mycom i125S, i160S, i125L, i160L, i160M Instruction Manual

2203M4JE-MY-iS2-N_2017.04.

i-Series Screw Compressor Instruction Manual

i125S / i125L

i160S / i160M / i160L

CAUTION

Before operating, servicing, or inspecting this product, read this manual thoroughly to fully understand the cont ents. 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 im pr ovements, and the like.

This manual is applied to each compressor after the serial number

shown below. i125S: 8750303 i125L: 8770301

i160S: 8710055 i160M: 8720018 i160L: 8730030

2203M4JE-MY-iS2-N_2017.04.

Preface

Screw Compressor i-series

Preface

Thank you for purchasing our

i-series screw compressor (hereinafter referred to as "this product"). This instruction manual (hereinafter referred to as "this manual") provides safety information and operation and maintenanc e procedures , so that users correct ly understand how t o handle this pr oduct and, as a result, can use it safely and efficiently.

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

i-Series Screw Compressor

Instruction manual

2203M4JE-MY-iS2-N_2017.04.

April 28, 2014

Revision

No.

Issue Date Major contents of revisions

Created

/ approved by:

00 April 28, 2014

Newly is

sued as applicable to the product after May

2014, due to modification of the i-series specifications.

Muta / Ikeda, Hirao

01 Sep. 24, 2014 Added models for IEC motor flange specifications.

Amanuma, Kato / Ikeda, Hirao

June 01, 2015

Modified the constitution of Chapter 4 and Chapter 5.

Added the basic multi-packaging points using plural

i-sereis compressors.

Kitahara,

Fujimoto / Ikeda

April 30, 2017

Corrected 2.3.1 Standard Specifications, 2.4.3 Parts Configuration Table . Deleted Contact Information.

Takenouchi, Ito / Kato

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Warranty and Disclaimer

Screw Compressor i-series

Warranty and Disclaimer

Warranty Clauses

MAYEKAWA shall repair or replace parts of this product for no charge if any failure resulting from defects in design or m anufacture occurs, und er normal use with th e purpose and method t hat 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". If there is a separate agreement, that agreement shall prevail in principle.

MAYEKAWA is not liable for production or m an-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 b y 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 deteri oration of this product due to abn ormal 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 c aused by devices or equipm ents not provided by MAYEKAWA including operation control methods of those devices.

• Malfunction or damage c aused by refrigerants, gases, or refr igerant 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 suc ks in the refrigerant liquid only after vaporizing it in th e

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

Screw Compressor i-series

iii

Important Information

Intended Use of this Product

This product is a general-p ur pose s c rew compressor for refrigeratio n and c o ld sto r age. Do not use this product for any other purpos es that are not intended for or which depart f rom the specifications. For specifications of this product, refer to "2.3 Compressor Specifications". 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 ha zards caused by human errors, or due to environmental cond itions 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 t his m anual or war ning lab els. Theref ore, when operat ing 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 b efore 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 invol ved and m eas ures to avoid dangers to ap proach 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 the

genuine parts.

 Not only workers but also m anagers should acti vely participate saf ety and health activities in

the workplace to prevent accidents.

 When closing or opening a valve during work , make sure to apply lock out/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” m eans disc onnec ting or k eepi ng disc onnec ted m ac hines and d evices b y lock ing their energy (po wer) sources. Lockout is not just simpl y 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.

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Important Information

Screw Compressor i-series

[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 clearl y stating to not operate energ y (power) sources, and ar e not for stopping block ing devices.

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

 Electrical maintenanc e of the pr oduct m ust be perform ed by certif ied/qual ified p ersonnel a nd

only those educated about the electrical control of the product.

 Before servicing or insp ecti ng the el ectrical equipm ent or devices , turn "OFF" th e m otor main

power and control power, and perform lock out/tagout to prev ent the power from bein g 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 in which this product is used. Make sure the power supply on the power source sid e is shut off, and perform lock out/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 fr om the descriptions in th is manual. If you have any questions, contact our sales offices or service centers. F or each sight of MAYEKAWA, refer to following URL. http://www.mayekawa.com/about/network/

 This manual is in English. I f an y other lan guage is requ ired, it is th e 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 i ncluded in this manual may differ from the appear ance of actual

product.

 If this manual is lost or dam aged, immediately request to one of our local sales offices or

service centers for a new m anual. Us ing this pr oduct without the m anual m ay res ult in saf ety issues.

 When you resell this product, be sure to transfer this manual to the next owner.

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Important Information

Screw Compressor i-series

Structure of This Manual

Chapter/Section Title Description

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 regar ding the work safety that is r equired for

handling this product.

2. Compressor Specifications and Configuration

Describes the main com ponents of this product, func tional

information,

specification, operating limits, drawings, and parts list.

3. Installation Describes the installation procedure of this product.

4. Compressor and Package

Unit Operation

Describes the precautions for operating this product

and the package

unit..

5. Maintenance and

Inspection

Describes sections and period for inspecting, and assembly and

disassembly of this product.

6. Troubleshooting

Describes troubl

eshooting methods for this product in case problems

occur during operation of this product.

7. Related Documents List of disassembly tools for i-series compressor, and other information

Appendix 1 : Packaging Points 1

Describes basic points for the design and manufacture of a i-

series

compressor package unit.

Appendix 2: Packaging Points 2

Describes basic multi-packaging points using plural i-sereis compressors.

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Table of Contents

Screw Compressor i-series

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

Structure of This Manual .................................................................................................... ⅴ

Table of Contents ................................................................................................. ⅵ

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 ................................. 1-2

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

1.1.1.5 Do's about the 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 Circuit 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 Configuration

2.1 Features of

i-Series Compressor ........................................ 2-1

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

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

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

2.3.2 Operation limits .................................................................................................... 2-3

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vii

2.3.3 Alarm Set Values ................................................................................................. 2-4

2.3.4 Outer Dimensions ................................................................................................ 2-5

2.4 Configuration of Compressor .................................................................. 2-18

2.4.1 Secti ona l Vie ws ................................................................................................. 2-18

2.4.2 Exploded Views ................................................................................................. 2-24

2.4.3 Parts Configuration Table .................................................................................. 2-26

2.5 Mechanisms .............................................................................................. 2-33

2.5.1 Basics of the Screw Compressor ...................................................................... 2-33

2.5.2 Sucti on Pr oces s ................................................................................................. 2-33

2.5.3 Compression Process ........................................................................................ 2-34

2.5.4 Disc har ge Proc es s ............................................................................................. 2-34

2.5.5 About Volume Ratio (Vi) .................................................................................... 2-34

2.5.6 Capac ity Control Mechanism ............................................................................. 2-36

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 ................................................................................... 3-3

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

3.2.5.1 Piping Connection ....................................................................................... 3-3

3.2.5.2 Equipment and Devices for Protection of the Compressor ......................... 3-4

3.2.6 Airtightness Test .................................................................................................. 3-4

3.2.7 Lubricating Oil Charge ......................................................................................... 3-4

3.2.7.1 Initial Charge of Lubricating OIL .................................................................. 3-5

3.2.7.2 Additional Charge of Lubricating Oil ............................................................ 3-5

3.2.8 Charge of Refrigerant .......................................................................................... 3-5

3.2.9 Check after Installation ........................................................................................ 3-5

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 Recommended Lubricating O ils .......................................................................... 4-2

4.1.2.1 Recommended Lubricating Oils for Ammonia Refrigerant .......................... 4-2

4.1.2.2 Oils for Systems Using Hydrofluorocarbon (HFC) Refrigerants .................. 4-3

4.1.3 Change of Lubricating Oil Brand ......................................................................... 4-3

4.1.4 Precautions for Handling Lubricating Oil ............................................................. 4-4

4.1.5 Lubricating Oil Management Criteria ................................................................... 4-4

4.1.6 Lubricating Oil Replacement Timing .................................................................... 4-5

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viii

4.1.6.1 After Starting the Initial Operation .............................................................. 4-5

4.1.6.2 During Normal Operation ........................................................................... 4-5

4.2 Precautions for Operation ......................................................................... 4-6

4.2.1 Prevention of Liquid Flow-back ........................................................................... 4-6

4.2.2 Purging of Non-Condensable Gases ................................................................... 4-6

4.3 When Stopping the Compressor for a Long Time .................................... 4-7

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 Dai l y Management ............................................................................................... 5-3

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

5.2.3 Guidelines for Compressor Overhaul Interval ..................................................... 5-6

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

5.3.1 Disassembly Tools and Work Place .................................................................... 5-7

5.3.2 Replacement Parts .............................................................................................. 5-8

5.3.3 Refrigerant Gas Treatment ................................................................................ 5-10

5.3.3.1 Valves Used ............................................................................................... 5-10

5.3.3.2 Refrigerant Gas Recovery ......................................................................... 5-10

5.3.4 Removing Parts Connected to the Unit ............................................................. 5-11

5.3.5 Removing and Lifting the Compressor .............................................................. 5-11

5.3.6 Removing Oil from Compressor ........................................................................ 5-11

5.4 Disassembly and Inspection ................................................................... 5-12

5.4.1 Shaft Seal Block ................................................................................................ 5-12

5.4.1.1 Disassembly .............................................................................................. 5-12

5.4.1.2 Inspection .................................................................................................. 5-13

5.4.2 Bear ing Co ver .................................................................................................... 5-14

5.4.2.1 Disassembly .............................................................................................. 5-14

5.4.2.2 Inspection ................................................................................................... 5-14

5.4.3 Balanc e Pist on ................................................................................................... 5-15

5.4.3.1 Disassembly .............................................................................................. 5-15

5.4.3.2 Inspection .................................................................................................. 5-15

5.4.4 End Cover .......................................................................................................... 5-15

5.4.5 Thrust Bearing Block ......................................................................................... 5-16

5.4.5.1 Disassembly .............................................................................................. 5-16

5.4.5.2 Inspection .................................................................................................. 5-16

5.4.6 Bear ing Hea d ..................................................................................................... 5-17

5.4.6.1 Disassembly .............................................................................................. 5-17

5.4.6.2 Inspection .................................................................................................. 5-17

5.4.7 Rotors ................................................................................................................ 5-17

5.4.7.1 Disassembly .............................................................................................. 5-17

5.4.7.2 Inspection .................................................................................................. 5-17

5.4.8 Radial Be ar ings ................................................................................................. 5-18

5.4.8.1 Disassembly .............................................................................................. 5-18

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5.4.8.2 Inspection .................................................................................................. 5-18

5.4.9 Sucti on Str ai ner and Check Valve ..................................................................... 5-18

5.4.9.1a Disassembly (i125*) ................................................................................... 5-18

5.4.9.1b Disassembly (i160*) ................................................................................... 5-18

5.4.9.2 Inspection .................................................................................................. 5-19

5.4.10 Unloader ............................................................................................................ 5-19

5.4.10.1 Disassembly .............................................................................................. 5-19

5.4.10.2 Inspection .................................................................................................. 5-19

5.5 Reassembly .............................................................................................. 5-20

5.5.1 Unloader ............................................................................................................ 5-21

5.5.2 Rotor and Inner Race of Radial Bearing ............................................................ 5-21

5.5.3 Bear ing Hea d ..................................................................................................... 5-22

5.5.4 Outer Race of Radial Bearing ............................................................................ 5-22

5.5.5 Suction Strainer and Check Valve ..................................................................... 5-23

5.5.5.1 i125*........................................................................................................... 5-23

5.5.5.2 i160*........................................................................................................... 5-23

5.5.6 Adjustment of Thrust Bearing and End Clearance ............................................ 5-24

5.5.6.1 End Clearance Measurement .................................................................... 5-26

5.5.6.2 End Clearance Adjustment ........................................................................ 5-27

5.5.6.3 Tightening after End Clearance Adjustment .............................................. 5-27

5.5.7 Balanc e Pist on ................................................................................................... 5-28

5.5.8 Bear ing Co ver .................................................................................................... 5-28

5.5.9 Shaft Seal Block ................................................................................................ 5-29

5.5.10 End Cover .......................................................................................................... 5-31

Chapter 6 Troubleshooting

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

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

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

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

05: Abnormally high pressure (abnormal discharge pressure) .................................... 6-3

06: Discharge temperature is abnormally high ............................................................. 6-4

07: Leak from mechanical seal part ............................................................................. 6-6

08: Squeaking sound from mechanical seal ................................................................ 6-6

09: Capacity control malfunction .................................................................................. 6-6

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

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Table of Contents

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Chapter 7 Related Documents

7.1 Tightening Angles for Lock Nuts .............................................................. 7-1

7.2 Disassembly Tools ..................................................................................... 7-2

7.3 Flange Motor and Connection Flange Size ............................................. 7-3

Appendix 1: Basic Points for Design and Manufacturing for the Compressor Package

1-1 Basic Flow of the Package Unit ........................................................... Appendix 1-1

1-2 Basic Flow of the Oil Cooler ................................................................ Appendix 1-2

1-3 Oil Temperature Control ...................................................................... Appendix 1-3

1-4 Economizer .......................................................................................... Appendix 1-3

1-5 Oil Separator ....................................................................................... Appendix 1-4

1-6 Protection Devices ............................................................................... Appendix 1-4

1-7 Power Supply and Control Devices ..................................................... Appendix 1-5

Appendix 2: Basic Points for Design and Manufacturing for the Compressors Multi-package

2-1 Preface ................................................................................................ Appendix 2-1

2-2 Reference Flow and Configuration Components for Multi-package ... Appendix 2-1

2-2-1 Package Flow Representative Example ......................................... Appendix 2-1

2-2-2 Oil Separator ................................................................................... Appendix 2-2

2-2-3 Pressure Regulator for Differential Oil Supply Press ure ............... Appendix 2-2

2-2-4 Oil Cooler ........................................................................................ Appendix 2-2

2-2-5 Oil Filter and Oil Line ....................................................................... Appendix 2-2

2-2-6 Stop Valves and Safety Valves ....................................................... Appendix 2-2

2-3 Economizer .......................................................................................... Appendix 2-3

2-4 Protection Devices and Control Devicess ........................................... Appendix 2-3

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Chapter 1 Safety

Screw Compressor i-series 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 attach safety and protective devices to the package unit.  The safety devices and protection systems must be regularly checked for their normal

operation.

