the compressor should be placed on a work bench which has properly size area to disassembling the compressor.

When moving the compressor from the unit base to the workbench, be sure to follow the instructions given in Chapter 3, Section 3.1 "General Installation Precautions" and Section 3.2.3 "Transfer" of this manual.

Note that some parts name given in the text of this manual is followed by a number enclosed in square brackets [ ], which indicates the part identification number given in assembly sectional views or Exploded views.

5.3.1 Disassembly Tools and Workplace

Prepare necessary disassembly tools for the compressor by referring to Section 7.5 "Disassembly Tools" in this manual Chapter 7.

In addition, prepare other necessary tools and materials including general hand tools, GC grinding stones, sandpapers of #80 to #100, about #400 to #800 sandpapers, parts cleaner, lubricating oil, oilcan, empty can to receive drain oil, waste, etc.

If the overhaul work is to be done with the compressor removed from the installation base, prepare the work bench whose size is at least around 1.5 times the length and the width of the compressor.

In addition, a special stand for the compressor is required in order to safely perform the removal / fastening of bolts and plugs on the bottom side of the compressor. Refer to Section 5.3.5 of this chapter.

To the extent possible, choose a dry and clean workplace free from sand or dust. Note that a sufficient space is required for the workplace. In addition, iti is necessary a temporary storage place for disassembled parts .

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. When ordering parts, be sure to inform the (a) model name, (b) serial number, (c) part name, (d) code

No. and (e) quantity required, to our sales offices or service centers. In particular, if the serial number (b) is unknown, the details of the applicable design and manufacturing

specifications cannot be identified, and thus it becomes difficult to choose correct parts. So, make sure to inform the (b) serial number to us.

Table 5-5 Replacement Parts of 3225**C Overhauling

P/N

Part Name

Code No.

Remarks

Q’ty.

6-1

Gasket, Suction Cover (1)

CS00600-4032CN

6-2

Gasket, Suction Cover (2)

CS00600-320N

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P/N

Part Name

Code No.

Remarks

Q’ty.

O-ring JIS B 2401 G95

PA12-095

12-1

Gasket, Bearing Head (1)

CS01200-400

12-2

Gasket, Bearing Head (2)

CS01200-320N

17-1

Gasket, Bearing Cover (1)

CS01700-400

17-2

Gasket, Bearing Cover (2)

CS01700-4032CN

Gasket, Balance Piston Cover

CS02300-320N

27-1

Main Bearing (1) with O-ring (No.432-1)

CS0270-4032N

27-2

Main Bearing (2) with O-ring (No.432-2)

CS0270-GRT

28-1

Side Bearing (1) with O-ring (No.433-1)

CS02800-4032N

28-2

Side Bearing (2) with O-ring (No.433-2)

CS0280-GRT

Balance Piston

CS03000-320

To be replaced if any abnormality is found.

Balance Piston Sleeve

CS03300-320

O-ring JIS B 2401 G190

PA12-190

38-1A

Thrust Bearing (1) A TPTB (DAIDO)

CS03800-T400M

38-1B

Thrust Bearing (1) B TPTB (DAIDO)

CS03800-T400F

38-2

Thrust Bearing (2) 320** A-angle Cast retainer

CS03800-320

38-2

Thrust Bearing (2) 320*** TPTB

CS03800-T00320

39-1

Lock Nut (1) AN28

NG31-028

To be replaced if any abnormality is found.

39-2

Lock Nut (2) AN21

NG31-021

40-1

Lock Washer (1) AW28X

NG32-028x

40-2

Lock Washer (2) AW21

NG32-021

63-1

O-ring JIS B 2401 G250

PA12-250

63-2

O-ring JIS B 2401 G240

PA12-240

65-1

O-ring JIS B 2401 P215

PA11-215

65-2

O-ring JIS B 2401 P200

PA11-200

66-1

Cap Seal (1) BE-215

CS06600-400

66-2

Cap Seal (2) BE-200

CS06600-320

68-1

Guide Pin (1)

NE2506-016

To be replaced if any abnormality is found.

68-2

Guide Pin (2)

NE2506-016

69-1

Lock Nut (1) AN10, Unloader Piston (1)

NG31-010

To be replaced if any abnormality is found.

69-2

Lock Nut (2) AN10, Unloader Piston (2)

NG31-010

70-1

Lock Washer (1), Unloader Piston (1) AW10

NG32-010

70-2

Lock Washer (2), Unloader Piston (2) AW10

NG32-010

73-1

O-ring JIS B 2401 G45

PA12-045

73-2

O-ring JIS B 2401 P44

PA11-044

75-1

O-ring JIS B 2401 G220

PA12-220

75-2

O-ring JIS B 2401 G210

PA12-210

78-1

Ball Bearing, Indicator Cam (1) #6302

CS07800-400

78-2

Ball Bearing, Indicator Cam (2) #6000

CS07800-200

79-1

Snap ring C type External S15

NG12-015

To be replaced if any abnormality is found.

79-2

Snap ring C type External S10

NG12-010

82-1

V-ring, Indicator Cam VH10 NBR

CS08200-200B

82-2

V-ring, Indicator Cam VH10 NBR

CS08200-200B

89-2

O-ring JIS B 2401 P24

PA11-024

93-1

Gasket, Suction Flange (1)

PL300-400

ANSI #300 16"

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Compound 2-stage Screw Compressor 4032**C 5.3 Compressor Disassembly Preparation

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P/N

Part Name

Code No.

Remarks

Q’ty.

93-2

Gasket, Suction Flange (2)

PL300-300

ANSI #300 12"

96-1

Gasket, Discharge Flange (1)

PL300-300

ANSI #300 12"

96-2

Gasket, Discharge Flange (2)

PL300-200

ANSI #300 8"

100

Mechanical Seal Assembly 400*** BBD-E

CS1002-400EBD

125

Micro Switch

CS12500-200

To be replaced if any abnormality is found.

129

Potentiometer 200-1 k, with lead wire

CS1299-E10

150-1

O-ring JIS B 2401 G290

PA12-290

150-2

O-ring JIS B 2401 G220

PA12-220

Gear Coupling Assembly (Current Type)

To be replaced if any abnormality is found.

159

Knurled Cup Point Socket Set Screw

NA83610-016

163

O-ring JIS B 2401 G65

PA12-065

201

Bevel Gear (1), Low-stage Indicator Casting

CS20100-1612C9

To be replaced if any abnormality is found.

202

Bevel Gear (2), Low-stage Indicator Casting

CS20100-1612C6

208-A

Snap Ring S10, Same above

NG12-010

To be replaced if any abnormality is found.

208-B

Ball Bearing #6000LL, Same above

CS16460-200

216-1a

Gasket, Lubricating Oil Inlet Flange(1) Main

PL300-050

ANSI #300 2"

216-1b

Gasket, Lubricating Oil Inlet Flange(1) Side

PL300-025

ANSI #300 1"

216-1c

Gasket, Lubricating Oil Inlet Flange TPTB

PL300-050

ANSI #300 2"

216-2

Gasket, Lubricating Oil Inlet Flange Journal

PL300-050

ANSI #300 2"

216-2

Gasket, Lubricating Oil Inlet Flange TPTB

PL300-025

ANSI #300 1"

219

Gasket, Oil Injection Inlet Flange

PL300-065

ANSI #300 2-1/2"

237-1

Tortional Slip Washer (1)

CS23700-400

237-2

Tortional Slip Washer (2)

CS23700-320

325

O-ring JIS B 2401 P70

PA11-070

328

O-ring JIS B 2401 P58

PA11-058

421

O-ring JIS B 2401 P58

PA11-058

432-1

O-ring JIS B 2401 G200

PA12-200

432-2

O-ring JIS B 2401 G165

PA12-165

433-1

O-ring JIS B 2401 G200

PA12-200

433-2

O-ring JIS B 2401 G165

PA12-165

674

O-ring, BOD type Mechanical Seal

PA62-039

AS568A -261

In case of replacing the main/side bearings of No.27 and No.28, it is not necessary to prepare the O-rings of No.432 and No.433 because the main/side bearings have the O-rings.

● 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

us when placing an order.

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5-10

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. To do this, there are the following methods for example.

Perform your recovery work in an appropriate manner considering site conditions, requirements of regulatory laws and regulations.

■ Use the bypass valve to release the high pressure gas in the unit into the low pressure side.

■ If there is an adjacent compressor to which a permanent bypass line is connected from this

compressor, run the adjacent compressor to drop the internal pressure of this compressor through the bypass line.

■ Operate the refrigerating system and close the supply source valve to turn the gas into liquid, and recover the liquid at the receiver.

■ Use a refrigerant recovery machine to recover the liquid at the receiver.

In using either method, prepare a working flow sheet of the system beforehand. Check the valves to be controlled during the recovery work, according to the method to be used, by comparing them with the ones in the flow sheet, and clearly note the valves to be operated, other connected devices, and tubes on the flow sheet.

Two flow sheets must be prepared: one at the foreman and the other for posting in the workplace. In addition, prepare a work procedure document for the refrigerant recovery work to reflect the actual

conditions of the workplace, and sufficiently share the work details among all the coworkers through checking and confirmation before actually starting the work.

The gas mask and other protective gears required at each stage of refrigerant recovery work must be prepared before starting the work.

 Before the work, be sure to check and communicate the work details and procedure

among all coworkers, and carry out hazard prediction activities based on the information shared. Neglecting to do this will increase the risk of on-the-job accidents and injuries to a considerable level.

 All the valves that have been opened or closed during the work must be prevented

from accidental operation through proper lock-out and tag-out procedures.

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5.3.4 Removal of Connections to the Package Unit

 If high-pressure refrigerant gas or refrigerant-mixed lubricating oil remains inside the

compressor, a gas and oil under pressure will gush out as soon as a sealed part is opened and cause injury to the operator such as frostbite or loss of eyesight. Be sure the check that there is no residual pressure before disconnecting any pipe joint.

When removing the compressor from the mounting base frame, the following parts must be disconnected beforehand:

(1) Coupling to connect the compressor to the driving machine; (2) Suction and discharge pipes of the compressor.

If the suction strainer is directly connected to the compressor, also remove the strainer;

(3) Oil supply lines to the compressor (Five lubricating oil inlet ports of low-stage, two lubricating oil inlet

ports of high-stage, one oil injection inlet port, and two ports for each of the capacity increase and decrease controls);

(4) Electric wiring for capacity control operation (In some cases, the unloader indicator assembly may

be removed without removing the wiring. Refer to Section 5.4.1.1 in this chapter.);

(5) Compressor mounting bolts (foot bolts); and (6) Intermediate connecting line from the low-stage discharge to high-stage suction of the compressor

(In some cases, this line is not removed, and the compressor is removed with this line attached.)

When removing oil lines from the compressor, there is possibility of gas and oil blowing out caused by residual gas pressure. And any residual oil in the pipe will flow out. To be prepared for this, either check the amount of oil outflow by slightly loosening the pipe joint or drain the oil from the oil temperature gauge at the supply header before removing the pipe.

Work carefully in particular when disassembling the unloader cylinder block since there is residual pressure and oil fills in the unloader cylinder. Moreover, prepare a larger volume container than the unloader cylinder volume to receive oil flowing out.

For easy reconnection, disconnected electric wires should be properly marked for identification. Any wrong reconnection may result in a startup failure or inability to operate the capacity control mechanism.

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5.3.5 Removal and Lifting the Compressor

 The work to lift up or move the compressor must be performed by a qualified operator.  Make sure that the lifting equipment and wires have sufficient load capacity for the

compressor.

 Never try to perform disassembly or assembly while the compressor is lifted in the air.

As the suction pipe is located immediately above the compressor, lift up or partially remove the pipe such that it will not interfere with the lifting device.

For the lifting positions of the compressor, refer to Figure 3-1 in page 3-3 of Chapter 3 in this manual. If the planned overhaul work includes separation between low-stage and high-stage blocks of the

compressor, place the compressor on a special stand as shown in following Figure 5-1 and then remove eight or more hexagon head cap screws around the bottom flange part.

Never try to remove these bolts while the compressor is lifted in the air. Note that these bolts cannot be removed once the compressor is placed on the work bench.

Figure 5-1 Special stand for removing the bolts of the bottom flange part of the compressor

(The leg parts are movable.)

5.3.6 Draining Oil from the Compressor

If three oil drain ports are sealed by flanges without any oil drain pipes, before lifting up the compressor from the base frame or at the stage of placing the compressor on the special stand as shown in Figure 5-1, remove the flanges and drain the oil in the compressor.

Prepare oil pans and draining oil containers to receive the large amount of oil flow out. The most part of the oil will be drained from these oil drain ports. The remaining oil will be drained as appropriate in the disassembly process on the surface plate work

bench.

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5.4 Disassembly and Inspection

During the overhaul work, be very careful in handling the parts. As the compressor is a delicate machine that is operated at very high speed, a minor handling error could result in a situation where the rotor and other major components must be entirely replaced. Another possibility is that it may cause a failure or performance degradation when the compressor is operated after the reassembly.

Please fully understand the following sections before starting the work. In general, the disassembly sequence will follow the flow shown on the left side of Figure 5-2

"Illustration of the Disassembly Sequence". Note that the sequence shown is an example, and it may change depending on the situation. For example, it is allowed to separate the low-stage and high-stage blocks at first, as shown on the right side of the flow.

Also, in the case of the flow on the left side, the sequence of disassembly may be reversed between the unloader cover/unloader cylinder block and the mechanical seal block.

Figure 5-2 Illustration of the Disassembly Sequence

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5.4.1 Unloader Indicator

On the 4032**C model, unloader indicators are installed on both the high and low-stages. The high-stage unloader has the same indicator as that for the UD-series single-stage compressors (standard model), while the dial and the micro-switch cam are designed for indicated load of 30 to 100 %.

On the low-stage side to be easy to see the indicator dial, the standard indicator assembly is attached with a fixture for 4032**C model that bends the indicator by 90° clockwise or counterclockwise viewed from either of the rotor shaft ends. In the C-series compressor models, 2520**C and 4032**C are made in this structure using "Unloader indicator fixture assembly" and "Standard type unloader indicator assembly" as a low-stage unloader indicator.

The unloader indicator assembly has a potentiometer, two micro switches, a micro switch cam, a set of retainers, micro-switch mooting plate, indicator pointer with dial and terminal block.

Figure 5-3 4032**C Low-stage Unloader Indicator Fixture Assembly

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Figure 5-4 Standard type Unloader Indicator

5.4.1.1 Disassembly

■ In 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.

The structure of an unloader indicator assembly is the same as both low-stage and high-stage.

a) By removing the three hexagon socket head cap screws [147] that are used to fasten the

indicator cover [146], the cover can be removed.

b) The indicator cover will be removed with the glass [141] and spacer [142] attached. While the

glass and spacer are glued, be careful not to drop these as they may be separated from the cover.

c) Remove the plastic plate on the terminal block, and then remove the wiring.

Apply vinyl insulation tape to the wiring terminals, and paint identification numbers to prevent them from being mixed up at recovery.

■ When removing unloader indicator assembly parts, with the wiring left as it is Steps a) and b) are the same as described above.

c) Loosen the cam set screw [128] which secures the micro-switch cam [127] on the shaft of the

indicator cam [77-2] on the high-stage side, or on the shaft of the indicator bar [208] of the indicator fixture on the low-stage side.

d) Loosen and remove the hexagon socket head cap screws [122] fastening the micro switch

mounting plate [121] to the unloader cover [74-2] on the high-stage side, or to the indicator fixture on the low-stage side.

e) Now, the assembly can be pulled out as it is in the axial direction.

5.4.1.2 Inspection

The inspection procedure is described in the "Reassembly" section of this chapter, as it is often the case that the unloader indicator block is removed as an assembly and later inspected and adjusted after the overhauled compressor is reassembled and installed on the mounting base. Refer to Section

5.5.15 "Unloader Indicator" for details.

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5.4.2 Unloader Cover

The unloader cover [74-1] [74-2] is mounted with the indicator cam [77-1] [77-2], 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 [78-1] [78-2] and fixed to the cover with a bearing gland [80-1] [80-2].

To make it airtight, the V-ring [82-1] [82-2], spring [83-1] [83-2], and spring retainer [84-1] [84-2] are also attached.

The indicator cam has a spiral groove of 340° to cover the moving range of the unloader slide valve. The indicator cam shaft is rotated being pushed by the guide pin [68-1] [68-2] on the top end of the unloader push rod [67-1] [67-2].

This block structure of the low-stage and the high-stage is the same, but there is only one different point that the low-stage hexagon socket head cap screw [81-1] which fastens the bearing gland [80-1] requires the spring washer [597].

[Low-stage] [High-stage]

Figure 5-5 Unloader Cover Block

5.4.2.1 Disassembly

a) Unscrew and remove the unloader cover mounting hexagon socket head cap screws [76-1] [76-2]. b) Pull the unloader cover with the indicator cam assembly out in the direction parallel to the axis of

the push rod in the unloader cylinder. Carefully pull it straight, because if the unloader cover is pulled sideways, the shaft of the indicator cam may be bent.

● The mass of unloader cover assembly is approximately 16kg for the high-stage and

approximately 20kg for the low-stage. Because the indicator cam is long, firmly hold the unloader cover assembly until it is completely pulled out from the unloader push rod. Carelessly handling the unloader cover assembly may cause the injury.

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Low-stage Unloader Cover High-stage Unloader Cover

c) If the indicator cam will not move normally, check the spiral groove of the indicator cam, ball

bearing , and guide pin. The disassembly sequence is as follows:

c-1) As the bearing gland [80-1] [80-2], which fixes the indicator cam in place, is secured by

three hexagon socket head cap screws [81-1] [81-2] on the cylinder side of the unloader cover, unscrew and remove these bolts.

c-2) Then, the indicator cam can be pulled out with the ball bearing [78-1] [78-2] and the snap

ring (retaining ring) [79-1] [79-2] attached to the shaft.

c-3) Inside the unloader cover, the spring retainer [84-1] [84-2], spring [83-1] [83-2], and then

V-ring [82-1] [82-2] are assembled in this order.

Because the V-ring is tightly engaged with the bore of the unloader cover, the lip of the

V-ring will be damaged when it is once removed, making it unusable again. Therefore, be sure to replace it with a new one once it is disassembled.

V-ring (Black colored Part material is NBR or FKM) Ball Bearing, Indicator Cam

5.4.2.2 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. In this case, replace the V-ring.

b) Check the spiral groove of the indicator cam. If an abnormal flaw or wear is observed, replace it

with a new one.

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5.4.3 Unloader Piston and Unloader Cylinder

Inside the unloader cylinder [60-1] [60-2] is an unloader piston [64-1] [64-2] around which the cap seal [66-1] [66-2] and O-ring [65-1] [65-2] are fitted. The unloader piston is assembled to the unloader push rod [67-1] [67-2], which operates the unloader slide valve, with the lock nut [69-1] [69-2].

Note that the low-stage lock nut [69-1] has a double nut arrangement, and that in the high-stage unloader cylinder 30 % (indicated load) unloader spacer is installed to prevent an abnormally high intermediate pressure at the time of compressor start-up.

Figure 5-6 Unloader Cylinder Block

5.4.3.1 Disassembly

a) Screw two M8 eyebolts in the thread holes of the unloader piston, and pull the unloader piston

[64-1] [64-2] fully towards you.

b) Since the low-stage lock nut [69-1] fixing the unloader piston on the unloader push rod has a

double nut arrangement, loosen and remove the front side nut by using a lock nut wrench.

c) Then, release the locking teeth of the lock washer [70-1] [70-2], such that the lock nut [69-1] [69-2]

can be turned. Then, loosen the lock nut using a lock nut wrench, and remove it.

d) Pull out the unloader piston using the M8 eye bolts again.

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e) The low-stage unloader cylinder [60-1] is fastened by

twelve hexagon socket head cap screws [594] to the low-stage bearing cover [16].

Even when all the hexagon socket head cap screws

are removed, the unloader cylinder will not drop off as it is securely engaged with the bearing cover. Pull out the unloader cylinder by holding the flange or rib.

There are some differences in the mass of unloader

cylinder according to the rotor lengths of each model, however each unloader cylinder weighs around 60 kg. Therefore, wind a sling belt on the cylinder as shown in the right picture and remove the cylinder using a crane or like lifting tools.

● In the case of M, L or LL in rotor size, when lifting and pulling out the unloader cylinder

completely by keeping the belt sling position as shown in the above picture, the cylinder may hit on the push rod due to the mass unbalance and tilt. When required, change the belt sling position and remove the unloader cylinder.

f) The high-stage unloader cylinder [60-2] is fastened to balance

piston cover by two shortly hexagon socket head cap screws [61] and fastened to suction cover with balance piston cover by six long hexagon head cap screws [62].

The high-stage unloader cylinder is to be pulled out similarly to

Step e) for the case of low-stage cylinder.

However, if the cylinder is to be further disassembled, leave the

two bolts [61] fastened. Remove eleven bolts [24] and six bolts [62] fastening the balance piston cover [22], and remove the unloader cylinder together with the balance piston cover.

In this, as oil remains in the balance piston and side bearing part,

be careful of the oil that will come out when the balance piston cover is removed.

If the gasket [23] is sticking and it does not come off, screw in two

M8 eye bolts to the two jucking screw threads on the balance piston cover to separate the gasket.