 If any safety device or protection system does not function normally or this product operates in

an abnormal manner, immediately stop the work and contact your supervisor. When the system is to be restarted, you must observe the decision and instruction of the supervisor.

 If this product has stopped operation due to an unknown cause, immediately contact your

supervisor. Before restarting the system , you must seek the decision and instruction of the supervisor.

 Depending on the type of refrigerant used, its leakage may generate a bad smell or poisonous

gas. Be sure to sufficiently ventilate the room while the machine is operated.

 Regarding the characteristics of the refrigerant and lubricating oil, e.g., corrosiveness,

degradability, and toxicity, be sure to obtain the Safety Data Sheet (SDS) of the m and follow the instructions given.

 When this produc t is not to be used for some peri od of time, close the suction (side) and

discharge (side) stop valves and shut off the m otor power source, heat er power, and control power.

1.1.1.2 Do’s on Maintenance

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

starting the work.

 If two or more peo ple are to work together, be sure to mutuall y check the work details and

procedures before the work. During the work, always keep track of the other workers’ actions.

 Before working on any troubleshooting during operation, before setting up this product, before

cleaning work, and before conducting maintenance or inspec ti on wor k, be sure to shut off the motor power source, control power, and power to other equipment, perform lock-out and tag-out procedur es, and take effective measures to p revent any accidental power -on during the work.

 Before working on any troubleshooting during operation, before setting up this product, before

cleaning work, and bef ore conducting m aintenance or inspection work, be sure t o check that the internal pressure of this product and the refrigeration/cold storage unit is at the atmospheric pressure.

 Depending on the t ype of refrigerant used, it ma y generate a bad smell or poiso nous gas or

could cause an oxygen deficient atmosphere. Before starting the work , measure the ox ygen content in the work area, as appropriate, and provide sufficient ventilation. The ventilation must be continued steadily until the work is completed.

 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 work, the tools us ed must be returned to the predefined locat ion. Be sure not to leave

them inside the package unit.

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Chapter 1 Safety

Screw Compressor i-series 1.1 Strict Requirements and Prohibitions

1-2

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

 A lock-out/tag-out mechanism must be installed for the main circuit breakers that supply power

to the motor and po wer to the control system . T he lock-out/tag-out after power do w n is a v er y effective means to ensur e t he s af et y wh en two or more work ers ar e work ing on t he system at the same time, as it can prevent p ossible i njury of workers t hat ma y be caused b y accidenta l power-on of the driving source by one of the workers.

 If there is a risk of danger, especially during cleaning, maintenance/inspection, or

troubleshooting work , be sure to l et the work ers per form the lock -out/tag-out pr ocedures after the motor main power and control power has been shut off.

 Because the workers m ay neglect to perform the lock-out/tag-out proced ures or cut-off the

power in the following situations, be sure to instruct them to strictly follow the correct procedure by clearly identifying the work that require lock-out/tag-out and the reasons why it is needed.

• As it is a cumbers ome task for the workers to cut off the motor m ain power and control power and use lock -out/tag-out devices before starting the w ork , they m ight negl ec t to do it.

• The workers m ight determ ine by th em selves th at it sh ould b e OK j ust to c ut off th e m otor main power and control power, and not use any lock-out/tag-out devices.

1.1.1.4 Do’s about Personal Protective Gear

 Prepare and use protective gear com pl ying wit h 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 an y neck ties or jewelry as there is a ris k 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 machine.

1.1.1.5 Do’s about Handling of Hazardous and Toxic Substances

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

Check the MSDS and fol low the han dling instr uctions recomm ended b y the manuf acturers to handle and store those substances.

1.1.1.6 Do’s about Handling Emergency Situations

 Formulate an emer gency action plan complying with the regulatio ns, 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 protecti on purposes. Follow the local, state, federal acts and regula tions and your company's rules when disposing of such waste oil, fluid and materials.

1.1.1.8 Other Do’s

 Keep clean the floor around the entire package unit. Provide a safety passage.  Walk only on the areas set up as a work f loor. Also, do not lea ve too ls and c lea ning sol utions

in that area.

 If water or oil is spi lled on this pr oduct or the f loor, immediately wipe it off to pr event work ers

from slipping and getting injured.

2203M4JE-MY-iS2-N_2017.04.

Chapter 1 Safety

Screw Compressor i-series 1.2 Warnings

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-c irc ui tin g or bypassing with out any permission.  Do not leave this pro duct unsafe and unattended, b y removing a safet y cover or some other

measures.

 Do not touch, clean or lubricate any part of this product which is moving.  Do not touch rela ys or electr ic systems such as terminal b lock with bare hands when t urning

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 auxili ary equipment may be heavily damaged. T herefore, be sure to always

observe the instructions of the warnings.

Table 1-1

Types and Meanings of Warnings

Symbol Meaning

Indicates that there is a high risk of death or severe injury if it is not avoided.

Indicates that there is a potential risk of death or severe injury if it is not avoided.

Indicates that there is a risk of light or medium injury if it is not avoided.

Indicates that there is a potential risk of property damage if it is not avoided.

2203M4JE-MY-iS2-N_2017.04.

Chapter 1 Safety

Screw Compressor i-series 1.3 Residual Risks

1-4

1.3 Residual Risks

The following inform ation assumes that this pr oduct is operated or i nspected/maintained as part of a general package unit for refrigeration/cold storage. It is impossible to predict all the risk sources involved in actual use of the package unit.

Devise appropriate countermeasures for hazardous sources in your systems.

Table 1-2

Hazardous Sources

Hazardous

sources

Predicted hazard

Measures to be taken

in operation

Countermeasures in

cleaning, inspection,

and parts replacement

Motor and

compressor coupling

 Caught in or entangled in

due to contact

 Install cover on the

opening of coupling, or 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

suction casing

 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

economizer and/or liquid injection port around and

piping

 Burn injury due to contact

Contact with or inhalation of hazardous substances generated by leakage or spout of refrigerant or the

 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.

Compressor

discharge casing and discharge piping

 Burn injury due to contact

Contact with or inhalation of hazardous substances generated by leakage or spout of refrigerant or the

 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.

Solenoid valve

for controlling compressor capacity

 Electric shock caused by

contact with live wires or electrical leakage

 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

Check valve, service valve and joint in each section

 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

Package Unit

Solenoid valve or motor operated valve

 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.

2203M4JE-MY-iS2-N_2017.04.

Chapter 1 Safety

Screw Compressor i-series 1.3 Residual Risks

1-5

Hazardous

sources

Predicted hazard

Measures to be taken

in operation

Countermeasures in

cleaning, inspection,

and parts replacement

Package Unit

Electric components in each part (oil heater, protective device, 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 drain

 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.

—

i125L with Spacer for NEMA i160L with Spacer for NEMA (example) (example)

Figure 1-1 Locations of Hazardous sources (Compressor)

2203M4JE-MY-iS2-N_2017.04.

Chapter 1 Safety

Screw Compressor i-series 1.4 Safety Devices

1-6

1.4 Safety Devices

For safe use and protection of this produc t, make sure to attach safet y devices to this produc t 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/inspectio n 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 this

product. If they do not operat e normally, immediately take countermeasures.

1.4.1 Emergency Stop Button



Overview/Function/Purpose

The emergency stop buttons are used for emergency shutdown of this product when an emergency situation arises.



Installation Positions

On the control board 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 operatin g c ondit io n, must be clearly defined and the inf ormation provided to the user of this product.



Inspection Method/Interval

The emergency stop buttons mus t be tested befor e commissioning a nd must also be periodicall y 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 Circuit 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 an y possibility of danger during work (especially during cle aning, maintenance, inspection, or tr oubleshooting), lockout/tagout devices must be used on the br eak ers of the m ain m otor and cont rol po wers t o prevent injuries to work ers 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 Safet y & Health Administration (OSHA) or local governing body.



Inspection Method/Interval

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.

2203M4JE-MY-iS2-N_2017.04.

Chapter 1 Safety

Screw Compressor i-series 1.4 Safety Devices

1-7

1.4.3 Compressor Protective Devices

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

the commissioning.

Install necessary protection devices shown in section 2.3.3 "Alarm Set Values" in this manual chapter 2. Also, install the following protection devices that are not indicate in section 2.3.3, as occasion demands.

• Protection from motor over current (OCR) This device activates an d applies appropr iate contro l when the c urrent e qual to or higher t han

the set level flows. In some cases, this device stops the compressor operation. For more information about setting and installation of this device, please refer to the instruction

manual of the motor.

• Protection from oil level decrease In case of the oi l supp ly by different ial pr essure, install a prot ection device to the oil separator

for protect form oil level decrease. Since there is a possibility that alarm for protection from lubricating differential press ure decr ease do es not act ivat e even if the amount of lubricat ing oil is insufficient.

• No Water Alarm If you use water cooling oil cooler and/or water cooling condenser, a suspension of water

supply protection is necessary. For more inform ation about setting and install ation of this protectio n d ev ice, pl eas e r ef er to the

instruction manual of the motor or the like used in the cooling water system.



Connection Positions and Settings

Specify the connection position and set ting f or e ach co m pressor protecti ve de vice, an d m ake s ure to provide users of this product with them.



Inspection Method/Interval

Compressor protect ive devices require operat ion tests and co nfirmation of the settings c alibration before commissioning as well as at regular intervals.

Specify the inspect ion methods/inter vals of the com pressor protect ion devices, and m ake sure to provide users of this product with such information.

 In the operation test, check that alarms and switches 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 oil pressure (OP) or high pressure (HP) activates, do not restar t

operation until the cause of activation is remove d.

2203M4-JE-MY-iS2-N_2017.04.

Chapter 2 Compressor Specifications and Configuration

Screw Compressor i-series 2.1 Features of i-Series Compressor

2-1

Chapter 2 Compressor Specif i c a t ions and Configuration

2.1 Features of

i-series Compressor

i-series compressor enables designers to design highly reliable and most compact refrigerating unit. It has a lot of features.



Centering is made unnecessary by mounting the motor using a flange.

By mounting the motor using a flange eliminates the need of the troublesome motor centering before starting the equipment.



Suction strainer and check valve built-in compressor

This compressor has built-in suction strainer and check valve which enable easy maintenance.



No oil pump required in differential pressure oil supply system

This compressor em ploys roller bearings which let lubrication oil res erved in part even when the machine is stopped. Ac cordingly, no lubrication failure will occur ev en with differential press ure oil supply system which has no oil pump installed.



3-step (100%, 75%, 50%) unloader

As it has a 3-step (100%, 75%, 50%) unloader built-in, flow adjustment can be done easily. In addition, inverter-controlled speed control is available.



High efficiency, and low vibration and noise

Use of original screw rotor profile attains high efficiency, and low vibration and noise.

2.2 Model Designation of the Compressor

This manual describes i125*-* and i160*-* models. The meaning of the type designation, which is engraved on the MODEL column of the compressor nameplate, is as follows.

i 1 2 5 * - *

Specifications of Vi (volume ratio) of the discharge port, which is L (Vi=2.63), M (Vi=3.65)

or H (Vi=5.80)

Specifications of rotor length, which is S or L (i125) and S, M or L (i160) Rotor diameter, which is 125 or 160 Indicates i-series.

2203M4-JE-MY-iS2-N_2017.04.