● In case of removing the high-stage unloader cylinder together with the balance piston

cover, depending on the model, their mass may weigh over than low-stage unloader cylinder alone. When removing the high-stage unloader cylinder with balance piston cover, make sure to screw toe eyebolts onto the upper part of the balance piston cover to use a crane or like lifting tools .

5.4.3.2 Inspection

a) Both the O-ring [65-1] [65-2] and cap seal [64-1] [64-2] that are on the periphery of the unloader

piston [64-1] [64-2] must be replaced by new ones.

b) As it is often seen that the inside of the unloader cylinder has flaws or is contaminated by oil residue,

thoroughly clean the area and use fine sandpapers to finish the surface.

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5.4.4 Shaft Seal Block

4032**C models use the double balanced mechanical seal assembly as the shaft seal.

According to the system applications and working fluids ( refrigerants), 4032**C 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.

These mechanical seals are compatible to each other. For disassembly and assembly work of these mechanical

seals, a qualified trained personnel and special tools are required. For details, contact us.

5.4.4.1 Disassembly

After removing the hexagon socket head cap screws [53] and seal cover [51], disassemble in the order of the colored number shown in Figure 5-7/5-8/5-9.

5.4.4.2 Inspection

Although it is instructed that the mechanical seal assembly must be replaced after abnormality is found in the inspection, only visually checking the sliding surface may be insufficient in determining any abnormality. It is thus recommended to always replace it with a new one, similarly to the case of O-rings and gaskets, if the inspection is done in such a way.

Figure 5-8 BBD Ⅱ type Seal Figure 5-9 BBDE type Seal

Figure 5-7 BOD type Seal

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5.4.5 Bearing Cover

The bearing cover [16] must be removed when the low-stage bearing block is inspected or the rotor is pulled out for inspection.

5.4.5.1 Disassembly

a) Before starting the work, protect the rotor axis with curing tapes and/or other protective covering

not to damage them. b) Unscrew and remove 22 in all the hexagon socket head cap screws with captive washer [18-1]. c) Instead of removed bolts, screw in two stud bolts (as shown white arrows in following picture) to top

two thread holes on the bearing head for safety. d) Screw two eyebolts into the thread holes on the upper bearing cover, and keep lifting using lifting

tools and a crane or like tools. e) From the back facing holes on the bearing cover flange surface removed the unloader cylinder,

unscrew and remove ten hexagon head cap screws [595A] and two screws [595B] that fasten the

bearing cover to the bearing head [11-1]. Even if remove all fastening bolts, the bearing cover is attached to the bearing head by two

alignment pins [19-1]. f) There are two jacking screw holes in the opposite positions of the bearing head. By screwing in

two left and right M8 eye bolts evenly, the bearing cover will be separated from the bearing head. When some gap is observed between them, use a thin scraper to remove one side of the gasket

[17-1] from the body. g) Further screwing in the eye bolts will disengage the bearing cover from the alignment pins.

Figure 5-10 Bearing Cover

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5.4.6 Separating High-stage and Low-stage Blocks

The high-stage and low-stage blocks must be separated before inspecting the gear coupling, high-stage thrust bearing, main bearing, pulled out rotor, etc.

As explained at the beginning of Section 5.5 of this chapter, the separation may be done at the initial stage of the overhaul work.

5.4.6.1 Disassembly

a) As it is explained in the Section 5.3.5 , the bolts on the bottom side must be removed by

placing the compressor on a special stand before starting the disassembly work. b) Remove the hexagon socket head cap screws [18-2] that fasten the high-stage bearing head [11-2]

to the low-stage suction cover [5-1]. c) As the gasket [17-2] is sticking to both surfaces of the

high-stage bearing head and the low-stage suction

cover, use the bolts [18-2] that have been removed to

screw them into the jacking threads in the bearing

head to evenly push the suction cover to separate the

two blocks. d) The gear coupling assembly [151 to 161] for power

transmission is located inside, on the side of the M

rotor shaft.

As the drive side and driven side of the coupling can be

separated along the shaft axis, move the main body

exactly along the shaft axis to separate them.

5.4.7 Gear Coupling

The gear coupling, which is used as a power transmission means, is divided into the high-stage side and the low-stage side blocks, with each block attached to the corresponding M rotor shaft, and these two blocks are directly connected by a drive sleeve.

5.4.7.1 Disassembly

a) The drive sleeve [151] can be removed by hand

after the high-stage and low-stage are separated. b) Both high-stage and low-stage, remove the snap

ring [18-2] [18-1] that fix the drive hubs [152]

using a external snap ring pliers. c) Both high-stage and low-stage, loosen and remove

the knurled cup point socket set screws [159] from

the drive hubs used for locking keys [157]. This set screw [159] has been redesigned to the

M10×16 with looseness preventing from the M10

×25 in January 2005. d) Both high-stage and low-stage, there are two screw holes in the drive hub. Screw M8 eye bolts into

these screw holes and pull out the drive hub. It can be easily pulled out, as clearance fit is used.

5.4.7.2 Inspection

Check the hub and sleeve for possible deformation of the gear teeth and wear on each tooth flank. If it is found abnormal, replace the whole gear coupling assembly. At the same time, investigate the

cause of the abnormality.

Figure 5-11 Gear Coupling Block

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5.4.8 Balance Piston

During the operation of a screw compressor, both the rotation rate and the thrust load of the M rotor are higher than those of the F rotor. Accordingly, the service life of the thrust bearing for the M rotor will be significantly shorter than that of the F rotor, if no special measures are taken. As such, in order to reduce the thrust bearing load on the M rotor side, a hydraulic piston is used on the shaft end of the rotor drive shaft to cancel the load.

◆ Note that no balance piston is used on the low-stage. Because the low-stage pressure condition is lower

than high-stage, the service life difference of the bearings is not so significant compared to the high-stage.

5.4.8.1 Disassembly

a) Remove the snap ring [32] retaining the balance

piston [30] on the shaft using external snap ring pliers. b) Pull the balance piston straight out by screwing two

eye bolts into the threaded holes. While the rotor shaft

has a balance piston key [31], it is unnecessary to

remove the key. In addition, to prevent rotation of the balance piston

sleeve [33], spring pin [34] is used in this models, it is

unnecessary to remove the pin. c) Remove the snap ring [37] securing the balance

piston sleeve using the internal snap ring pliers. As the snap ring is pressed out by the internal O-ring

[35], slightly pushing it can easily remove the snap ring. d) Remove the balance piston sleeve and O-ring.

As clearance fit is used to engage the outside of the sleeve with the suction cover, you can easily

pull it out.

As there is an O-ring spacer [36], also remove the spacer.

5.4.8.2 Inspection

While you will be able to find some trace of wear on the inside surface of the balance piston sleeve, such wear is not abnormal as it is caused because the clearance between the balance piston and the sleeve is narrower than the clearance between the rotor shaft and the bearing.

Because enough clearance is given to the outside of balance piston sleeve in order not to apply the bearing load to the balance piston, no further development of the wear is expected.

However, you should still carefully check the condition because when the side bearing is significantly worn, the balance piston may also be worn.

Figure 5-12 Balance Piston Block

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5.4.9 Low-stage Suction Cover and Side Bearings

If the work sequence is such that the thrust bearing block is disassembled first and then the suction cover is removed, there is a risk that, when the suction cover is separated from the main rotor casing, the rotor may also be pull out and dropped. As such, in the procedure described in this manual, the suction cover is removed first, and then the thrust bearing is disassembled.

 In this procedure to remove the suction cover before disassembling the thrust bearing

block, it is necessary to sufficiently loosen the lock nut that are securing the thrust bearing while the rotor is supported by both the main and side bearings, in order not to damage the rotor during the disassembly process.

5.4.9.1 Disassembly

a) Screw in two eye bolts to the threaded holes on upper part of low-stage thrust bearing glands

[43-1A] [43-1B], then hook and lift them using crane or like lifting tools. b) Remove the hexagon head bolts [45-1] with spring washers [46-1] fastening the thrust bearing

gland [43-1], and then remove the O-ring [150-1] and thrust bearing gland.

The thrust bearing gland may not be removed by pulling only your hands due to the O-ring [150-1] stuck with the thrust bearing gland. In such a case, insert a flat blade screw driver or the like to the gap between the thrust bearing gland and the bearing head, and slightly pull it toward you. The thrust bearing will come off.

c) Unbend the tooth of the lock washers [40-1], and loosen the lock nuts [39-1] on both M rotor side

and F rotor side using a lock nut wrench.

d) Hook up the eyebolts of the low-stage suction cover to the lifting tools of a crane or the like, and

then loosen and remove the hexagon socket head cap screws [2-1] securing the suction cover

[5-1] to the low-stage main rotor casing [1-1]. e) Drive in the alignment pins [3-1] to the main rotor casing side. If it is not feasible, screw in suitable

bolts to the jacking screw holes on the flange to push the suction cover evenly. f) At this time, the alignment pins will also be disengaged. Even after the alignment pins are

disengaged, as the rotor shaft and side bearing are still engaged together, pull out the suction

cover carefully along the shaft axis.

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g) The side bearing [28-1] has been press fit from the balance piston cover side of the suction cover. Remove the snap ring [29-1] holding the side bearing using internal snap ring pliers. h) Either push out the side bearing from the main rotor casing side using some block or pull it out

using a special tool. For the details of the special tool, refer to Section 5.5.2 in this manual.

5.4.9.2 Inspection

a) Check the oil inlet path to the balance piston part of the suction cover by spraying air, or like. b) We recommend unconditional exchange of the side bearings on the occasion of the compressor

overhaul, but for confirmation of the compressor condition and system operating condition,

carefully check the sliding part metal surface of the side bearings. If the metal surface is gray or any foreign matter is buried, also carefully check the wear of the rotor

shaft. c) The inside surface of the main rotor casing should have no problems because sufficient clearance

is provided. However, if any trace of scraping by the end of the rotor is found, it should be

determined that the thrust bearing is defective. It is also necessary to check the operational

condition, such as whether the system is operated for a long time with a high intermediate

pressure.

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5.410 High-stage Suction Cover and Side Bearings

Similarly to the case of the low-stage side, the lock nut fastening the thrust bearing must be loosened before removing the suction cover.