Chapter 2 Compressor Specifications and Configuration

Screw Compressor i-series 2.3 Compressor Specifications

2-2

2.3 Compressor Specifications

2.3.1 Standard Specifications

Table 2-1 Specifications of i-series Compressor

Items

Model

i125S

i125L

i160S

i160M

i160L

Flange motor connection

NEMA — 3**C, 40*C 3**D, 4**D IEC — FF400 FF500 FF500 / FF600

Product mass (Compressor only)

330 350 520 560 600

Mass of

compressor with motor spacer

for NEMA

490 510 670 710 750

for

IEC

FF400

440 — — — —

FF500

kg — 480

630

670

710

FF600

kg — —

660

700

740

Standard speed 50Hz/60Hz min-1 2950/3550 Rotation direction — Clockwise as viewed from motor

Swept volume 50Hz/60Hz

m3/h

197/237

296/356

415/499

519/624

622/749

CFM 116/139 174/210 244/294 305/367 366/441

Refrigerant

—

R717 / R404A / R507A / R134a

Design pressure *Note MPa

2.6

(Applies to i-series compressors manufactured

and shipped in May 2014 or after.)

Capacity control — 3-step (100%, 75%, 50%) unloader

Connected pipe size

Suction flange —

MYCOM 100A (4")

ANSI ＃300 5"

Discharge flange

—

MYCOM 65ACD ANSI ＃300 3"

Oil inlet port

— Rc1/2 MYCOM 65A

Economizer — Rc3/8 Rc3/4

Aquamizer (Liquid injection)

— Rc1/4 Rc1/2



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



For limits of working temperature and pressure, see Section 2.3.2 "Operation Limits" in this

Chapter.

*Note: The design pressure varies according to each area, laws and ordinances of the country. The design pressure of this list is the maximum value of the compressor. Therefore, the

real design pressure may become less than this value according to the law. Please confirm real pressure on a name plate and individual specifications.

2203M4-JE-MY-iS2-N_2017.04.

Chapter 2 Compressor Specifications and Configuration

Screw Compressor i-series 2.3 Compressor Specifications

2-3

2.3.2 Operation Limits

Table 2-2 Operation Limits of i-series Compressor

Item

Normal operation range

*Note 1

Permissible limit

Speed

min-1

2950 @50 Hz 3550 @60 Hz

125S, 160S: Max. 4500 *Note 2 125L, 160M, 160L : Max. 3550

Discharge pressure

MPa

1.0 to 1.9 Max. 1.9

Suction pressure

MPa

0.02 to 0.35

Max. 0.6 Min. -0.05

Differential pressure for lubrication (Po - Ps)

*Note3

MPa

≥ 0.5 Min. 0.5 *Note 4

Discharge gas temperature

°C

Condensing temperature +

15 to 90

Max. 90

Superheating degree of suction gas

°C

5 to 20 —

Oil supply temperature

°C

30 to 60

Max. 80 BBSE

*Note 2

Min. 30

Supply oil viscosity

(kinematic viscosity)

mm2/s

13 to 40

Min. 13

Max. 300 (At start-up time)

Vibrat ion standar d value at

shipment

μm

(Half amplitude) 20 —

Noise standard value at

shipment

dB (A)

125S, L, 160S, M: 84

160L: 85

—



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

*Note 1: For operations outside the normal operation ranges, consult our compressor manufacturing

division.

*Note 2: When performing a speed-increasing operation by inverter at 70 °C or a bove oil temperature,

contact our compressor manufacturing division to confirm the temperature on the mechanical seal sliding surface.

*Note 3: Po = Oil supply pressure, Ps = Suction pressure *Note 4: This value excludes the start-up of the compressor. Refer to Note 2 in the next section.

 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 mi nutes after sto pping the compressor before restarting i t .

2203M4-JE-MY-iS2-N_2017.04.

Chapter 2 Compressor Specifications and Configuration

Screw Compressor i-series 2.3 Compressor Specifications

2-4

2.3.3 Alarm Set Values

To protect the compressor, please set the alarm shown in the table below.

Table 2-3 Application Limits of i-series Compressor *

Note 1

Item

Unit Alarm

Stop

Rotation speed min-1

High

—

i125S, i160S: 4550 (0 sec.)

i125L, i160M, i160L: 3650 (0 sec.)

Low — 1450 (0 sec.)

Discharge pressure MPa

High

1.9 (0 sec.)

2.0 (0 sec.)

Low — —

Suction pressure MPa

High

0.6 (30 sec.)

0.6 (60 sec.)

Low -0.05 (30 sec.) -0.05 (60 sec.)

Differential pressure for lubrication

(Po - Ps) *Note 2

MPa

High — —

Low 0.6 (30 sec.) 0.5 (30 sec.) *Note 3

Discharge temperature °C

High

90 (5 sec.)

95 (0 sec.)

Low — —

Suction temperature °C

High

60 (60 sec.)

—

Low -58 (30 sec.) -60 (30 sec.)

Discharge superheat °C

High — —

Low 15 (60 sec.) 10 (60 sec.)

Suction superheat °C

High —

—

Low 0 (30 sec.) 0 (60 sec.)

Lubrication temperature °C

High

80 (60 sec.)

85 (60 sec.)

Low 30 (60 sec.) 25 (60 sec.)



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

*Note 1: The values in the parentheses are the maximum operation delay times.

The values have been set to protect the compressor.

*Note 2: Po = Oil supply pressure, Ps = Suction pressure

*Note 3: This alarm stop is set for normal operation. At the time of the start-up of the compressor,

it is not necessary to perform this alarm monitoring after start until 300 seconds.

2203M4-JE-MY-iS2-N_2017.04.

Chapter 2 Compressor Specifications and Configuration

Screw Compressor i-series 2.3 Compressor Specifications

2-5

2.3.4 Outer Dimensions

Figure

2-1 i125S Outer Dimensions with a Spacer for Flange Motor (NEMA)

2203M4-JE-MY-iS2-N_2017.04.

Chapter 2 Compressor Specifications and Configuration

Screw Compressor i-series 2.3 Compressor Specifications

2-6

Figure

2-2 i125S Outer Dimensions with a Spacer for Flange Motor (IEC FF400)

2203M4-JE-MY-iS2-N_2017.04.

Chapter 2 Compressor Specifications and Configuration

Screw Compressor i-series 2.3 Compressor Specifications

2-7

Figure

2-3 i125L Outer Dimensions with a Spacer for Flange Motor (NEMA)

2203M4-JE-MY-iS2-N_2017.04.

Chapter 2 Compressor Specifications and Configuration

Screw Compressor i-series 2.3 Compressor Specifications

2-8

Figure

2-4 i125L Outer Dimensions with a Spacer for Flange Motor (IEC FF500)

2203M4-JE-MY-iS2-N_2017.04.

Chapter 2 Compressor Specifications and Configuration

Screw Compressor i-series 2.3 Compressor Specifications

2-9

Figure

2-5 i160S Outer Dimensions with a Spacer for Flange Motor (NEMA)

2203M4-JE-MY-iS2-N_2017.04.

Chapter 2 Compressor Specifications and Configuration

Screw Compressor i-series 2.3 Compressor Specifications

2-10

Figure

2-6 i160S Outer Dimensions with a Spacer for Motor Flange (IEC FF500)

2203M4-JE-MY-iS2-N_2017.04.

Chapter 2 Compressor Specifications and Configuration

Screw Compressor i-series 2.3 Compressor Specifications

2-11

Figure

2-7 i160S Outer Dimensions with a Spacer for Flange Motor (IEC FF600)

2203M4-JE-MY-iS2-N_2017.04.

Chapter 2 Compressor Specifications and Configuration

Screw Compressor i-series 2.3 Compressor Specifications

2-12

Figure

2-8 i160M Outer Dimensions with a Spacer for Flange Motor (NEMA)

2203M4-JE-MY-iS2-N_2017.04.

Chapter 2 Compressor Specifications and Configuration

Screw Compressor i-series 2.3 Compressor Specifications

2-13

Figure

2-9 i160M Outer Dimensions with a Spacer for Motor Flange (IEC FF500)

2203M4-JE-MY-iS2-N_2017.04.

Chapter 2 Compressor Specifications and Configuration

Screw Compressor i-series 2.3 Compressor Specifications

2-14

Figure

2-10 i160M Outer Dimensions with a Spacer for Flange Motor (IEC FF600)

2203M4-JE-MY-iS2-N_2017.04.

Chapter 2 Compressor Specifications and Configuration

Screw Compressor i-series 2.3 Compressor Specifications

2-15

Figure

2-11 i160L Outer Dimensions with a Spacer for Flange Motor (NEMA)

2203M4-JE-MY-iS2-N_2017.04.

Chapter 2 Compressor Specifications and Configuration

Screw Compressor i-series 2.3 Compressor Specifications

2-16

Figure

2-12 i160L Outer Dimensions with a Spacer for Flange Motor (IEC FF500)

2203M4-JE-MY-iS2-N_2017.04.

Chapter 2 Compressor Specifications and Configuration

Screw Compressor i-series 2.3 Compressor Specifications

2-17

Figure

2-13 i160L Outer Dimensions with a Spacer for Flange Motor (IEC FF600)

2203M4-JE-MY-iS2-N_2017.04.

Chapter 2 Compressor Specifications and Configuration

Screw Compressor i-series 2.4 Configuration of Compressor

2-18

2.4 Configuration of Compressor

2.4.1 Sectional Views

Figure

2-14 i125L Longitudinal Sectional View

2203M4-JE-MY-iS2-N_2017.04.

Chapter 2 Compressor Specifications and Configuration

Screw Compressor i-series 2.4 Configuration of Compressor

2-19

Figure

2-15 i125L Cross-Sectional View

2203M4-JE-MY-iS2-N_2017.04.

Chapter 2 Compressor Specifications and Configuration

Screw Compressor i-series 2.4 Configuration of Compressor

2-20

Figure 2-16

i125* Longitudinal Sectional View of Suction/Capacity Control Section

2203M4-JE-MY-iS2-N_2017.04.

Chapter 2 Compressor Specifications and Configuration

Screw Compressor i-series 2.4 Configuration of Compressor

2-21

Figure

2-17 i160S Longitudinal Sectional View

2203M4-JE-MY-iS2-N_2017.04.

Chapter 2 Compressor Specifications and Configuration

Screw Compressor i-series 2.4 Configuration of Compressor

2-22

Figure

2-18 i160S Cross-Sectional View

2203M4-JE-MY-iS2-N_2017.04.

Chapter 2 Compressor Specifications and Configuration

Screw Compressor i-series 2.4 Configuration of Compressor

2-23

Figure 2-19

i160* Longitudinal Sectional View of Suction/Capacity Control Section

2203M4-JE-MY-iS2-N_2017.04.

Chapter 2 Compressor Specifications and Configuration

Screw Compressor i-series 2.4 Configuration of Compressor

2-24

2.4.2 Exploded Views

Figure 2-20

Exploded View of i125S/L Parts with Motor Spacer

2203M4-JE-MY-iS2-N_2017.04.

Chapter 2 Compressor Specifications and Configuration

Screw Compressor i-series 2.4 Configuration of Compressor

2-25

Figure 2-21

Exploded View of i160S/L Parts with Motor Spacer

2203M4-JE-MY-iS2-N_2017.04.

Chapter 2 Compressor Specifications and Configuration

Screw Compressor i-series 2.4 Configuration of Compressor

2-26

2.4.3 Parts Configuration Table

Table 2-4 i125S/L Parts Configuration Table

P/N Part name Code No. Remarks Qty

Main Rotor Casing

－

i125S-* port

S:1

Main Rotor Casing

－

i125L-* port

L:1

2-1 Hexagon Socket Head Cap Screw NB35412-050 M12×50 SCM435 45

2-2

Hexagon Socket Head Cap Screw

NB35412-035

M12×35 SCM435

Alignment Pin NE242A13-050A

Φ13×50 with internal thread

and slot

Alignment Pin NE242A13-050A

Φ13×50 with internal thread and slot for Motor

Spacer

4-1

Eye Bolt

NB600-16

M16 3 4-2

Eye Bolt

NB600-20

M20 1 4-3

Eye Bolt

NB600-30

M30 1 5-1

Suction Adapter －

i125

5-2

Strainer Cover

CS00510-I125

i125 1 6-1

Gasket, Suction Adapter

CS00600-I125

i125 t=0.5

6-2

Gasket, Strainer Cover

CS00900-I125

i125 t=0.5

1 7 O-ring

PA12-140

JIS B 2401 G140

10-1

Hexagon Socket Head Cap Plug

NF06-004

R1/8 S45C

10-2

Hexagon Socket Head Cap Plug

NF06-008

R1/4 S45C

10-3

Hexagon Socket Head Cap Plug

NF06-010

R3/8 S45C

S:6 L:5

10-4

Hexagon Socket Head Cap Plug

NF06-015

R1/2 S45C

Bearing Head

CS01100-I125

i125 1 12

Gasket, Bearing Head

CS01200-I125

i125 t=0.5

Bearing Cover －

i125 1 17

Gasket, Bearing Cover

CS01700-I125

i125 t=0.5

18-1

Hexagon Socket Head Cap Screw

NB35416-055

M16×55 SCM435

Spring Pin

NE3203-008

Φ3×8

End Cover

CS02200-I125

i125 1 23

Gasket, End Cover

CS02300-I125

i125 t=1.0

Male Rotor －

i125SM/SF FCD S:1set

Female Rotor

－

Male Rotor

CS02500-I125L (M,F ASSY)

i125LM/LF FCD L:1set

Female Rotor

27-1

Radial Bearing

CS02800-FM125M

NU2308ET7

27-2

Radial Bearing

CS02800-FM125F

NU2309ET7

29-1

Snap Ring

NG11-090

H90 C type-Internal

29-2

Snap Ring

NG11-100

H100 C type-Internal

29-3

Snap Ring

NG12-040

S40 C type-External

Balance Piston

CS03000-I125

i125

Slotted Set Screw

NA14708-016

FM160 (M8×16)

Snap Ring

NG12-045

S45 C type-External

2203M4-JE-MY-iS2-N_2017.04.

Chapter 2 Compressor Specifications and Configuration

Screw Compressor i-series 2.4 Configuration of Compressor

2-27

P/N Part name Code No. Remarks Qty

Sleeve, Balance Piston

CS03300-I125

i125

Spring pin

NE3206-015

FM160 (Φ6×15)

O-ring

PA11-016

JIS B 2401 P16

38-1

Thrust Bearing M

CS03800-I125MP

Shared with i125M,FM11S

38-2

Thrust Bearing F

CS03800-125FP

Shared with i125F,125

39-1

Lock Nut

NG31-008

AN8 1 39-2

Lock Nut

NG31-009

AN9

40-1

Lock Washer

NG32-008

AW8 1 40-2

Lock Washer

NG32-009

AW9 1 41-1

Spacer, Thrust Bearing Outer Race M

CS25000-FM11S

FM11S Thrust Washer

41-2

Spacer, Thrust Bearing Outer Race F

CS04100-I125F

i125F

42-1

Spacer, Thrust Bearing Alignment M

CS04200-I125M

i125M

42-2

Spacer, Thrust Bearing Alignment F

CS04200-125

125***

43-1

Thrust Bearing Gland M

CS04300-I125M

i125M

43-2

Thrust Bearing Gland F

CS04300-I125F

i125F 1 45

Hexagon Head Bolt

NB111008-035

M8X35-10.9 SCM435

Spring Was her

ND320-008

Retainer, Oil Seal

CS04800-125

125*** 1 49

O-ring

PA12-085

JIS B 2401 G85

Oil Seal

CS05000-125D

125*** Rareflon

51 Seal Cover CS05100-125BBS

Shared with 125*** seal pot

specifications

Gasket, Seal Cover

CS05200-125N

125*** 1 53

Hexagon Socket Head Cap Screw

NB35406-020

M6×20 SCM435

Hexagon Socket Head Cap Screw

NB35408-030

M8X30 SCM435

Coupling Key

CS09100-125

125L** 1 92

Suction Flange with hole

CS74000-100

MYK 100A (Male)

Suction Cover Flange

CS71400-P100

MYK 100A(Male)

Gasket, Suction Flange

CR72000-100N

MYK 100A

Hexagon Head Bolt, Suction Flange

NB12022-060

M22×60 SCM435

S:4 L:8

Discharge Flange with hole

CS71400-065CDMK

MYK 65CD (Male)

235

Discharge Flange Spacer

FX101-125

65CD for 125

236

Gasket, Suction Flange Spacer

CS23600-125N

65CD for 125

Gasket, Discharge Flange

CS23600-125N

MYK 65CD

Hexagon Head Bolt, Discharge Flange

NB12016-045

M16×45 SCM435

S:4 L:8

100

Mechanical Seal Assembly

CS10002-125EBS

BBSE 125***

1set

235-1

Motor Spacer

－

for NEMA Motor Flange

CS23500-I125IEC40

for IEC FF400

CS23500-I125IEC50

for IEC FF500

235-2

Plate, Motor Spacer

CS23510-I125

i125

－

for IEC FF400 (1), (2)

－

for IEC FF500 (1), (2)

235-3

Hexagon Socket Head Cap Screw

NB35406-010

M6×10 SCM435

237-1

Torsional Slip Washer M

CS23700-FM125M

FM125 M

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Chapter 2 Compressor Specifications and Configuration

Screw Compressor i-series 2.4 Configuration of Compressor

2-28

P/N Part name Code No. Remarks Qty

237-2

Torsional Slip Washer F

CS23700-125

125L**

250-1

Thrust Washer M CS04200-I125M

i125M Spacer, thrust bearing alignment

250-2

Thrust Washer F

CS25000-125

125***

391 Unloader Piston CS39100-I160 i160* 2

392

Spring

CS39200-F125

FM125

393

Unloader Cover

CS39300-I160

i160* 2 395

Gasket, Unloader Cover

CS39500-I160

i160*

480

Strainer Element

CS48000-I160

i160* 1 481

Retainer, Strainer Element

CS48100-I125

i125

482

Hexagon Socket Head Cap Screw

NB35406-015

M6×15 SCM3

485

Check Valve Spring

CS48500-F125

FM125

486

Hexagon Nut

NC622-10

U-NUT M10

487

Plain Washer ND193-10

JISB1256 small-sized, round-shaped 10-22H

488-1

Seat Stopper (1)

CS48800-F125

FM125

488-2

Seat Stopper (2)

CS48800-F1252

FM125

489

Valve Seat

CS48900-I125

i125 1 490

Valve Plate

CS49000-I125

i125

491

Check Valve Shaft

CS49100-I125

i125 1 495

O-ring

PA11-007

JIS B 2401 P7

533 Solenoid Valve

KF711-XOF1

SPOLAN XOF-120V

KF711-XOF2

SPOLAN XOF-240V

534

Nipple (High Pressure)

NN410-080

R3/8 Sch40 80L

535

Connection (L-type)

NJ3-0803NE

L-Φ8-R3/8 JO4060

536

Connection (L-type)

NJ3-0802KNNT

L-Φ8-R1/4 JO4050

538

Piping

QA11-08

Φ8 STS

546

Wave Washer

ND91-016

FM125 BW16

555

Angle Valve

NF042-0302N

R1/4×Rc1/4

795

Cover Plate, Discharge Flange

CS71500-I1251

i125 4.5x84D

１

795

Cover Plate, Suction Flange

CS71500-I1252

i125 4.5x123D

１

 The part code of the O-ring is the one assigned to NBR-70-1 which is standard

material. When the material of the O-ring is other than NBR, a different part code is used for each material. If you are using O-rings made from other than the standard material, please contact MAYEKAWA when pl acing an order.

2203M4-JE-MY-iS2-N_2017.04.

Chapter 2 Compressor Specifications and Configuration

Screw Compressor i-series 2.4 Configuration of Compressor

2-29

Table 2-5 i160* Parts Configuration Table

P/N

Part name Code No. Remarks

Qty

Main Rotor Casing

－

i160S-* port (L, M, H)

S:1

Main Rotor Casing

－

i160M-* port (L, M, H)

M:1

Main Rotor Casing

－

i160L-* port (L, M, H)

L:1

Hexagon Socket Head Cap Screw

NB35416-055

M16×55 SCM435

3 Alignment Pin NE242A13-050A

13×50L With internal thread and slot

3 Alignment Pin NE242A13-050A

13×50L With internal thread and slot for Motor Spacer

4-1

Eye Bolt

NB600-12

M12 3 4-2

Eye Bolt

NB600-24

M24 1 4-3

Eye Bolt

NB600-24

M24 1 5

Strainer Cover

CS00500-I160

i160

Gasket, Strainer Cover

CS00900-I160

i160 t=0.5

7-1

O-ring

PA12-150

JIS B 2401 G150

7-2

O-ring

PA12-140

JIS B 2401 G140

Check Valve Cover

CS00800-I160

i160 1 10-1

Hexagon Socket Head Cap Plug

NF06-004

R1/8 S45C

10-2

Hexagon Socket Head Cap Plug

NF06-008

R1/4 S45C

10-3 Hexagon Socket Head Cap Plug NF06-010 R3/8 S45C

S,L:3

M:4

10-4 Hexagon Socket Head Cap Plug NF06-015 R1/2 S45C

S, L:15

M:14

10-5

Hexagon Socket Head Cap Plug

NF06-020

R3/4 S45C

10-6

Hexagon Socket Head Cap Plug

NF06-025

R1 S25C

Bearing Head

CS01100-I160

i160 1 12

Gasket, Bearing Head

CS01200-I160

i160 t=0.5

Bearing Cover

CS01600-I160

i160 1 17

Gasket, Bearing Cover

CS01700-I160

i160 t=0.5

18-1

Hexagon Socket Head Cap Screw

NB35412-040

M12×40 SCM435

Spring Pin

NE3203-010

3×10L

End Cover

CS02200-I160N

i160 1 23

Gasket, End Cover

CS02300-I160N

i160 t=1.0

25 Male Rotor

－

i160SM/SF FCD S:1set

26 Female Rotor －

Male Rotor

－

i160MM/MF FCD M:1set

26 Female Rotor

－

25 Male Rotor －

i160LM/LF FCD L:1set

Female Rotor

－

27-1

Radial Bearing M

CS02800-FM160M

NU2311ET7

27-2

Radial Bearing F

CS02800-FM160FCT

NU2312ET7

29-1

Snap Ring

NG11-120

H120 C type-Internal

29-2

Snap Ring

NG11-130

H130 C-type-Internal

29-3

Snap Ring

NG12-060

S60 C type-External

30 Balance Piston CS03000-I160 i160 1

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Chapter 2 Compressor Specifications and Configuration

Screw Compressor i-series 2.4 Configuration of Compressor

2-30

P/N

Part name Code No. Remarks

Qty

Balance Piston (LT) CS03300-FM160LT

Special part for FM160 For H-port

Slotted Set Screw

NA14708-016

FM160 (M8×16)

Snap Ring

NG12-055

S55 C type-External

Sleeve, Balance Piston

CS03300-I160

i160

33 Sleeve, Balance Piston (LT)

CS03300-FM160LT

Special part for FM160 For H-port

Spring pin

NE3206-015

FM160 (6×15L)

O-ring

PA11-024

JIS B2401 P24

38-1

Thrust Bearing M

CS03800-FM160P

7311B Shared with FM160

38-2

Thrust Bearing F

CS03800-160P

7312B Shared with 160

39-1

Lock Nut

NG31-011

AN11

39-2

Lock Nut

NG31-012

AN12

40-1

Lock Washer

NG32-011

AW11

40-2

Lock Washer

NG32-012

AW12

41-1

Spacer, Thrust Bearing Outer Race M

CS04100-I160M

i160 M

41-2

Spacer, Thrust Bearing Outer Race F

CS04100-I160F

i160 F

42-1

Spacer, Thrust Bearing Alignment M

CS04200-I160M

i160 M

42-2

Spacer, Thrust Bearing Alignment F

CS04200-I160F

i160 F

43-1

Thrust Bearing Gland M

CS04300-I160M

i160 M

43-2

Thrust Bearing Gland F

CS04300-I160F

i160 F 1 45

Hexagon Socket Head Cap Screw

NB35410-050

M10×50 SCM435

46-1 Conical S pri ng Was her ND150-10

46-2 Plain Washer

ND193-10

JIS B 1256 Small-sized, round-type 10-22H

Retainer, Oil Seal

CS04800-160

160***

O-ring

PA12-090

JIS B 2401 G90

Oil Seal Rareflon

CS05000-160VD

160*** (S55×70×9)

Seal cover

CS05100-160

160***

Gasket, Seal Cover

CS05200-160N

160*** t=0.5

Hexagon Socket Head Cap Screw

NB35408-030

M8×30 SCM435

Coupling Key

CS09100-160

160*** single round12×8×75

Suction Flange with hole

NX2381-125MK

ANSI #300 5"

Suction Cover Flange

CZA01-300C05B

ANSI #300 5"

Gasket, Suction Flange

PL300-125

ANSI #300 5"

94-1

Stud Bolt (Suction Side)

NBU703/4-103

3/4-10UNC 103L

94-2

Hex Nut (Suction / Discharge)

NCU1503/4-10UNC

3/4-10UNC

Discharge Flange with hole

NX2381-080MK

ANSI #300 3"

Discharge Cover Flange

CZA01-300C03B

ANSI #300 3"

Gasket, Discharge Flange

PL300-080

ANSI #300 3"

Stud Bolt (Discharge Side)

NBU603/4-10UNC

3/4-10UNC

100

Mechanical Seal Assembly

CS10002-160EBS

160V BBSE

1set

150-1

O-ring, Thrust Bearing Gland M

PA12-110

JIS B 2401 G110

150-2

O-ring, Thrust Bearing Gland F

PA12-115

JIS B 2401 G115

2203M4-JE-MY-iS2-N_2017.04.