5.4.10.1 Disassembly

a) Remove the hexagon head bolts [45-2] and the conical spring washers [46-2] that are used to

fasten the thrust bearing gland [43-2]. Take care not to lose them. b) Similarly to the case of the low-stage, it is not easy to remove the thrust bearing gland due to the

O-ring [150-2]. Take care not to drop the thrust bearing gland because it weighs 11 kg.. c) Unbend the tooth of the lock washer [40-2] securing the thrust bearing on the rotor shaft, and

loosen the lock nut. d) As the height of the high-stage main rotor casing is low, the casing is installed like a bridge to

connect between the suction cover and the bearing head. As such, the main rotor casing will be

supported only by one side (i.e., overhang) when the suction cover is removed. To avoid this, either

place squared timbers or use a lifting device to properly support the main rotor casing. Moreover, hook up the eyebolts of the high-stage suction cover to the lifting tools of a crane or the

like. e) Loosen and remove the hexagon socket head cap screws [2-2] securing the high-stage suction

cover [5-2] to the high-stage main rotor casing [1-2]. f) As the gasket [6-2] of the suction cover is sticking to the surface of the flange, screw two hexagon

socket head cap screws [2-2] that have been removed into the screw holes in the main rotor casing

flange to evenly push the suction cover. When some gap is observed between them, use a scraper

to remove one side of the gasket from the surface. g) When it comes to the position the alignment pins are disengaged, pull out the suction cover at

once along the shaft axis. h) Remove the snap ring [29-2] holding the side bearing using internal snap ring pliers. i) Either push out the side bearing from the main rotor casing side using some block or pull it out

using a special tool. For the details of the special tool, refer to Section 5.5.2 in this manual.. j) As the high-stage suction cover is installed with an O-ring [328] and O-ring gland [326-2] in the

opening for the push rod to pass through, remove them. As the four bolts fastening the O-ring

gland are small (M5), be careful not to lose them.

5.4.10.2 Inspection

The inspection must be performed similarly to the case of the low-stage side.

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5.4.11 Thrust Bearing Block

5.4.11.1 Disassembly of the High-stage Thrust Bearing Block

For the high-stage thrust bearing, one of two

types of bearings, i.e. the ball bearing and the tilting pad thrust bearing, is used according to the working fluid, requirements of the use of the package unit and the applicable standard. This section describes the ball bearing specifications.

The specifications of two type bearings are not compatible due to the machining difference of the bearing head.

In case of the tilting pad thrust bearing specifications on the high-stage thrust bearing block, refer to next Section "Disassembly of

the Low-stage Thrust Bearing Block". Figure 5-13 High-stage Thrust Bearing Block

The high-stage thrust bearing block of 4032**C has no spacer for the thrust bearing outer race. While the thrust bearing outer race spacer is used to support (i.e., ensure a sufficient support width for) the outer race of the thrust bearing, 250 or higher models use no spacer for the thrust bearing outer race because the case (bearing head) side has sufficient margin to the support it.

a) Remove the lock nut [39-2] that has been loosened. Then, remove the torsional slip washer [237-2],

lock washer [40-2], and thrust washer [250-2]. b) The clearance fit is applied to two gaps between the outer race of the thrust bearing and the

bearing head, between the inner race of the thrust bearing and the rotor shaft.

Prepare a 1 or 2 mm diameter aluminum wire, make the tip of the wire flat by hammering, and

slightly bend the tip to make a hook. Then, insert the tip of the wire between the outer race and the

ball retainer of the thrust bearing [38-2] to hook and pull out the bearing. In this way, the bearing

can be easily removed. c) The whole thrust bearing will be removed helped by the surface tension of the oil on the side face.

If you have failed to remove the whole bearing at once, put the components in the order of the

removal. d) Inside the thrust bearing is an alignment spacer [42-2] for the inner race on the rotor shaft side.

The M rotor side has a marking of "M", and the F rotor side has a marking of "F".

Neatly arrange the parts removed, i.e., the thrust

bearing gland, thrust washer, thrust bearing, and thrust bearing alignment spacer, separately for the M rotor and F rotor as shown in the right picture.

You must be very careful because if an assembly

error is made to result in a wrong combination of parts after failing to neatly arranging and separating the parts, it can lead to performance degradation and/or dragging accident due to overheating caused by being too narrow clearance, for example.

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5.4.11.2 Disassembly of the Low-stage Thrust Bearing Block

a) Remove the lock nut [39-1] that has been

loosened. Then, remove the torsional slip

washer [237-1], lock washer [40-1], and

thrust washer [250-1]. b) Remove the key [346] for TPTB (Tilting Pad

Thrust Bearing) on the rotor shaft. This key

is easy to lose because it is small. Take care

not to lose. c) Screw two eyebolts into the TPTB and pull it

out straight along the rotor shaft until the

screw hole for eyebolt comes out (following

picture to the left). d) Attach the lifting eyebolt on the top of the

TPTB and pull out it along the rotor shaft

using a lifting device (picture in the middle

below). e) Remove the thrust bearing alignment spacer [42-1] (following picture to the right).

5.4.11.3 Inspection

High-stage Ball Bearing

a) The thrust bearing is normal if the bearing balls are found fully glossy after the thrust bearing has

been fully washed and cleaned. It is abnormal if the ball surface has tarnish or streaky pattern. b) Support the inner race with your hand and rotate the outer race. If you feel abnormal vibration on

the hand, the rolling contact surface of the inner or outer race or some balls may be in an abnormal

condition. So, carefully check the conditions. You could feel some irregular click even with a small f

foreign matter that has entered during the removal process. In such a case, it should return to the

normal condition when high pressure air is used to blow out the foreign matters after washing and

cleaning the unit. If the bearing is determined to be defective, it must be replaced with new ones. c) If the inner race and outer race can be easily separated, the wear is considered excessive. If so,

you cannot reuse the bearing. d) After washing the bearing, you should be able to hear a clattering sound when the bearing is

rotated by hand. Such a sound is due to the motion of the ball within the backlash or play, or the

gap between the retainer and the ball. Such a sound will not be heard if the bearing is held

horizontal and turned. If some lubricating oil is applied after washing the bearing, the sound should

not be heard when the bearing is turned. If you can still hear the sound, the bearing is abnormal. e) If any abnormality is seen in the thrust bearing in the above inspection, replace with new ones.

In addition, carefully check the reason whether due to mere aging or any problem with the

operating condition and/or lubricating mechanism. If the compressor has been operated for more than 20000 hours without replacing the thrust

bearing, it is recommended to replace the bearing with a new one for safely continuing the

operation until the next overhaul, even if no abnormality is found in the above described inspection.

Figure 5-14 Low-stage Thrust Bearing Block

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Low-stage TPTB (Tilting Pad Thrust Bearing)

a) Disassemble the TPTB and visually inspect the surfaces of the tilting pad and the thrust collar. If any flaw and/or abrasion is found in each tilting pad piece, it is necessary to replace the TPTB

assembly with a new one. If a flaw of the thrust collar is small, finish with sandpaper. b) Perform visually inspection of the sliding surface of the floating seal and the thrust collar. If each flaw is small, wash and finish it with sandpaper.

Figure 5-15 Tilting Pad Thrust Bearing

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5.4.12 Rotors and Main rotor casing (Low-stage/High-stage)

5.4.12.1 Disassembly

a) While you can pull out the rotor either from the M or F side, you should be very careful in the work

as both of rotors are very heavy. In particular, be careful not to flaw the Low-stage M rotor shaft

because the shaft area is installed the mechanical seal assembly. We recommend you to protect

the shaft portion using curing tapes beforehand. When pulling out the M rotor (or F rotor) first, pull out about 2/3 of the full length of the rotor by

holding the shaft upward a little and turning it in the CW (or CCW) direction.

 You should carefully note that the rotor must be rotated in the specified direction

while pulling it out. If the M (F) rotor is not turned during the pulling out process, the F (M) rotor can also be pulled out together.

b) As a preparation, use a nylon belt or other lifting belt that

will not blemish the lifting surface to support the center of

the rotor. Then, pull out the rotor while slightly lifting up

the rotor using the belt. c) The pulled out rotor should not be directly placed on the

floor. Use appropriate wood boards to support the rotor as

a cushion to prevent blemishing or use V-blocks to

support the shaft to prevent blemishing of the outer

surface (See right picture.)

5.4.12.2 Inspection

a) No abnormality should be observed on the surface of the rotor lobes under normal operations.

Regarding the contact surface of the lobes black luster should be seen on the root area of the M rotor lobes and on the tip area of the F rotor lobes.

In other cases, when the suction gas or oil is contaminated by fine dust, there may be fine linear scratches on the shaft surface, in the direction perpendicular to the shaft axis. If any such flaw is found, use a fine sandpaper or grindstone to smooth the surface.

b) In case of ammonia refrigerant or gas compressor, the non-contact surface of the rotor may be

discolored by rust or deposits. Use sandpapers or others to finish the surface according to the degree of the problem.

c) Then, check the bearing areas of the rotor shaft. Two types of finishing are used: one is the

induction hardening (polish finishing) for the standard specification, and the other is the hard chrome plating (polish finishing), as a special specification. The most suitable finish is selected according to the type of refrigerant and operation conditions.

Very little wear will be present unless the compressor is operated for a long time using dirty oil or any hard matter is buried in the metal of the inner circumference of the bearing.

d) Check the portion of the shaft on which the thrust bearing is mounted for any trace to show that the

inner race of the bearing has rotated. f the lock nut that fastens the inner race of the thrust bearing is loosened, or if the bearing is abnormally worn, the inner race will become rotate. If any trace of rotation is seen, correct the problem. Depending on the degree of the rotating trace, it might be necessary to replace the rotors with new ones.

e) Check the inner surface of the main rotor casing.

There is a narrow clearance between the periphery of the rotor and the main rotor casing. Any slight flaw present on the tip of the rotor lobes or on the inner surface of the main rotor casing, due to small foreign matters, will not be a problem. If there is any trace to show that the tips of the rotor lobes have hit the inner surface of the main rotor casing, it is an abnormal condition. In such a case, the possible cause is that the main bearing and/or side bearing is worn out. Take proper actions by finding the cause of the problem, such as contamination of the lubricating oil or entrance of foreign matters.

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5.4.13 High-stage Bearing Head and Main Bearings

On the rotor mounting side of the bearing head [11-2], there is a gas discharge port as determined by the operating conditions of the compressor. This discharge port affects the performance of the compressor. In addition, the bearing head has the main bearing that supports one end of the rotor.

5.4.13.1 Disassembly

a) Remove all the hexagon socket head cap screws [2-2] fastening the main rotor casing and the

bearing head. Support the foot of the main rotor casing using squared timbers. b) Use jacking bolts to evenly push the bearing head. Once some gap is produced between the main

rotor casing and the bearing head, use a scraper to detach the gasket from the bearing head and

put it on to the main rotor casing side.

When the alignment pins are disengaged, the bearing head is separated from the main rotor

casing. c) The main bearing [27-2] is lightly press fit into the bearing head. When removing the main bearing,

first use internal snap ring priers to remove the snap ring [29-2]. Then, either use a plastic block or

other suitable element to push the main bearing from the rotor side or use a special tool to pull out

the main bearing. For the details of the special tool, refer to Section 5.5.2 in this manual. d) The unloader slide valve can be removed as an assembly by pulling it out from the bearing head

side. If no specific abnormality is found, no further disassembly is required. e) The guide block stem [88-2] is screwed in from the bottom of the main rotor casing, and the guide

block [87-2] is engaged from the top. To replace the O-rings [89-2], remove the guide block stem.

5.4.13.2 Inspection

a) We recommend as well as the side bearings, unconditional exchange of the main bearings on the

occasion of the compressor overhaul, but for confirmation of the compressor condition and system operating condition, carefully check the sliding part metal surface of the main bearings.

If the metal surface is gray or any foreign matter is buried, also carefully check the wear of the rotor

shaft.

b) Check the condition of the surface of the bearing head on the rotor side, where the discharge port is.

Properly mend the surface if any flaw is observed. If the entire surface has significant flaws, either the thrust bearing is defective or the end clearance adjustment is poor.

If oil compression has been caused during the operation, carefully and thoroughly check the area of

the discharge port in particular. If the continued use is in doubt at all, perform the penetrant testing to determine if it can be used or not.

c) With the unloader slide valve mounted in position, check the step height between the slide valve

and the main rotor casing surfaces. Usually, the surface of the slide valve should be lower than the surface of the main rotor casing. If the top surface of the slide valve has a trace of hitting the rotor, the probable cause is that the slide valve is worn or the rotor shaft/bearing is worn. In this case, please contact our sales offices or service centers.

d) Check the properness of the guide pin [68-2] at the tip of the unloader push rod [67-2] that engages

with the indicator cam [77-2].

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5.4.14 Low-stage Bearing Head and Main Bearings

5.4.14.1 Disassembly

a) Unscrew and remove all the hexagon socket head cap screws [2-1]. b) Drive in the alignment pins [3-1] from the bearing head side to the main rotor casing side. c) Screw tow jacking bolts into screw holes on the flange portion of the main rotor casing, then screw

the bolts evenly to push and separate the bearing head and the main rotor casing. d) Separate them carefully along the shaft axis, as the unloader push rod [67-1] is engaged. e) The main bearing [27-1] can be easily pulled out by removing the snap ring [29-1] and then lightly

tapping it from the rotor side via a pad. Otherwise, use a special tool to pull it out. f) Remove the slide valve as an assembly, using the same procedure as for the high-stage unit.

Carefully perform the work using lifting tools, as you are handling a heavy object.

5.4.14.2 Inspection

The inspection must be performed similarly to the case of the high-stage side.

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5.5 Reassembly

 During the reassembly work, be very careful in selecting the correct replacement

O-rings of the specified standard, not to make a mistake regarding the size, material, for fixed use, for sliding use, etc. Using a wrong O-ring can lead to oil leak or other problems.

 Some gaskets are not symmetrically shaped. In such a case, be careful not to misplace

the gasket. If the gasket is misplaced, it can lead to a significant problem such as blocking any oil supply route on the casing.

After completing the disassembly and inspection procedures, start the assembly process. Fist, read Section 5.1 "Precautions for Maintenance and Inspection" again in this Chapter 5.

Before starting the assembly, check the replacement parts once again. Like gaskets, all O-rings that have been removed during the compressor disassembly must be replaced

with new ones. The assembly sequence is mostly the reverse of the disassembly sequence. First of all, clean the work

bench and the tools to be used. Immediately prior to the assembly, use washing agent (e.g., kerosene, parts cleaner) to clean the parts

to be assembled, dry them with compressed air, and sufficiently apply lubricating oil, etc. For this, prepare a sufficient amount of clean lubricating oil for the reassembly. Also, apply oil on both sides of the gasket.

Because the assembly procedure is mostly similar between the high-stage and low-stage, the following Sections provide explanations that are commonly used for both stages. For this purpose, the part number given in the common explanations will omit the distinction between high-stage and low-stage by means of a hyphenated suffix (the suffix of [**-1] for low-stage and [**-2] for high-stage part number will be omitted).

Please fully understand the details in this Section 5.5 for correct assembly work.

Table 5-6 Tightening Torques for Hexagon Socket Head Cap Screws

Torque unit

M10

M12

M14

M16

M20

M24

M30

N・m

140

240

450

750

1600

kgf・cm

100

250

500

900

1400

2400

4500

7500

16000

When fastening the hexagon socket head cap screws, use the tightening torque specified in the above table.

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Figure 5-16 Illustration of the Assembly Sequence (Example)

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5.5.1 Unloader Slide Valve

a) Attach two O-rings [89] on the guide block stem [88] and screw in the guide block stem securely

from the bottom of the main rotor casing [1]. Then, mount the guide block [87] in the casing. In the case of 4032**C models, the guide block is not used in the low-stage main rotor casing. b) If the slide valve assembly has been disassembled, first make sure that the alignment position

between the unloader slide valves [54] and [55] is accurately reproduced and then tighten the

hexagon socket head cap screws [58] with spring washers [267] at the specified torque. The outer

diameter of the spring washers used here is less than normal spring washers for hexagon socket

head cap screws. So, be careful not to mix up with other washers. In the case of 4032**C models, the unloader slide valve [55] is only used in high-stage side. c) After using a grind stone or fine sand paper to lightly finish the circumference of the assembly,

mount the assembly in the main rotor casing using a crane or like. In the high-stage side, slowly push-in the slide valve while aligning the groove of the slide valve

with the guide block. d) After it is assembled, hold the unloader push rod and move it for several times to check that it

moves smoothly. Then, carefully check the joint with the casing that there is no step between them.

◆ A slight step between the surfaces of the unloader slide valve and the casing is allowed if the

slide valve side is lower.

 If the step is such that the surface of the unloader slide valve is higher than the

surface of the rotor casing, it is considered the problem of assembly. In such a case, it must not be left uncorrected. Be sure to reassemble it. Otherwise, the periphery of the rotor can make contact with the slide valve, resulting in a severe damage.

e) The low-stage slide valve assembly has a external snap ring [661] not to move the slide valve

toward the bearing head exceeding the necessary position (i.e., indicated load 0%). If you remove this snap ring [661] at the time of disassembly,, never forget to attach the snap ring. Without this snap ring, it may occur the incident that the slide valve assembly will not move toward

loading direction.

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5.5.2 Bearing Head and Main Bearings

The main bearing (O-ring type) [27] is installed by a light press fit. The size of O-ring [432-1] attaching on the low-stage main bearing has been changed to JIS B 2401 G200 from G210 according to the design modification in September 2012.

a) Align the notch on the main bearing with the spring pin [14]

that is driven in into the bearing head [11], and then drive it

in with a pad. For the alignment, it is convenient to use a

tool such as a guide bar (as a red arrow shown in the right

picture) . b) After the bearing has been inserted, install the internal snap

ring [29] to retain the bearing in position. Securely install the snap ring to be fully seated in the ring

groove, by pushing the snap ring with a guide bar or the like,

or by lightly hitting the guide bar with a hammer while

placing the guide bar on the snap ring.

When press fitting the bearing, it is recommended to prepare a collared plastic cylinder (spacer) that exactly fits inside the inner diameter of the bearing and also a collared weight that fits inside the plastic cylinder as shown in Figure 5-17. Then, hit the top of the weight for easy press fitting of the bearing.

Figure 5-17 Example Tool for Press Fitting the Bearing

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5.5.3 Bearing Head and Rotor Casing

 Since the bearing head gasket [12] is not symmetrically shaped, carefully check the

orientation when installing the gasket.

 If you place the bearing head gasket by just hanging it on the stud bolts, the gasket

will protrude into the inside of the rotor casing when the casing is assembled. Apply sufficient amount of oil, etc. to the gasket to make it fully attached to the surface to prevent protruding upon the assembly.

a) After fitting the unloader push rod [67-1] into the hole of the bearing head [11-1], slide either the

bearing head or the rotor casing [1] to join them together.

b) As the full height of the high-stage main rotor casing [1-2] is lower than that of the bearing head,

both centers will not be aligned when they are placed on the work bench. Therefore, either use a

pedestal as used in the disassembly process or lift the main rotor casing using a crane or other

device to align the centers. c) After lightly fastening two bolts, drive in the alignment

pins [3] to fix the position by using a copper or an

aluminum hammer. Note that a low-stage hexagon socket head cap screw

[2-1] is a washer faced bolt. d) After tightening the bolts [2], check that the bearing

head gasket is not protruding into the inside of the main

rotor casing. e) Also, move the slide valve back and forth to check that

it works normally. f) The bottom bolts that cannot be fastened on the work

bench are to be fastened later on.

 Be sure to check for possible protrusion of the gasket after the bearing head and

rotor casing have been assembled together. If you forget to check it out, it may lead to a measurement error in the end clearance adjustment process, as the gasket may be placed in between the rotor end and the bearing head surface. Furthermore, if the compressor is operated after the end clearance is erroneously adjusted and fixed in this condition, it may compromise the performance.

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g) Attach the O-ring gland [326-1] on the low-stage bearing head where is the part of the unloader

push rod protruding. Attach two O-rings [325] and four backup rings [419] alternately on the two O-ring grooves in the

O-ring gland inner circumference. h) Also attach the O-ring [9] on the O-ring groove of the O-ring gland outer circumference. i) Then, mount the O-ring gland on the unloader push rod and push it into the bearing head [11-1].

Figure 5-18 Low-stage O-ring Gland

j) Tighten the O-ring gland to the low-stage bearing head using four hexagon head cap screw [166-1]. k) Attach the O-ring [73-1] on the tip of the unloader push rod.

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5.5.4 Installing the Rotors

The rotor must be sufficiently reworked. If any slight flaw is observed on the shaft surface in the area of attaching the bearing and mechanical seal assembly, use a sand paper to correct and finish the surface. After finishing the surface to attach the seal, apply protective tape on the surface.

Both the M rotor and F rotor have a specific engagement position, and the position is marked by carving.

In order to make it easier to match the positions when the rotors are installed into the main rotor casing, a number is marked on the lobe tip: the M rotor has the marking on the discharge side, and the F rotor has the marking on the suction side.

a) Apply sufficient amount of lubricating oil on the main bearing in the bearing head and on the

bearing area of the rotor shaft. b) While it is easier to mate the markings if the F rotor is first installed into the casing, it is not a

mistake to install the M rotor first.

 Regardless of which rotor is installed first, the tooth of the M rotor with the

carved marking of "1" must be set in between the F rotor’s teeth that are marked "1" and "2". As it affects smooth engagement of the teeth as well as the balance, be sure to mate the markings as described above.

 As the circumference of the rotor is touching the rotor casing in this condition, any

rotation of the rotor should be kept to the minimum required. Otherwise, the teeth tip of the rotor may be worn.