Chapter 2 Compressor Specifications and Configuration

Screw Compressor i-series 2.4 Configuration of Compressor

2-31

P/N

Part name Code No. Remarks

Qty

216-1

Flange with hole , Oil Inlet Port

CR74000-025

MYCOM 25A (Male)

216-2

Flange Gasket, Oil Inlet Port

CR72000-025N

MYCOM 25A

216-3

Hexagon Head Bolt

NB35412-035

M12×35 SCM435

216-4 Cover Plate (for Airtight/Pressure Test) CS71500-025

MYCOM 25A Attached at shipment.

235-1 Motor Spacer

CS23500-I160N for NEMA Motor Flange

CS23500-I160IEC50

for IEC FF500

CS23500-I160IEC60

for IEC FF600

235-2 Plate, Motor Spacer

CS23510-FM160

NEMA Motor Flange Spacer

FF500 Motor Flange Spacer

FF600 Motor Flange Spacer

235-3

Hexagon Socket Head Cap Screw

NB35406-010

M6×10 SCM435

235-4

Hexagon Socket Head Cap Screw

NB35416-055

M16×55 SCM435

237-1

Torsional Slip Washer M

CS23700-FM160M

FM160

237-2

Torsional Slip Washer F

CS23700-160

160***

250-1

Thrust Washer M

CS25000-FM160M

FM160

250-2

Thrust Washer F

CS25000-160

160*** Thrust washer

391

Unloader Piston

CS39100-I160

i160 2 392

Spring

CS39200-F125

FM125

393

Unloader Cover

CS39300-I160

i160

395

Gasket, Unloader Cover

CS39500-I160

i160 t=1.0

Hexagon Socket Head Cap Screw

(common to No.58)

NB35408-030 M8×30 SCM435 12

480

Strainer Element

CS48000-I160

i160 #150 Φ160×200

481

Retainer, Strainer Element

CS48100-I160

i160

485

Check Valve Spring

CS48500-I160

i160 1 486

Hexagon Nut

NC622-10

FM160(U-NUT M10)

487

Plain Washer

ND193-10

Small-sized SPCC1 M10

488

Seat Stopper

CS48800-I160

i160 1 489

Valve Seat

CS48900-I160

i160 1 490

Valve Plate

CS49000-I160

i160

491

Check Valve Shaft

CS49100-I160

i160 1 495

O-ring

PA11-007

JIS B 2401 P7

533 Solenoid Valve

KF711-XOF1

SPORLAN XOF-120V

KF711-XOF2

SPORLAN XOF-240V

534

Nipple (High Pressure)

NN410-100

Rc3/8×100L Sch40

535

Connection (L-type)

NJ3-0803NE

L-Φ8-R3/8 JO4060

536

Connection (L-type)

NJ3-0802KNNT

L-Φ8-R1/4 JO4050

538

Piping

QA1802-08

Φ8 STS

550 Check Union KD122-12E I-Φ12-R3/8

L: 2

S, M: 1

551 Connection (I-type) NJ2-1203NE I-Φ12-R3/8 JO4570

L: 2

S, M: 1

552

Piping

QA1802-12

Φ12 STS

2203M4-JE-MY-iS2-N_2017.04.

Chapter 2 Compressor Specifications and Configuration

Screw Compressor i-series 2.4 Configuration of Compressor

2-32

P/N

Part name Code No. Remarks

Qty

553

Chuck Union

KD122-10E

I-Φ10-R1/4 KZC10-050E

554

Angle Valve

NF067-02

TC-1 R1/4×Rc1/4

555

Angle Valve

NF067-03

TC-1 R3/8×Rc1/4

556

Connection (I-type)

NJ2-1003NE

I-Φ10-R3/8

557

Piping

QA1802-10

Φ10 STS

558

Hexagon Bushing

NF031-0403

JO5007 R1/2×Rc3/8

559

Hose Nipple

NN5102-050

8A×50

795

Cover Plate, Discharge Flange

CS71500-I1601 i160 4.5x146D １

794 Cover Plate, Suction Flange

CS71500-I1602 i160 4.5x213D １

 The part code of the O-ring is the one assigned to NBR-70-1 which is standard

2203M4-JE-MY-iS2-N_2017.04.

Chapter 2 Compressor Specifications and Configuration

Screw Compressor i-series 2.5 Mechanisms

2-33

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 2-22, the ref rigerant (g as) is contin uousl y com press ed by the 3-dim ens ional space s 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 protr uding lobe profiles is called a male or M rotor, and the rotor having 6 c oncave profiles is called a female 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 2-22

Compressor Mechan ism

2.5.2 Suction Process

As shown in Figure 2-23, the rotors with different lobe profiles are engaged. As the rotors turn, the volume between the M and F rotor lobe profiles and the com press or cas ing graduall y increas es 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

2-23 Suction Process

2203M4-JE-MY-iS2-N_2017.04.

Chapter 2 Compressor Specifications and Configuration

Screw Compressor i-series 2.5 Mechanisms

2-34

2.5.3 Compression Process

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

2.5.4 Discharge Process

The volume between the r o tor lobes decreases t o a le ve l pre det er mined by the dischar ge p ort. 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) are indicated in property tables or catalogs by using port symbols L, M and H. The volume ratio represented by each symbol ( screw compressor) is as follows: L=2.63, M=3.65, H=5.80.

Volume of suctioned refrigerant gas immediately before the start of compression

Vi = Volume of refrigerant gas just before pushed

out to discharge port

Decide which volume ratio (L, M or H ) should be used 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:

(Vi）κ＝ πi ＝ Pｄ/Ps κ = Cp/Cv of refrigerant gas Vi = Design volume ratio πi = Design compression ratio

Vi is related to the specific heat ratio (κ) and therefore its value relative to the compression ratio varies depending on the type of refrigerant gas.

Figure 2-24 Compression Process

Figure 2-25 Discharge Process

Figure 2-26 Volume Ratio

2203M4-JE-MY-iS2-N_2017.04.

Chapter 2 Compressor Specifications and Configuration

Screw Compressor i-series 2.5 Mechanisms

2-35

(A) Properly adapted Vi to load condition

Both the required compr es sion ratio and Vi are low. Both the required compression ratio and Vi are high.

(B) Improperly adapted Vi to load c on dition

Too low Vi compare d with necessary compr es sion ra t io. Too high Vi compared with necessary compr es sion ra tio

Figure 2-27 Relationship between Volume ratio (Vi) and Operation Conditions

2203M4-JE-MY-iS2-N_2017.04.

Chapter 2 Compressor Specifications and Configuration

Screw Compressor i-series 2.5 Mechanisms

2-36

2.5.6 Capacity Control Mechanism

The capacity control of i-series com pr essor can be co ntrol led in t hree steps of 50%, 75% and 100% via the unloader piston installed at each male rotor side and female rotor side in the main rotor casing.

Each unloader piston controlled by solenoid valve.

Figure 2-28 Capacity Control Mechanism

Table 2-6 Control of Solenoid V alves for Capacity Control

A B

100% ON (Opened) ON (Opened)

75% OFF (Closed) ON (Closed) 50% OFF (Closed) OFF (Closed)

Standstill

(50%)

OFF (Closed) OFF (Closed)

No. Description

①

Female Rotor

②

Male Rotor

③

Unloader Piston

④

Piping

Solenoid Valve

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Chapter 2 Compressor Specifications and Configuration

Screw Compressor i-series 2.5 Mechanisms

2-37



Solenoid Valve for Capacity Control

Table 2-7 Specifications of the Solenoid Valves

Item

Solenoid Valve

SX07-03GN

(Japan domestic)

SPORLAN XOF

(Foreign)

Coil ratings Volts

AC V

100, 200

120, 208 to 240

DC V — 24

Watts W 11/10

Cycles

50/60

Piping joint

—

Rc3/8

3/8 NPT Female

Port size

mm 3 2.8

Maximum Operating pressure differential required

Mpa 2 1.7

Note: The pressure value represents the gauge pressure.

●

Solenoid valves for capacity control are indoor specifications. Make sure not to drop

dew condensation water onto the solenoid valves by installing appropriate thermal protection on the s uction piping to t he compressor.

2203M4JE-MY-iS2-N_2017.04.

Chapter 3 Installation

Screw Compressor i-series 3.1 General Precautions for Installation

3-1

Chapter 3 Installation

3.1 General Precautions for Installation

 The description in Chapter 3 “Installation” assumes that the compressor is installed to a package

unit intended for standard type refrigeration/cold storage. If the package unit you are actually using is not the one for standard type refrigeration/cold storage, prepare a proper installation m anual by referr ing to the desc ription in thi s chapter and paying due consideration to safety, before installing the compressor. If there are any questions, please contact one of our local sales offices or service centers.

 In some cases, it may be required that install ation is performed b y qualified personnel. Mak e

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

 Read this chapter and related documents, and fully understand their contents before

performing installation.

 Electrical works should be performed only by electrical engineers.

3.2 Installation Works

3.2.1 Unpacking

Check that there are no abnormalities such as damage on the compressor.

 If there are abnorm alities or deficient parts on t he compressor, please contact one of our local

sales offices or service centers immediately.

 Unnecessary packing mater ials should be discarded according to th e laws and ordinances, or

your company's rules.

3.2.2 Storage

Perform the followings to store the compressor before installation.

 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 any one t o be under the lifted compres sor.

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

2. Secure sufficient space for safe lifting.

3. Always chec k the wire ropes bef ore using them. T horoughly check the wire ropes for problem s

such as kinks, k nots and brok en s trands. D o no t perf orm lifting work bef ore c onfirm ing the s afet y of the wire ropes. If you cannot make a correct evaluation or judgment, entrust an expert to check.

2203M4JE-MY-iS2-N_2017.04.

Chapter 3 Installation

Screw Compressor i-series 3.2 Installation Works

3-2

4. To lift the compressor, attach the wire ropes to the appended eye bolts by using appropriate shackles and hooks. Use the eye bolts only for lifting the compressor.

Figure 3-1 Eye bolts for lifting the compressor (Arrows)

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

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

5. Check path of compres sor installation to m ake sure it is free of o bstacles in cons ideration of the compressor size.

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

7. Before starting to lift up the compressor, instruct all the work ers to be sufficiently awa y from the

lifting area.

8. Just before s tarting to lift up, provide the c owork ers with a sign (s uch as a call, hand s ignal, etc.) of starting the lifting action. Do not start to lift up unl es s the sign ( suc h as a call, hand signal, etc.) has been fully acknowledged.

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 com pressor is not ti lted. If the compr essor is tilted, retur n the com pressor 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 s tarts, obser ve to see if wire rop es an d liftin g t ools 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 n ot lower the compressor on the s afety passage. Always keep the safet y passage free of

obstacles.

17. Rem ove an y obs tacles bef ore lo wering the c om pressor ont o th e groun d. T he co m pressor s hould not be tilted or unstable.

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

19. W hen 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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3-3

3.2.4 Preparation for Installation



Installation Space

Secure sufficient working space for easy operation, cleaning, maintenance, and inspection.



Lighting

Provide sufficient lighting to allow easy operation, cleaning, maintenance, and inspection.



Ventilation

If natural ventilation is insufficient, install venti lat ion fans according to the relevant regulations.

3.2.5 Installation

Check that the surface of the package unit, where the compressor is to be installed, is even and horizontal. If it is uneven a nd non-horizontal, tightening the b olts m ay lead to com pr essor deform ation, which may prevent normal operation.

3.2.5.1 Piping Connection



Refrigerant Piping

The size of the connection piping, refer to Section 2.3.4 "Outer Dimensions" in this manual.

Observe the following when connecting the refrigerant piping.

 The compressor is one of the few devices installed within the refrigerating/cold storage 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 thos e f or ex por t) ar e c h arged with nitrogen gas to pr e ven t rus t. B e

sure to release the pressure before starting piping work.

 Be sure not to allow moisture to enter the p iping. There is a high probabi lity that it will cause

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

 Improper piping may cause oper ating prob lems such as oil not returni ng to the co mpress or 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 conn ected to the com pressor applied onto f langes or joints.

Be sure to prepare proper supports for piping.



Oil Supply Piping

When constructing t he multi-package unit w ith i-series c ompressors , in order to prevent back flow from the compress or, we recommend the installatio n of a solenoid valve of PARKER or an electric motor ball valve in the lubricating oil supply system.