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5.5.5 Suction Cover and Side Bearings

Similarly to the main bearing, the side bearing (O-ring type) [28] is machined to the size that will allow light press fitting to the suction cover [5].

In addition as is the case with the O-ring for the main bearing, the size of the O-ring for the low-stage side bearing has been changed to JIS B 2401 G200 from G210 according to the design modification.

a) Press fit the bearing by aligning the notch position of the side bearing with the spring pin [8] for

positioning the side bearing driven-in on the suction cover. During the press fitting process, check

that the notch position of the bearing is at the pin position. If the position has been shifted, pull out

the bearing and try the press fitting process again. Similarly to installing the main bearing, for press fitting the side bearing, it is convenient to use a

guide bar and/or a special tool for installing/removing the sleeve type bearing. b) After the bearing has been installed, install the internal snap ring [29] to retain the side bearing.

Make sure that the snap ring is fully seated in the ring groove either by pushing the ring with a

guide bar or tapping the head of the guide bar while applying the bar on the snap ring.

c) Attach the O-ring [328] on stepped processing part of the high-stage suction cover [5-2] hole where

the unloader push rod passes. Then, attach the O-ring gland [326-2] on the hole and tighten the O-ring gland to the suction cover

using four hexagon socket head cap screws [166-2].

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5.5.6 Installing the Suction Cover

Both of the high-stage and low-stage suction cover gaskets [6] are not symmetrically shaped.

Also, as shown in Figure 5-19, there are three type gaskets in the same sizing. Be careful not to use a wrong gasket.

After the design modification in June 2008, the tabs have been added on the suction cover gasket for identifying the left/right and the applicable model

a) Apply sufficient oil on both sides of the gasket,

confirm the oil supply/return holes position and put

the gasket on the main rotor casing. b) At first on the high-stage, pass the unloader push rod

through the hole at the bottom of the suction cover

[5-2].

Slide (or use a lifting device to move) the suction

cover in parallel along the shaft axis to engage the

rotor shafts with the side bearings. At this time, be

careful not to damage the inside surface of the side

bearing by the shaft end.

As the low-stage unloader push rod is out to

the bearing head side, be careful only with the

rotor shaft end in this work. c) After the suction cover has been pushed in up

to the flange surface, lightly fasten some of the

bolts [2]. d) Using a copper hammer or an aluminum

hammer, drive in the alignment pins [3]. e) Tighten the hexagon socket head cap screws

evenly up to the specified tightening torque. The bolts on the bottom side (about 6 bolts) are to be tightened during the final assembly stage, on

the special stand used in the disassembly process. f) For both the high-stage and low-stage blocks, move the unloader push rod back and force by hand

to check that it is working normally. g) Hold and rotate the M rotor shaft to check if it works normally.

In addition, check that the rotor has an axial play (i.e., the rotor can move in the axial direction).

Figure 5-19 Suction Cover Gasket

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5.5.7 Balance Piston and Balance Piston Sleeve

Install the balance piston sleeve to the high-stage suction cover, and install the balance piston on the M rotor shaft end portion of the high-stage suction cover side.

The installation of the balance piston sleeve may be done either before the suction cover installation to the main rotor casing.

a) First install the internal snap ring [37] for the O-ring

spacer [36], and then install the spacer [36]. b) After setting the O-ring [35] in position, install the

balance piston sleeve [33]. Insert the chamfered side of the balance piston

sleeve towards the O-ring already placed. Also, align the notch of the balance piston sleeve

to the spring pin [34] for rotation stop and to the oil

supply port. c) Insert the snap ring [37] to retain the balance

piston sleeve. As it should be difficult to fit the snap

ring into the groove due to the elastic force of the

O-ring, either push the side of the ring by a guide

bar or tap the head of the guide bar to fit the

ring securely into the groove. d) Confirm the balance piston key [31] attached on the M rotor shaft end of the high-stage suction

cover. e) Push the balance piston [30] into the high-stage suction cover using two eyebolts. f) Install the snap ring [32] using external snap ring pliers and retain the balance piston. Confirm the

snap ring fitted into the groove.

g) Install the O-ring [73-2] on the unloader push rod [67-2].

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5.5.8 Thrust Bearing Block

[Low-stage] [High-stage]

Figure 5-20 Thrust Bearing Block

Table 5-10 Components of the thrust bearing block

P/N

Part Name

Q'ty

Low-stage

High-stage

Low-stage

High-stage

42-1

42-2

Thrust bearing alignment spacer (1), (2)

2 2 38-1A

38-2

Thrust bearing (1), M rotor, (2)

1 2 38-1B

Thrust bearing (1), F rotor

1 - 346

Shaft key for TPTB

2 - 150-1

150-2

O-ring 2 2

43-1A

43-2

Thrust bearing gland (1A), (2)

1 2 43-1B

Thrust bearing gland (1B)

1 - 250-1

250-2

Thrust washer (1), (2)

2 2 40-1

40-2

Lock washer (1), (2)

2 2 237-1

237-2

Torsional slip washer (1), (2)

2 2 39-1

39-2

Lock nut (1), (2)

2 2 46-1

Spring washer, hexagon socket head cap screw

12 - -

46-2

Conical spring washer (2)

- 8 45-1

Hexagon socket head cap screw (1)

12 - -

45-2

Hexagon head bolt (2)

 The torsional slip washer [237] and lock washer [39] must be replaced with new ones.  If the removed thrust bearing is to be installed as it is, check the marking of "M" or

"F" on the thrust bearing alignment spacer and assemble it in the same combination as it was disassembled. This is important in controlling the end clearance on the discharge side of the rotor.

 Even if the same bearing is installed, the work must be very carefully done as the

dimension can change if any foreign matter such as a chip of paint or dust is pinched by the alignment spacer.

 In determining the installation direction of the thrust bearing, there are two methods

depending on the existence of an alignment "V" marking on the outer circumference of the bearing. Install the bearing according to the following procedure provided for each case.

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5.5.8.1 High-stage Block

As described in Section 5.4.11, for the high-stage thrust bearings, two types of bearings, i.e. the ball bearing and the tilting pad thrust bearing, is used according to the working fluid, requirements of the use of the package unit and the applicable standard. This section describes the ball bearing specifications. In the case of the tilting pad thrust bearing specifications on the high-stage thrust bearing block, refer to next Section "Low-stage Block". The thrust bearing alignment spacer [42-2] and the thrust bearing gland [43-2] are different from the ball bearing specifications.

The assembly sequence for this part is as illustrated in Figure 5-20. The important points to be noted in the procedure are described below:

a) Check the marking of either "M" or "F" on the thrust

bearing alignment spacer to ensure that the units are

assembled in the same combination of parts. The front and back of the thrust bearing alignment

spacer must be distinguished when it is installed. The

larger chamfering side is on the machine side, and the

smaller chamfering side is on the thrust bearing side. b) If thrust bearing has a "V" marking on the outer circumference, it means that the installation

direction of the bearing will sensitively affect the end clearance adjustment. In this case, the

bearing must be installed with the pointed end of the marking pointed toward the inside of the

machine.

If there is no "V" marking, it means that the direction of the bearing installation will not affect the

end clearance adjustment. However, in order to clearly determine the orientation (whether it is on

the inside or outside of the machine), first combine both bearings with the bearing number carving

facing the outside of the machine. Then, use a blue whetstone to write the above "V" marking on

the bearing to show the inside direction of the machine. Then, install the bearing (above picture). c) After the thrust bearing has been installed, attach the thrust washer [250-2], lock washer [40-2],

and torsional slip washer [237-2]. Then, tighten the lock nut at the specified range of the tightening

angle (refer to Chapter 7, Section 7.3 "Tightening Torques for Bolts and Nuts" in this manual) to

secure the inner race of the thrust bearing on the rotor shaft. This specified range of lock nut tightening angle is the same as the ball bearing specifications and

the TPTB specifications.

Tightening the lock nut while keeping the setting position between the lock nut wrench hooks and the lock nut grooves may cause to make the rotor run-out to enlarge due to uneven tightening forces. Change the setting position between the lock nut wrench hooks and lock nut grooves about four times when fastening the lock nut.

 As clearance fit is used for the inner race of the thrust bearing, this tightening work is

very important because the bearing is secured only by the tightening force of the lock nut.

 When the thrust bearing has been replaced, the dimensional difference between the

sides of the inner race and outer race varies even if it is within the tolerance of the applicable standard specification. As such, if the thickness of the thrust bearing alignment spacer that has been used is insufficient, and if the lock nut is securely tightened from the first, the end clearance between the rotor shaft end and the end face of the discharge side bearing head will be lost. Furthermore, as the balls are pressed against the rolling contact surface to create impression on the surface, it will damage the bearing. To avoid this, gradually tighten the lock nut while rotating the rotor to make sure the outer race is free, until the lock nut is fully tightened. If it comes to require more force to turn the rotor while the lock nut is being tightened, the thickness of the spacer is considered insufficient

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5.5.8.2 Low-stage Block

The TPTB (Tilting Pad Thrust Bearing) is used as the low-stage thrust bearing. The TPTB for M rotor and the TPTB for F rotor are the same in outer diameter and inner diameter, but are different in lengths. The M rotor TPTB is longer than the F rotor TPTB because M rotor thrust load is larger than F rotor thrust load.

Check the End Play

Before assembling this block, measure the end play of the TPTB. When putting the TPTB on the flat and smooth top of the work bench, the end face of the thrust collar rises up as shown below left picture.

Then, putting the TPTB on a pedestal which has a larger inner diameter hole than a outer diameter of the thrust collar, the thrust collar falls in the pedestal hole as shown below right picture.

We call this amount of movement of the thrust collar end face as the end play. If this value (end play) is not within the specified range as shown in Table 5-10, the TPTB can not to be used. Record the measurement value.

Table 5-10 Specified Value of End Play

Assembly

a) Apply protective tape or like on the M rotor axis portion

installing the shaft seal beforehand. b) Confirm the marking M/F of the thrust bearing alignment

spacer [42-1], and install them with the same combination

when disassembled. There is a specific installing direction

of the thrust bearing alignment spacer. The larger

chamfering side is on the machine side, and the smaller

chamfering side is on the thrust bearing side. c) Attach a lifting eye bolt on the top of the TPTB in the same

manner at the time of disassembling, and install the TPTB

while lifting by a crane or like lifting device. Using two

eye bolts and pushing with them will make the work easier.

At this time, align the detent protrusion of the TPTB (as

shown a red arrow in right above picture) beneath. d) Attach the shaft key [346] for the TPTB. e) After installing the TPTB, install the thrust washer [250-1],

lock washer [40-1], and torsional slip washer [237-1]. Then, tighten the lock nut [39-1] with the specified range

of lock nut tightening angle to secure the thrust collar of

the TPTB on the rotor shaft. Note: In case of using the TPTB for the high-stage, align the

protrusion of the TPTB just above. In addition, the thrust washer is not installed to the high-stage.