Also, make sure to provide a check valve between the compressor and the valve described above.

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3-4

3.2.5.2 Equipment and Devices for Protection of the Compressor



Oil Filter

According to the requirem ents of the use of the pack age unit or the s tandard to a ppl y, install an oil filter of appropriate filtration precision in the lubrication system of the compressor.

In the case of general app lications such as closed-cyc le refrigeration s ystems, we recomm end 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. The oil filter may be clogged just after the commissioning. 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 operation, install an oil heater on the oil separator. In cold districts, install a band heater to the oil supply piping. Make sure to install a protection function (thermostat, etc.) to the heater to prevent overheating.



Suction Strainer

The i-series compressor has built-in suction strainer. The same strainer elements are used for both models of the i125* and i160*. The mesh size of strainer element is 150 meshes.

During commissioning, small particles and scale may com e from the system. We recommend to install a finer filter temporarily.



Line Filter for Economizer/Aquamizer (Liquid injection)

When using an economizer or/and aquamizer (liquid injection), install a filter with filtration accuracy of not higher than 100μm within the line.



Compressor Protective Devices (Safety Devices)

Install the necessary protective devices, referring to Section 1.4.3 "Compressor Protective Devices" and Section 2.3.3 "Alarm Setting Values", in this manual.

3.2.6 Airtightness Test

Before commissioning, perform an airtightness test on the refrigerating/cold storage package unit. Use the design pressure of the refrigerating unit as the test pressure. Keep that pressure for at least 30

minutes, and perform a leak test on the connecting/jointing parts like flanges by using leakage detection liquid (soapy water, etc.).

3.2.7 Lubricating Oil Charge

 In the packaging of the refrigerating unit, install two valves at the front and the rear of

an oil filter. Install an oil charge port between the oil filter and th e upstream side valve.

 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 wh en ref i lling.  To ensure that the lubricating oil does not absorb air moisture, keep it indoors in an

airtight container until use.

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3-5

3.2.7.1 Initial Charge of Lubricating oil

At initial commissioning or after periodica l ins pection, the com pr essor 's moving parts suc h as bearings and mechanical sea ls may not be sufficiently lubricate d. So, c har g e t he c ompressor with lubric ati ng oi l according to the following procedure.

1. Thoroughly evacuate the compressor and oil separator (approximately 40 Torr).

2. Open the do wnstream side valve of the o il filter, and charge 10 liters of lu bric at ing o il from the oil

supply port.

3. Turn the compressor's rotor shaft.

4. Close the downstream side valve of the oil filter.

5. Open the upstream s ide valve of the oil filter, and charge lubr ica tin g o il to the oil separator unt il it

reaches the specified level.

 Be sure to conduct the initial charge of lubricating oil in such a way that the oil cooler and oil filter

are filled with lubricating oil.

 For details about lubric ati n g oi l to be used, refer to Section 4.1 "Lubricating Oil (Refrigerant O i l)"

in this manual.

 Depending on the equipment configuration of your package unit, define the amount of initial

charge of lubricating oil, and make sure to provide users of this product with the information.

3.2.7.2 Additional Charge of Lubricating Oil

Define 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 filling work accordingly.

In addition, specify the pro cedure of the additional filling of ref rigerant, mak e sure to provide users of this product with the information.

3.2.9 Check after Insta llation

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. Also, make sure to record and keep the results of your confirmation.

In addition, in case of i160*, make sure to confirm the following point. Do not forget it.

 The angle valve (P/N: 554) shown in Figure 3-2

should be always closed during oper a t ion. Confirm that the valve is closed at the check work after installation before the com m i ssi oning.

Note that i125* models don’t hav e thi s valve.

Figure 3-2 Location of P/N 554 Valve (i160*)

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Chapter 4

Compressor and Package Unit Operation

Screw Compressor i-series 4.1 Lubricating Oil (Refrigerant Oil)

4-1

Chapter 4 Compressor and Package Unit Operation

4.1 Lubricating Oil (Refrigerant Oil)

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

4.1.1 Precautions for Selecting the Lubricating Oil

 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 co nsidered when s electing lubric ating oil are the pro perties of the oi l that include not only the viscosity but also such characteristics as compatibility 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 com ponents in the compressors. The viscos it y to b e c onsid er ed in th is c as e should be the visc osity the oil shows at the oil i nlet of the com pressor. The viscosity of the lubricating oil significantly changes depending on the type of the refrigerant used in combination with the lubricating oil. If the ref rigerant dis solves in th e lubricati ng oil (or th e lubricating oil and refrigerant are compatible), the viscosit y of th e lubr icat ing o il drops t o a lev el rem ark abl y below the level required for operation of the compressor under some operating conditions. On the contrary, if the refrigerant does not dissolve in the lubricating oil (or the lubricating oil and refrigerant are incompatible), 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 to 40 mm

/s) in the

operating state.

 The circulation of th e lubricatin g oil for the entire system must be consid ered. After lubric ating

and cooling each part of the compress or, the lubricating oil is discharge d with refr igerant gas. Most of the oil which is discharged f rom this compr essor is trapped by the oil separator an d is cycled to the compressor. A small quantity of refrigerant oil goes to the condenser and the evaporator. The lubricating oil is req uired to ha ve sufficient f luidit y and stabi lit y inside e ach part in the refrigerating cycle where temperatures differ.

 Note that some lubricating oils cannot be used depending on the combination with the

refrigerant. The following caution is an example case that is required especially attention.

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

refrigerant.

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Screw Compressor i-series 4.1 Lubricating Oil (Refrigerant Oil)

4-2

4.1.2 Recommended Lubricating Oils

When selecting lubricati ng oil , not only compatibility with refrigerant but also effects on O-rings must be considered. To prevent compressor malfunctions, we recommend the lubricating oil described below.

4.1.2.1 Recommended Lubricating Oils for Ammonia Refrigerant



Mineral Oils (incompatible oils)

Brand

Kinematic

viscosity

(40°C) mm2/s

Manufacturer Type

SUNISO 3GS

Sun Oil

Naphthene base

SUNISO 4GS 55 Sun Oil REFOIL NS 3GS 30 JX GARGOYLE ARCTIC C HEAVY 46 Exxon Mobil

GARGOYLE ARCTIC 300

Exxon Mobil

CAPELLA WF46 46 Texaco

CAPELLA WF68

Texaco

CP-1009-32 34 CPI Hydrotreated

paraffinic base

CP-1009-68 69 CPI REFLO 46A 46 Petro C an ada

REFLO 68A

Petro Canada

CAPELLA PREMIUM 67 Texaco

RHT-68

Kluber

REFLO XL 59 Petro Can ada



Synthetic Oils (incompatible oils)

Brand

Kinematic

viscosity

(40°C) mm2/s

Manufacturer

Type

Acemire 300 59 Acemire AB

Mycold AB6 8

BVA

ZERICE S46 46 Exxon Mobil

ZERICE S68

Exxon Mobil

BERREL FREEZE 46S 46 Matsumura Oil Co., Ltd.

CP-4700-32

CPI

CP-4700-68 56 CPI

Gold - Cold 300

Golden West

GARGOYLE ARCTIC NH68 64 Exxon Mobil PAO+AB

REFLO SYNTHETIC 68A

Petro Canada

Gargoyle arctic SHC 224 Note 30 Exxon Mobil PAO

Gargoyle arctic SHC 226 (E) Note

Exxon Mobil

Note: Use only the standard BBSE-type mechanical seal assembly.

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Screw Compressor i-series 4.1 Lubricating Oil (Refrigerant Oil)

4-3

4.1.2.2 Oils for Systems Using Hydrofluorocarbon (HFC) Refrigerants



Polyolester Synthetic Oil (POE) for R404A and R507A: Compatible Synthetic Oil

Brand

Kinematic viscosity (40°C)

mm2/s

Manufacturer Type

SUNICE SL-68S 67 Sun Oil POE EMKARATE RL68H 72 Lubrizol



Polyolester Synthetic Oil (POE) for R134a: Incompatible Synthetic Oil

Brand

Kinematic viscosity (40°C)

mm2/s

Manufacturer Type

JOMO Freol α100

107

POE



When using lubricating oil of a brand not described in this section, or when using

 Lubricating oil

along with refrigerants or gases not described in this section,

please contact us.

4.1.3 Change of Lubricating Oil Brand

When changing the lubricating oil brand in currently use for 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 beca use appropriate steps must be surely followed.

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

(compatible/incompatible with refrigerant). As a general rul e, changing compatible oil to incompatible oi l or vice versa is not allowed.

 Lubricating oil contains various add itives to fulfill necessar y lubricating conditions. Types of

additives and their m ixing r atio d ep end o n eac h o il br a nd. W e, ther ef ore, rec ommend to a vo id mixed use of different brands of lubricat ing oil. If mix ed brands of lubr icating oi l 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 lubr icati ng oil, collect as much as oil as possible f r om

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 probl em in changing the viscos ity level within the sam e brand. However, make

sure that the viscosit y grade will not cause problems dur ing operation. (Example: SUNISO 3GS→SUNISO 4GS)

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Chapter 4

Compressor and Package Unit Operation

Screw Compressor i-series 4.1 Lubricating Oil (Refrigerant Oil)

4-4

4.1.4 Precautions for Handling Lubricating Oil

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

container until use.

 Always charge a ll o il fr om the oil co nta iner. We recommend that e ven if som e oil rem ains, do

not use it subsequently.

4.1.5 Lubricating Oil Management Criteria

Lubricating oils that are managed by the criteria are classified into the following categories: (1) Mineral oils: Naphthenic base oils and paraffinic base oils

(2) Synthetic oils: Alkylbenzene (AB) and Polyalphaolefine (PAO) (3) Synthetic oils: Polyolesters (POE)

 Oil sampling and analysis is recommended every six months.



If the following control criteria are not satisfied, replace the oil.

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 Mineral Oil and Synthetic Oil (AB, PAO)

Item

Criteria

(a) Color phase

ASTM color scale: 6.0 or les s

(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 4-2 Synthetic Oil (POE)

Item

Criteria

(a) Color phase

ASTM color scale: 4.0 or les s

(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

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4-5

4.1.6 Lubricating Oil Replace m e nt Timing

4.1.6.1 After Starting the Initial Operation

As the oil can easily be contaminated and degraded relatively quickly during the initial operation due to scales and deposits rem aining in piping and vessels, be sure t o sample and an alyze the oil after 500 hours of operation.

If it is found as a result of the analysis that the criteria given in T abl es 4-1 to 4-2 are not satisfied, the oil must be replaced.

4.1.6.2 During Normal Operation

Lubricating oils will degrade gradually as the system is operated over time. The rate of degradatio n depends on the operati ng condit ion, t ype of oil a nd am ount of for eign m atters

and moisture contained in the oil. The lubricating oil m ust be sampled and analyzed ever y six months. If it is found as a resu lt of the

analysis that the control criteria given in Tables 4-1 to 4-2 are not satisfied, the oil must be replaced. If the oil filters are frequently clogged or th e oil color quick ly becomes dark er and unclear, replace the

oil after removing the cause of the problem.

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Chapter 4

Compressor and Package Unit Operation

Screw Compressor i-series 4.2 Precautions for Operation

4-6

4.2 Precautions for Opera tio n

4.2.1 Prevention of Liquid Flow-back

Liquid flow-bac k is a phenomenon where refrigerant that did not c ompletely 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, properly adjust the expansion valve of each liquid cooler.

For details, refer to "Troubleshooting" in this manual C.

4.2.2 Purging of Non-Condensable Ga s es

 Some types of refrigerants emit bad smells or toxic gases. Make sure to ventilate

the air during work.

If there is a leak on the low-pressure side of the refrigeration cycle, air may enter the package unit. If non-condensable gas like air enters the unit, the condensing pressure rises and the energy

consumption increases. This leads to uneconomical operation. Follow the procedure below to check for non-condensable gases.

1. W hen the compress or is stopped, allow the cooling water to flow to the condenser for at least 15 minutes. Check the condensing pressure by using the pressure gauge of the compressor.

2. Check the cooling water temperature.

3. Compare the condens i n g pres s ure c hec ked in step 1 above with t he r ef r iger an t s atur at ion pres s ure

that depends on the cooling water temperature (as shown in Table 4-3).

4. When the pressure inside the condenser and the refrigerant saturation pressure that depends on the cooling water temperature are approximately equivalent, non-condensable gases do not exist. When the pressure inside the condenser is 0.05 MPa or more higher than the refrigerant saturation pressure that depends on the c ool ing water t em perature, th ere is a p oss ibilit y of non-condensable gases entering the unit. In that case, purge the non-condensable gases from the condenser.