Using for

Specified Value

Low-stage M rotor

0.30 - 0.39 mm

Low-stage F rotor

0.25 - 0.34 mm

High-stage

in case of TPTB

0.20 - 0.25 mm

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5.5.8.3 End Clearance Measurement

At this point (i.e., after the thrust bearing block has been fully assembled), measure the clearance between the bearing head end face and the rotor end face on the discharge side. This clearance is called as the end clearance.

There is no difference between the TPTB and the ball bearing specifications in the manner of end clearance measurement and adjustment.

If the measured clearance does not satisfy the range specified in Table 5-11, proper adjustment must be made.

Table 5-11 Specified Limits of End Clearance

End Clearance (mm)

Tightening

Torque (N･m)

S M L

High-stage

O.17 to 0.21

0.20 to 0.24

0.23 to 0.27

0.26 to 0.30

Low-stage

O.70 to 0.80

0.75 to 0.85

0.80 to 0.90

0.85 to 0.95

0.80 to 1.00

120

a) Pressing the rotor shaft on to the discharge side with securing the thrust bearing to the rotor shaft. In case of the high-stage, the rotor can be pushed to the discharge side by tapping with cushion

like Teflon block, not striking the rotor shaft end directly, but the same method cannot be applied to

the low-stage. Manufacturing and preparing a jacking bolt to press the rotor shaft end face from the suction side

and its supporting jig (i.e., a steel plate with about 15 mm thickness and threaded hole at the

position of the rotor end face, fixing to two opposite positions bolt holes of the suction cover flange)

will make this pressing work easier. b) Prepare the thrust bearing gland to be readily mounted. Mount a dial gauge on the axial end of the

rotor, and set the indication needle to zero point while the rotor is fully pressed onto the discharge

end face. c) Without inserting the (conical) spring washer [46] and the O-ring [150], tighten the fastening bolts of

the bearing gland sequentially and evenly up to the specified tightening torque.

In case of the TPTB, align the notch of the thrust bearing gland to the protrusion of the TPTB.

Tightening each bolt at once at the specified torque must be avoided because it will result in

uneven tightening. So, repeat to sequentially tighten the bolts for several times.

Figure 5-21 End Clearance Measurement

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d) Then, read the dial gauge indication. This value shows the actual end clearance. If the end

clearance is outside the specified value, perform the adjustment work described in the next section.

If the end clearance is within the specified value, turn the M rotor shaft by hand and confirm the

smooth turning without uneven tightening. And then perform the measurement of the run-out of the

rotor shaft described in next section (3).

5.5.8.4 End Clearance Adjustment Procedure

(1) When the end clearance is less than the specified value

In this case, a shim (thrust adjustment liner) must be inserted between the thrust bearing alignment spacer [42] and the inner race of the thrust bearing to increase the end clearance.

The thickness of the shim must be determined by the difference between the specified end

clearance and the measured value.

◆ Although the thrust adjustment liner is not shown in the exploded view, you can place an order to us indicating the model name.

(2) When the end clearance exceeds the specified value

If any shim (thrust adjustment liner) has been inserted between the thrust bearing alignment spacer and the inner race of the thrust bearing, and the thickness corresponds to the difference between the measured end clearance and the specified value, just remove the shim.

If no shim is used or the thickness of the shim is insufficient to compensate for the excess end

clearance, use a surface-grinding machine (or ask a vendor) to make the thrust bearing alignment spacer [42] thinner by the amount of the end clearance difference between the measured and specified values. After the surface grinding is done, use a micrometer to measure the thickness of the spacer for the entire circumference to make sure the thickness is uniform.

(3) Measuring the run-out of the rotor shaft (low-stage M rotor)

If the end clearance adjustment has been successfully completed, then measure the run-out of the low-stage M rotor shaft using a dial gauge at the point of the mechanical seal attachment and turning the shaft by hand.

A run-out of up to 0.03 mm is acceptable for all models. The run-out occurs if the thickness of the

thrust bearing alignment spacer is not even or the marking on the thrust bearing is not properly positioned. And it occurs if fastening the lock nut performed without changing the position of the lock nut wrench (i.e., uneven fastening of the lock nut). The run-out also becomes significant if any small foreign matter is present in between relevant parts.

5.5.8.5 Tightening after Finishing the End Clearance Adjustment

a) Remove the thrust bearing glands [43]. b) Bend the tooth of the lock washer [40] to set it in the notched part of the lock nut to prevent

loosening.

c) Attach the O-ring [150] to removed thrust bearing gland. Without inserting the (conical) spring

washers [46] in the same manner as in the case of the end clearance measurement/alignment, tighten the hexagon head bolts [45] in a diagonal sequence, a little at a time, and finally tighten them to the specified torque.

d) Remove one of the hexagon head bolts fastening the thrust bearing gland, insert the (conical)

spring washer, tighten the bolt at the specified torque, and repeat this procedure for all other hexagon head bolts.

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5.5.9 Balance Piston Cover and High-stage Unloader Cylinder

a) Install the unload spacer [420] attached two O-rings [421] in the inner circumference grooves on

the high-stage unloader push rod [67-2].

This unload spacer is used as high-stage load capacity adjustment (minimum 30 % load) to

prevent overload of the driving machine at the time of compressor start-up.

b) Install the unloader cylinder [60-2] on the balance piston cover [22] and then install the resulting

assembly on the high-stage suction cover [5-2].

However the balance piston cover and the unloader cylinder are often not disassembled, so

following procedures c) to f) are applied to the case that this block has disassembled.

c) Attach the O-ring [63-2] in the O-ring groove on the machined surface of the balance piston cover

along which the unloader cylinder is installed.

d) Align the position of the balance piston cover with the unloader cylinder. As no gasket is used on

the mating flange between the balance piston cover and unloader cylinder, evenly and thinly apply liquid gasket (made of special synthetic rubber) on the surface of the flange of the unloader cylinder inside from the center of the bolt holes.

e) As the O-ring of the balance piston cover is already installed, lightly tap the flange surface with a

soft hammer to install it.

f) When joining the flanges, also align the bolt hole positions. Then, insert two hexagon socket head

cap screws [61] in the positions near the 10:10 of clock to tighten the unloader cylinder to the balance piston cover.

g) Confirm the O-ring [73-2] is attached in the O-ring groove on the tip of the unloader push rod [67-2],

at the position where the unloader piston is installed.

h) Attach the O-ring [65-2] without lubricating oil on the unloader piston [64-2], and then install the cap

seal [66-2] on it. It can be smoothly installed by slightly folding the cap seal along the circumferential direction. Also, using a small and smooth spatula will facilitate the assembling work.

i) Install the unloader piston fitted with the O-ring and cap seal in the unloader cylinder. One side of

the unloader piston is with screw holes for eye bolts, while the other side does not have such holes. First, to make it easier to fit the cap seal on the unloader cylinder wall, lightly press one side of the piston onto the chamfered area of the unloader cylinder by hand, changing the side of the piston for several times. Finally, apply lubricating oil to the unloader cylinder, then, push and install the piston with the screw holes side of the piston facing the unloader cover. After the installation, check that the cap seal is not broken or pinched.

j) Push the unloader piston into the unloader cylinder and set it in the middle of the cylinder, pull the

unloader push rod [67-2] toward you.

k) Apply sufficient amount of oil to the balance piston cover gasket [23] and attach the gasket on the

balance piston cover flange surface. Then, lift up the assembly of the balance piston cover and the unloader cylinder using a crane or like lifting device, and install the assembly onto the high-stage suction cover.

In the middle, pushing the unloader piston into the push rod and temporarily fastening the lock nut

[69-2] in the course of the work will make later work easier.

m) After joining the flanges together, tighten the hexagon socket head cap screws [24] of the balance

piston cover and tighten the hexagon socket head cap screws [62-2] of the unloader cylinder at each specified torque.

n) Use the eye bolts to pull the piston toward you, once remove the temporarily fastened lock nut,

install the lock washer [70-2] and lock nut [69-2], and then tighten the lock nut at the specified torque. To prevent loosening, bend the tooth of the lock washer at the notch of the lock nut.

Lastly, use the eye bolts to check the smooth movement of the piston.

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Figure 5-22 Bearing Cover

5.5.10 Bearing Cover

a) Before installing the bearing cover [16], check that the

teeth of the lock washers of the thrust bearing part have been properly bent to prevent rotation and that the hexagon head bolts fastening the thrust bearing gland are with spring washers.

b) For ensuring the safety, screw two stud bolts in the

upper bolt holes on the flange of the low-stage bearing head [11-1].

c) After applying sufficient amount of oil or like on the

flange surface of the bearing head as well as on both sides of the bearing cover gasket [17-1], hang the

gasket from the upper stud bolts and attach the gasket onto the flange surface of the bearing head.

d) While lifting the bearing cover [16] using a lifting hook

on the eye bolt, install the bearing cover carefully not to make contact with the M rotor shaft and/or the push rod.

e) After correctly setting the position of the alignment

pins, lightly tap the flange at opposite places alternately using a copper hammer or soft hammer to install the cover in position.

f) When the cover has come to the position the bolts can

be screwed in, screw in two or three hexagon socket head cap screws [18-1] and evenly tighten them to reduce the clearance and make the cover contact the body. Then, tighten all the bolts at the specified torque.

g) There are two types of the hexagon socket head cap screws as [595A] and [595B] shown in Figure

5-22. These bolts are used for fastening the countersunk processed screw holes of the bearing cover flange surface installing the unloader cylinder.

First, tighten opposite four positions, i. e., up, down, right and left with M24 bolts [595A].

Then, screw two M20 bolts [595B] into thread holes positioned 10:10 of clock, and tighten to the specified torque.

h) Tighten all remaining bolts [18-1] and [595A] at the specified torque.

5.5.11 Shaft Seal Block

The assembly procedure of the shaft seal block is the reverse sequence described in Section 5.4.4 as shown in the order of the colored number of each sectional view drawing. Disassembly and assembly works of this block especially require qualified trained personnel and special tools. For details contact us. 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 " fastening margin of the seal" is; 3 mm as BOD type seal, 5 mm as BBDⅡ type seal, and 6 mm as BBDE type seal.