Table 4-3

Typical Refrigerant Temperatur e and Saturation Pressure

Temperature °C

Pressure MPa *1

Ammonia

R404A

R507A

R134a

0.328

0.509

0.523

0.192

0.396

0.590

0.606

0.237

0.472

0.678

0.696

0.287

0.557

0.775

0.795

0.342

0.652

0.881

0.903

0.403

0.756

0.996

1.021

0.471

0.871

1.121

1.148

0.545

0.998

1.256

1.286

0.626

1.137

1.401

1.435

0.714

1.289

1.559

1.595

0.811

1.454

1.728

1.768

0.916

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

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Chapter 4

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Screw Compressor i-series 4.3 When Stopping the Compressor for a Long Time

4-7

4.3 When Stopping the Compressor for a Long Time

When stopping the compressor for a long period of time, make sure to perform the following steps:

 Turn off the motor main power.  Turn off the heater power and control panel power.  Close the suction and discharge side shut-off valves.  If an economizer or liquid injection is used, close the stop valve located at the compressor inlet.

When the compressor is stopped for more than a month, perform the following steps once a month:

 Turn the compressor shaft by removing the motor spacer plate (P/N: 235-2).  Measure the unit pressure.  Check for refrigerant leakage.

When restarting the compres sor which has been stopped f or more than a year, perform the following steps.

 Check the motor insulation resistance.  In addition, conduct the items instructed in the motor instruction manual.  Replace or analyze the lubricating oil. When anal yzing, if it is found as a result of the analysis

that the control criteria given in this Chap ter, Section 4.1.5 Tables 4-1 to 4-2 are not satisf ied, the oil must be replaced.

 Check for refrigerant leakage.  Supply power to the oil heater at least half a day before staring operation..  Before starting the oper ation, conf irm that the refrigera nt is not co ndensed i n the pack age unit

by checking the package temperature and pressure.

. .

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Chapter 5 Maintenance and Inspection

Screw Comp ressor i-series

5.1 Precautions for Maintenance and Inspection

5-1

Chapter 5 Maintenance and Inspection

5.1 Precautions for Mainte nan c e 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 th at there i s 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 th e mac hine a nd bef ore worki ng on a r egula r ins pecti on or overha ul,

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 noti f ication tag to prohibit the o pe r at ion (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 c rane, 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 b y 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 instructi ons on the safety of each instr uction manual.

 Be sure to use only genuine parts f or re pl ace m ent . U sing parts that are

not genuine can cause damage to this product or othe r devices during o pe r at ion.

 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 us e such a l ifting 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 tool s for the work. Ne glec ti ng t he abov e war ni ng ca n l ead to l ow back pain of the worker or injury due to dropping of t he parts .

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

procedures to s hare a common underst anding 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.

2203M4JE-MY-iS2-N_2017.04.

Chapter 5 Maintenance and Inspection

Screw Comp ressor i-series

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 operati on.

 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 suf fici ent s pace and refrain fr om putt ing t ools direct ly 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 bearing

heads 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 servi ce, keep the tools clean all the tim e. 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 dama ge.

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

Pay attention to a ny parts falling down, which could le ad to personal inj ury.

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

understand the di sassembly 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 compr essor.

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

contact your nearest sales office or service center of MAYEKAWA.

 When removing a pa r t , 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 cl eaner.  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 ga p. Sc r ew ja ck b ol t s usi ng t he sc re w hol e s 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

Screw Comp ressor i-series

5.2 Maintenance and Inspection List

5-3

5.2 Maintenance and Inspection List

5.2.1 Daily Management

As daily management, check the items listed in Table 5-1 "Daily Inspection Items" and record the results.

By regularly recordin g the daily operational data in a n operation log, it should be ab le to detect any significant change in the system. This is significantly effective in preventing compressor failures.

It is particularly important to check whether the temperature/pressure correlations related to the refrigerant evaporatio n and c ond ens at ion is proper. This makes it possible to q uickly find out prob lems in the compressor or the system.

If a failure or accident should occ ur in the compressor or the s ystem, the operation logbook will hel p determine the cause and take prompt and proper actions.

Table 5-1

Daily Inspection Items

Inspection Item

Inspection Details

Check Points and Actions

■ Compressor

Operating hours

hour

Total operating hours



Judgment of periodic maintenance

interval

Suction pressure

Mpa

Difference from the set

value of evaporation temperature equivalent

pressure

 Contamination on the cooling pipe

surface

 Temperature, flow rate, etc. of the

object to be cooled

Discharge

pressure

MPa

Difference from cooling

water temperature equivalent condensing pressure



Contamination on condenser cooling

pipes

 Non-condensable gases mixed into

the system

 Quantity, temperature, etc. of cooling

water

Oil supply

pressure

MPa

Difference from discharge

pressure

 Whether differential pressure is

decreasing

 Operation with liquid flow-back



Whether compressor parts are worn

Oil filter pressure

loss

MPa

Pressure difference

between oil filter inlet and

outlet



Contamination of lubricating oil

 Clogging of oil filter element

Suction temperature

℃

Whether within upper and lower limits

 Temperature, flow rate, etc. of the

object to be cooled

Degree of

superheat for

suction

℃

Whether degree of

superheat is proper



Adjust expansion valve

 Insufficient refrigerant flow

Discharge

temperature

℃

Whether within upper

limit

 Non-condensable gases mixed into

the system

 Oil supply temperature, insufficient oil

supply



Compressor failure

Oil supply temperature

℃

Whether within upper and lower limits



Contamination on cooling pipes of oil

cooler

Capacity control

Specified load

％

Whether operation is

normal

 Damage to solenoid valve coil

 Improper adjustment of manual

control valve of electromagnetic

assembly

Leak from

mechanical seal

Leak per hour



Mechanical seal failure

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5-4

Inspection Item

Inspection Details

Check Points and Actions

Noise and vibration

Abnormal noise/vibration

 Compressor failure

■ Others

Motor current

Whether it is higher than at test run



Compressor failure

Oil level of oil separator

Oil level

 Oil loss



Replenish oil

Fluid level in the receiver

Fluid level



Check for refrigerant leak

 Replenish refrigerant

Refrigerant leak check

Leak or not

 The machine room and load side

facilities

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



Daily Maintenance Items

1. Lubrication oil level

When the oil level in the oil separator reaches the lower limit, charge lubricating oil.

2. Replacing oil filter element

When the pressure d ifferenc e bet w ee n th e inlet and out let por ts of th e o il f ilter e x c eeds 0.1 MPa, replace the oil filter element. At the beginning of the operation, the differential pressure of the oil filter may increase quickly.

3. Cleaning of suction strainer

When the compressor operating hours exceeds 500 hours, check the suction strainer. If a temporary filter is installed for the initial stage of operation, remove it.

At the beginning of the op eration or after periodical check , the pressure difference between th e front and back of the suc tion strainer may increase q uickly. If the differential press ure becomes large, check and clean the suction strainer.

4. Lubricating oil leak rate from mechanical seal

If much oil leaks f rom the mechanica l seal, determine the leak rate per h our. The following table shows guidelines for allowable leak rate and the rate at which inspection must be done.

If any problem (damage, etc.) is found in mechanical seal, replace the mechanical seal assembly.

Table 5-2

Guideline for Leak from Mechanical Seal Section

Condition

i125* / i160*

Allowable leak rate

mL/hr

≤ 3

Rate at which inspection must be done

mL/hr

≥ 9

Note: The specifications above are just guidelines. They are not guaranteed values.

5. Contamination on the cooling water side of the cooling pipes of condenser and oil cooler

Clogging and contamination of the cooling pipe is largely affected by the quality of cooling water. When the oil temperature and discharge pressure gradually rise during the initial stage of operation, inspect an d clean the cooling water side of oil cooler and c ondenser even when the time has not yet come at which inspection must be done.

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5.2 Maintenance and Inspection List

5-5

5.2.2 Periodic Inspection

Check the following items at specified intervals. In addition, observe r elevant la ws and regulati ons on the inspections and r ecording of the results that

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

Table 5-3

Periodical Inspection Items

Item Inspection Interval Remarks

Pressure gauge/

pressure sensor

Once per year

Temperature/

temperature sensor

Once per year

Protection devices

and Safety valves

Operation test and clean once per year

Suction strainer

Check after 500 hours from the initial

operation.

If the pressure difference between

the front and back of the suction

strainer increases, check and clean

the suction strainer.

Check and clean once per year.

Lubricating oil

Analyze oil after 500 hours from the

initial operation.

When the analysis results do not

satisfy the management criteria provided in Chapter 4 Section

4.1.5, replace oil.

Analyze oil every 6 months.

Oil filter element

Replace once per year.

Replace oil filter element if the

differential pressure between the inlet and outlet ports of the oil filter exceeds 0.1 MPa.

Cooling water side of

oil cooler

Once per year

Clean if excessively contaminated.

Cooling water side of

condenser

Once per year

Clean if excessively contaminated.

Mechanical seal

section

Check once per year or per 8,000

operating hours.

To be replaced if any abnormality is

found. If it is difficult to stop the compressor operation except for scheduled inspections, replace the mechanical seal assembly at each inspection.

■ Inspection frequency is the specified period after delivery or operating hours, whichever comes first.

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5-6

5.2.3 Guidelines for Compressor O ver haul Interval

The compressor overh aul interval is large l y affected b y the com pr essor operat ing c onditi ons, t ype a nd status of refrigerant and oil, and the system/equipment in which the compressor is operated.

The table below lists overhaul intervals recommended by MAYEKAWA which are categorized based on the compressor operating conditions.

Table 5-4

Standard Package Operation Conditions and Overhaul Interval Guidelines

Category of operating condition Application example

Recommended Overhaul

Interval

Relatively stable operating condition

Refrigeration and cold storage

Every 5 years or 40,000 operating hours

Relatively changing operating condition Ice maker/chiller

Every 4 years or 30,000 operating hours

Frequently started/stopped, and relatively changing operating condition

Heat pump

Every 3 years or 20,000 operating hours

Note 1: The above guidelines are only applicable when the compressor is operated within the operation

limits specified separately. (Refer to Section 2.3.2 "Operation Limits" in this manual.)

Note 2: The above guide lines are onl y applicable when the com pressor undergo es daily and period ic

inspections Specified separately. (Refer to Section 5.2.1 "Daily Management" in this manual.)

Note 3: Inspect the compressor at the intervals of specified period or operating hours, whichever comes

first.

Note 4: The above guidelines do not constitute any warranty.

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5.3 Compressor Disassembly Preparation

Screw compressors are very reliable compressors. However, it is necessary to disassemble and inspect parts after a certain period of operation.

This chapter 5 describes the essential points of disassembly methods, where to inspec t on parts, and reassembly procedure of the i-series compressor.

As a general rule, over hauling of the sc rew compressor that require com plete disassem bly s hould be done at the maintenance factory.

At the installation location of the compressor, it is only possible to inspect/replace mechanical seals and suction strainers.

Read this manual thoroughly and fully understand the compressor structure as well as the work procedure before starting work. Numbers denoted b y [ ] that follow part nam es refer to the part numbers (P/N) used in as sembly sectional views or parts configuration table.

5.3.1 Disassembly Tools and Work Place

Prepare special hand too ls required f or disassembly. Refer to Section 7.2 "Disassembly Tools" in this manual Chapter 7.

In addition, prepare standard hand tools, green carbonite grinding stone, #80- to #100-grit sandpapers, # about #400 t o #800 sandpapers, pa rts cleaner, lubrication oil, a s quirt c an, a c an for o il s um p, and a waste cloth.

A work bench with a large surface plate is useful to perform work accurately and with ease. If the surface plate cannot be prepared, use a commercially available steel plate. The steel plate should

be approximately 1000 mm × 1500 mm in s ize and have a thick ness of approximately 1.5 m m if the work location is flat.

Perform the work in a dr y place with as little s and and dust as possible, wit h a sufficiently wide space around there. In addition it is necessary a temporary storage place for disassembled parts.

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5.3.2 Replacement Parts

Prepare genuine replacement parts. Table 5-7 and table 5-8 are lists of standard parts to be replaced when i-series compressor overhauled. When purchasing any part, inform its (a) model, (b) serial number, (c) part name, (d) part code and (e)

required number to our sales offices or service centers.

The serial number (b) is especially required among them. Unless serial number is informed, it is difficult to identify design and pr oduction specificati on details that are ne eded to identif y the part you want to purchase.