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5.5.12 Low-stage Unloader Cylinder

The installation of the low-stage unloader cylinder may be done either after the bearing cover installation described in Section 5.5.10 or after the assembly of the shaft seal block.

a) Check that the O-ring [73-1] is inserted in the O-ring groove on the tip of the unloader push rod

[67-1], at the position where the unloader piston is installed. b) Install the O-ring [65-1] and cap seal [66-1] on the unloader piston [64-1]. c) Install the unloader piston fitted with the O-ring and cap seal in the unloader cylinder [60-1]. The

work procedure is the same as that for the high-stage side as described in Section 5.5.9, item i). d) In case of 4032**C, the O-ring [63-1] for sealing between the bearing cover [16] and the unloader

cylinder is installed on the O-ring groove in the unloader cylinder. e) Install the unloader cylinder into the bearing cover, and fasten the twelve hexagon socket head cap

screws [594] evenly at the specified tightening torque. f) Set the lock washer [70-1] and lock nut [69-1] on the unloader push rod, and fasten the lock nut at

the specified torque using a lock nut wrench.

To prevent loosening, align the positions of the lock washer’s tooth and the notched part of the lock

nut, and bend the lock washer’s tooth.

Lastly, use the eye bolts to check the movement of the unloader piston.

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5.5.13 Unloader Cover

[Low-stage] [High-stage]

Figure 5-23 Unloader Cover Block

a) Use eye bolts to move the unloader piston back and forth to check the normal operation again. b) Assemble the ball bearing [78] on the shaft portion of the indicator cam [77]. When fitting the

bearing onto the shaft, push the inner race of the bearing. Pushing the outer race may damage the

bearing. Push the bearing to the stepped portion of the indicator cam and retain the bearing with

the external snap ring. c) Sufficiently apply oil on the unloader cover [74], and install the V-ring set [82] in it. One of the rings

of the V-ring set (i.e., dark colored one) is made of rubber to improve the sealing performance, and

is placed as the second item from the outside. The orientation of the V-ring must be such that the

apex of the V-shape faces the outside and the lips face inside. d) Install the spring [83] and the spring retainer [84] into position. Then, insert the shaft of the indicator

cam assembled in Step b) above into the V-ring. Lastly, fasten three hexagon socket head cap

screws [81] to tighten the bearing gland [80] onto the unloader cover to retain the bearing.

 In case of 4032**C low-stage, the spring washers [597] are required for the hexagon

socket head cap screws [81] tightening the bearing gland [80]. Be careful not to forget setting the spring washer.

e) After making sure that the indicator cam rotates smoothly, attach the O-ring [75] to the unloader

cover.

f) Install the unloader cover on the unloader cylinder [60]. Making sure that the guide pin [68] of the

unloader push rod [67] is well engaged in the spiral groove of the indicator cam, push-in the unloader cover.

With the oil supply hole for the unloader operation up, secure the unloader cover by fastening the

hexagon socket head cap screws [76] at the specified torque.

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Figure 5-24 Gear Coupling Block

5.5.14 Coupling the High-stage and Low-stage Blocks

a) Both high-stage and low-stage, install the

drive hub [152] and shaft key [157] on the

M rotor axis. b) Attach the external snap ring [187] to retain

the drive hub.

c) Fasten the M10 hexagon socket set screw [159] to

retain the shaft key [157]. This set screw is self-locking

and knurled type screw. d) Set the drive sleeve on the low-stage drive hub. e) Screw in two stud bolts into two of the upper bolt holes

in the low-stage suction cover flange. f) After applying sufficient amount of oil, or like. on both

sides of the bearing cover gasket (2) [17-2], hang the

gasket from the upper stud bolts and correctly attach the

gasket onto the flange surface. g) After slightly lifting up the high-stage block from the work bench using a lifting device, slowly move

the block to approach the low-stage side. At this time, the gear coupling can be engaged smoothly if the low-stage M rotor shaft is rotated

clockwise and counterclockwise alternately for a small amount. h) Once the gear coupling has been successfully engaged, push the high-stage block onto the

low-stage block along the rotor shaft axis. Then, insert 4 to 6 hexagon socket head cap screws

[18-2] into the bolt holes, while avoiding the bolt holes that are adjacent to the left and right

alignment pins, and temporarily fasten them evenly to eliminate the clearance between the

low-stage and high-stage flanges. i) After the flange surfaces have contacted, slightly loosen the bolts that have been temporarily

fastened. Then, drive in the left and right alignment pins [19-2]. j) Rotate the low-stage M rotor using a special tool or something to check that no abnormality is

found. k) Tighten the hexagon socket head cap screws (22 in total) to the specified torque. The lower four

screws [18-3] are 20 mm longer than the [18-2] screws. Care must be taken not to confuse them. These four longer screws [18-3] for fastening the lowest flange part, unlike [18-2] screws, must be

tightened at the flange part from the low-stage suction cover side. When tightening the lower flange part, it is necessary to place the compressor on a special stand

as well as in the case of disassembly.

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5.5.15 Unloader Indicator

The unloader indicator is implemented with two micro-switches, a micro-switch cam, and a potentiometer. These parts are used to detect the change in the rotation angle of the indicator cam shaft, which converts the axial position change of the unloader slide valve into rotational position change, convert the change into an electric signal, and send the signal to the package unit and/or the controller of the refrigeration system.

To check the unloader indicator after inspection, adjustment, or parts replacement, coordination with the controller side will be required. Even in a case where the compressor is carried out of the installation site for overhaul, the indicator assembly is often removed from the compressor (to be kept at the site) and the inspection/adjustment and parts replacement are performed at the site. Thus, this section provides a detailed procedure, which may be helpful after the reassembly work.

 When removing the indicator block or performing inspection/adjustment or parts

replacement, be sure to shut down the control power and use lock-out and tag-out procedures. If the power is not shut down, there is a risk of electric shock.

The high-stage of 4032**C is implemented with an indicator assembly that is identical to the one used in a standard single stage compressor (except that the dial and micro-switch cam which are exclusively designed for 4032**C high-stage, for the range of 30 to 100 %).

On the low-stage of 4032**C, a standard indicator assembly is mounted on the special fixture for 4032**C low-stage that converts the axial direction of the indicator assembly to the lateral direction.

5.5.15.1 Potentiometer

The potentiometer [129] of the standard type indicator is a rotary instrument for measurement over a full turn.

It senses the continuously variable position (indicated load of 0% to 100%) of the unloader slide valve, and feeds the sensed position as electric signals to the control side of the package unit or refrigerating system.

While the expected service life of the potentiometer will significantly vary depending on the installation environment of the compressor (e.g. corrosive gas atmosphere, moisture, etc.) and operational conditions (e.g. frequent partial load operations, frequent start/stop operation, vibration, etc.), the potentiometer is a consumable part that requires regular replacement according to the situation.

■ Disassembly Refer to Section 5.4.1 in this manual for the low-stage/high-stage disassembly procedure.

■ Inspection

a) Check at the terminal block that the lead wires of the potentiometer are not loosened. b) Check for any crack or other defects in the soldering of the lead wires of the potentiometer. c) Manually rotate the shaft of the potentiometer and measure the resistance value using a circuit

tester to check that the resistance value changes smoothly.

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5.5.15.2 Micro-switches and Micro-switch Cam

The unloader indicator uses two micro-switches [125] and one micro-switch cam [127] to detect the commanded 0% (30% for the high-stage) and 100% capacity control positions of the unloader slide valve.

If the micro-switch fails or any of these connections becomes loose for some reason, correct position detection cannot be made, and it causes a problem in the operation control of the compressor.

■ Disassembly

Refer to Section 5.4.1 in this manual for the low-stage/high-stage disassembly procedure.

■ Inspection

a) In the normal condition where the hydraulic line for the capacity control of the compressor is not

opened, set the unloader piston to the no load and full load positions from the manual capacity control circuit and check the operation of the control circuit to see if the micro-switch can detect the 0% (30%) and 100% positions of the micro-switch cam (i.e., by checking the operation of the relevant relays and contacts).

If the hydraulic line for the capacity control of the compressor is opened for overhaul or other

work, use nitrogen gas or compressed air to set the unloader piston to the no-load and full load positions and check if the micro-switch can detect the 0% (30%) and 100% positions of the micro-switch cam.

b) After shutting down the control power and carrying out the lock-out and tag-out procedures,

remove the indicator glass and check that the micro-switch screws [126] are not loosened.

c) Check that the hexagon socket head set screw [128] securing the micro-switch cam [127] are

not loosened.

d) After checking that the wiring for the micro-switch has been removed, turn on and off the switch

to check the normal switching operation of the micro-switch using a circuit tester.

e) Carry out other visual inspection including any indication of water intrusion in the indicator, any

rust on switch terminals, any wear of the switch roller or micro-switch cam, and so on.

5.5.15.3 Reassembly

To carry out the reassembly, follow the disassembly procedure in reverse. Lastly, correctly set the indicator needle (pointer) [138] position according to the following procedure:

a) If the hydraulic line for the capacity control of the compressor is opened for the purpose of overhaul

or other work, use nitrogen gas or compressed air to set the unloader piston to the no-load position.

Then, set and fix the indicator needle to the starting point of an illustration (on the indicator dial)

which indicates rotation. Next, set the piston to the full load position. Make sure the indicator

needle points to the end point of the range drawn on the dial. b) In the normal condition where the hydraulic line for the capacity control is not opened, use the

manual capacity control circuit to move the piston. While the control power is turned on, the indicator cover [146] must be mounted to prevent

possible electric shock. Then, after the piston position is fixed, control power is turned off, and the lock-out and tag-out

procedures are completed, remove the indicator cover and secure the indicator needle in position.

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Figure 5-25 Unloader Indicator Assembly

Table 5-12 Component Parts of the Unloader Indicator Assembly

P/N

Part Name

Q'ty

P/N

Part Name

Q'ty

121

Micro-switch base plate

136

Hexagon socket set screw, M3 × 14

122

Hexagon socket head cap screw, M6 × 20

137

Dial, 30 to 100 %

123

Micro-switch base plate

137

Dial, 0 to 100%

124

Phillips Screw, M3 × 10

138

Phillips Screw, M3 × 5

125

Micro-switch

139

Indicator needle

126

Phillips Screw, M3 × 25

140

Phillips Screw, M3 × 10

127

Micro-switch cam, 30 to 100 %

141

Indicator glass

127

Micro-switch cam, 0 to 100 %

142

Indicator glass spacer

128

Hexagon socket set screw, M4 × 8

143

Electric cable gland

129

Potentiometer

144

Bracket, 125L

130

Potentiometer mounting plate

145

Hexagon socket head cap screw, M6 × 15

131

Phillips Screw, M3 × 5

146

Unloader indicator cover (2)

132

Terminal block

147

Hexagon socket head cap screw, M6 × 15

133

Phillips Screw, M3 × 20

148

Plug 1 134

Dial plate support [2]

214

Spring pin 2 dia. × 8

135

Dial plate support [1]

265-2

Spring washer, M3

Note: For the items 127 and 137, the range of 30 to 100% is specified for the high-stage and the

range of 0 to 100% is specified for the low-stage..

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

Specifications and Main Features

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