Table 5-7 Replacement parts of i125*

P/N Part name Code No. Remarks Qty

6-1 Gasket, Suction Adapter CS00600-I125 i125 1 6-2 Gasket, Strainer Cover CS00900-I125 i125 1

7 O-ring see Note 1 PA12-140 JIS B 2401 G140 1

12 Gasket, Bearing Head CS01200-I125 i125 1 17 Gasket, Bearing Cover CS01700-I125 i125 1

23 Gasket, End Cover CS02300-I125 i125 t=1.0 1 27-1 Radial Bearing CS02800-FM125M NU2308ET7 2 27-2 Radial Bearing CS02800-FM125F NU2309ET7 2

Balance Piston see Note 2

CS03000-I125 i125 1

33 Sleeve, Balance Piston see Note 2

CS03300-I125 i125 1

35 O-ring see Note 1 PA11-016 JIS B 2401 P16 1 38-1 Thrust Bearing M CS03800-I125MP Shared with i125M,FM11S 1 38-2 Thrust Bearing F CS03800-125FP Shared with i125F,125 1 40-1 Lock Washer NG32-008 AW8 1 40-2 Lock Washer NG32-009 AW9 1

49 O-ring see Note 1 PA12-085 JIS B 2401 G85 1

50 Oil Seal see Note 2

CS05000-125D 125*** Rareflon 1

52 Gasket, Seal Cover CS05200-125N 125*** 1

100

Mechanical Seal Assembly see Note 3

CS10002-125EBS BBSE 125*** 1set 237-1 Torsional Slip Washer M CS23700-FM125M FM125 M 1 237-2 Torsional Slip Washer F CS23700-125 125L** 1

395 Gasket, Unloader Cover CS39500-I160 i160* 2 480 Strainer Element see Note 2

CS48000-I160 i160* 1

489 Valve Seat CS48900-I125 i125 1 491 Check Valve Shaft see Note 2

CS49100-I125 i125 1

495 O-ring see Note 1 PA11-007 JIS B 2401 P7 1

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Table 5-8 Replacement parts of i160*

P/N Part name Code No. Remarks Qty

6 Gasket, Strainer Cover CS00900-I160 i160 t=0.5 2 7-1 O-ring see Note 1 PA12-150 JIS B 2401 G150 1 7-2 O-ring see Note 1 PA12-140 JIS B 2401 G140 1

12 Gasket, Bearing Head CS01200-I160 i160 t=0.5 1 17 Gasket, Bearing Cover CS01700-I160 i160 t=0.5 1

23 Gasket, End Cover CS02300-I160N i160 t=1.0 1 27-1 Radial Bearing M CS02800-FM160M NU2311ET7 2 27-2 Radial Bearing F CS02800-FM160FCT NU2312ET7 2

Balance Piston see Note 2

CS03000-I160 i160 1

Sleeve, Balance Piston see N ote 2

CS03300-I160 i160 1

35 O-ring see Note 1 PA11-024 JIS B2401 P24 2 38-1 Thrust Bearing M CS03800-FM160P 7311B Shared with FM160 1 38-2 Thrust Bearing F CS03800-160P 7312B Shared with 160 1 40-1 Lock Washer NG32-011 AW11 1 40-2 Lock Washer NG32-012 AW12 1

49 O-ring see Note 1 PA12-090 JIS B 2401 G90 1

Oil Seal see Note 2

CS05000-160VD 160*** (S55×70×9) 1 52 Gasket, Seal Cover CS05200-160N 160*** t=0.5 1 93 Gasket, Suction Flange PL300-125 ANSI 300 # 5" 1 96 Gasket, Discharge Flange PL300-080 ANSI 300 # 3" 1

100

Mechanical Seal Assembly see Note 3

CS10002-160EBS 160V BBSE 1set

150-1 O-ring see Note 1 PA12-110 JIS B 2401 G110 1 150-2 O-ring see Note 1 PA12-115 JIS B 2401 G115 1 216-2 Flange Gasket, Oil Inlet Port CR72000-025N MYCOM 25A (Male) 1 237-1 Torsional Slip Washer M CS23700-FM160M FM160 1 237-2 Torsional Slip Washer F CS23700-160 160*** 1

395 Gasket, Unloader Cover CS39500-I160 i160 t=1.0 2 480 Strainer Element see Note 2 CS48000-I160 i160 #150 Φ160×200 1 489 Valve Seat CS48900-I160 i160 1 491 Check Valve Shaft see Note 2 CS49100-I160 i160 1 495 O-ring see Note 1 PA11-007 JIS B 2401 P7 1

Note 1: The part code of the O-ring is the one assigned to NBR-70-1 which is standard material. Note 2: W hen checking eac h part (No.30, 33, 50, 480 , 491) If a special malf unction is not seen, it is

possible to use in the continuation. Note 3: Mechanical seal assembly (No.100) should be replaced if any defect is found during inspection.

Actually, however, it is sometimes difficult to find out def ects on the sli ding surf ace onl y through vis ual inspection. In such circumstances, MAYEKAWA recommends to replace it with a new one. Also, if it is difficult to st op the compressor oper ation except for s cheduled inspections, MAYEKAWA recommends replacing No.100 in the same way.

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5-10

5.3.3 Refrigerant Gas Treatment

5.3.3.1 Valves Used

Before removing the c ompressor or when perfor ming air tightness test or evacuat i on, r ef r igeran t gas is recovered and charged. As the i-series compressor has a built-in check valve, care should be taken. Work procedures differ between the i125* and i160*.

<i125*>

Two service valves are mounted to the check valve, one at the top and the other at the bottom. When removing gas from the compressor, the valve at the bottom is used. The valve on the top side is used when charging gas into the compressor.

<i160*>

Check that the valve attached to t he startup pressure equa lizer line is open, and remove or charg e gas by using the service valve (one location).

5.3.3.2 Refrigerant Gas Recovery

After stopping the package unit operation, internal pressure of the compressor remains high. Before disassembling the c ompressor, it is necessary to lower the internal pr essure to atmospheric pressure. To do this, there are the follo wing methods for ex ample. Perform your recover y work in an appropriate manner considering site conditions, requirements of regulatory laws and regulations.

 By using the bypass valve, release the high press ure gas in the package unit to the low pressure

side.

 If there is another refrigerating unit connected by existing bypasses piping, operate the other

compressor and lower the pressure.

 Operate the refrigerating unit, close the refrigerant fluid supply master valve, and collect the

liquefied gas in the receiver.

 By using a refrigerant recovery machine, recover the liquefied refrigerant in the receiver. For any of the above methods, prepare a flow sheet describing the operations of the work. Verify valve

operations that are necessary for each method, according to the flow sheet and on the actual unit. Specify operation valves as well as connected devices and tubes on the flow sheet. Prepare one flow sheet for the foreman and another one for display at the work area. In addition, prepare a refrigerant collection procedure with the workplace situation considered. Be sure that all the personnel related to the work will read it together for confirmation, before 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.

 Be sure to confirm and make known the work contents and procedures described

in the work procedure, and inform the estimated risks to the related personnel, before the work. Neglecting these efforts will increase the industrial accident occurrence rate to a level that cannot be ignored.

 After closing (opening) a valve for work, conduct lockout/tagout to prevent it

from being handled accidentally during work.

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5-11

5.3.4 Removing Parts Connected to the Unit

 If refrigerant gas or a mixture of refrigerant and oil remains in the compressor,

refrigerant gas may blow off when the closed circuit is opened. This may result in injury such as frostbite or loss of vision. Be sure to confirm that there is no residual pressure before opening any pipe connections.

 If the compressor is removed when the temperature around the suction flange is

extremely lower than the ambient temperature, dew condensation may occur inside the system. After stopping the refrigerating unit, leave it as it is for some time.

When removing the compressor from the unit frame, disconnect the following parts.

(1) Flange motor (and motor wiring if necessary) (2) The compressor's suction piping and discharge piping (3) Compressor's lubrication piping (4) Compressor's economizer piping and aquamizer (liquid injection) piping (5) Electrical wiring for capacity control solenoid valves (6) Motor spacer (7) Bolts for installing compressor (leg bolts)

Since remaining oil may leak out when disconnecting the oil piping from the compressor, slightly

loosen the piping and observe the oil flow to decide whether to disconnect the piping right now or extract oil first from the oil temperature gauge on the lubrication header. When disconnecting electrical wiring, put markings so that it can be reconnected easily. Unless reconnected correctly, the compressor may not start up or the capacity control system may not operate.

5.3.5 Removing and Lifting the Compressor

When performing this section’s work, also refer to Section 3.2.3 "Transportation" in this manual Chapte r 3.

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

compressor before starting the compressor lifting work.

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

5.3.6 Removing Oil from Compressor

Disconnection of the capacity control Φ8 piping [538] from the compressor will cause the oil remaining inside to be drained by approx. 1 liter (i125*) or by 2 liters (i160*).

Prepare a container to receive oil and an empty can for storage before starting the work.

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5.4 Disassembly and Inspection

5-12

5.4 Disassembly and Inspection

Be careful with han dling of the par ts during disass em bly and inspec tion. Since t he c om press or rotates at a very high speed, even the slightest handling error could cause a situation that requires replacement of the rotor and all other important parts. Such errors can also cause problems or performance deterioration after the compressor is reassembled. Be sure to fully understand the following before starting the work.

5.4.1 Shaft Seal Block

To prevent refrigerant gas and oil leakage, a reliable mechanical seal assem bly is used for the shaft seal of the M rotor.

Mechanical seal assembly is mainly composed of "rotating ring" installed on the rotor shaft and "stationary ring" installed i n the seal cover. Rotating ring rotates with the shaft, and slides each other with the stationary ring whil e maintaining a m icron class gap. The sliding eac h other place is called as the sliding surface.

Mechanical seals have a precisely machined sliding surface and are made of fragile material. Handle them with special care since leakage may occur if damaged.

Photo 001

P/N

Part Name (Rotating rings)

P/N

Part Name (Stationary rings)

109

Seal collar

101

Mating ring

111

Seal collar set screw

102

Insert lock pin

112

O-ring

103

O-ring

5.4.1.1 Disassembly

a) O f the eight hexagon socket hea d cap screws securi ng the seal cover [51], remove six a nd leave

the two on the opposing sides.

b) Loos en the r em aining two scr ews alternate l y and evenly, a little at a time. After a certain amount of

loosening, the seal cover of the mechanical seal will be pushed by the repulsion force of the bellows and a gap will appear. A gap will not appear if the gasket is stuck. In that case, remove the sea l

cover; push the seal cover by screwing M8 eye bolts into the jacking threaded holes. c) Use a container to catch the oil that will leak from the gap in the seal. d) Pull out the seal cover, while keeping it parallel with the shaft (rotor shaft). The mating ring is

attached inside the seal c over by using a n O-ring [103]. Be c areful not to l et the mating r ing [101]

and the shaft damaged by contact. e) Remove the O-ring [49] from between the seal cover and seal retainer [48].

Figure 5-1 Details of BBSE Type Mechanical Seal Assembly

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Photo 002 Removing Seal Cover Photo 003 Seal Cover and Mating Ring

f) After removing th e se al c over, wipe clean and ins pect the shaft sur face. If there ar e scr atches , use

fine sandpaper to smooth them over. This is done to prevent damage to the inte rnal O-ring when

pulling out the mechanical seal. g) Loosen the set screws [111] of the seal collar [109] by turning them approximately three times

(Photo 004). Do not rem ov e the s et s c rews c ompletely, but leave them so that their ends ar e be lo w

the surface of the sea l collar. These screws are located in two places 90 degr ees apart fr om each

other.

Photo 004 Loosening the Seal Collar Set Screws

Photo 005 Seal Retainer

h) Pull out the seal collar with your fingers. While pulling out, make sure that the ends of the set screws

do not touch the shaft surface. Axial-direction scratches on the shaft can cause leaks. i) Screw two M8 eye bolts into the jacking threaded holes. T hen pull out the seal retainer while

maintaining a right angle to the rotor shaft. j) Remove the mating ring from the seal cover. At this time, be careful not to damage the mating ring.

5.4.1.2 Inspection

Mechanical seal sh ould be replaced if any defec t is found during inspection. Ac tually, however, it is sometimes difficult to find out def ects on the sliding surface only through visual inspect ion. In such circumstances, MAYEKAWA recomm ends to replace it with a new one in th e same manner as with O-rings or gaskets.

The contact between the sliding surfaces of the mating ring and seal collar must be checked even when replacing the seal. If there are obvious traces of uneven contact or damage, find out the cause (degradation over time, problems such as heating operation, etc.) and take necessary actions.

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5.4.2 Bearing Cover

5.4.2.1 Disassembly

a) Remove two threaded alignment pins [3] by using a slide hammer (Photo 006). b) Attach lifting tools, and remove all of th e hexagon socket head ca p screws. If the bearing cover

gasket [17] is stuck, use a jack bolt to remove.

At this moment, lubricating oil remaining ins ide the be aring cover will flow out. Prepare a container

to catch oil. c) Remove the bearing cover [16]. Exercise care not to le t it hit against the shaft and cause damage.

Photo 006 Removing Alignment Pin

5.4.2.2 Inspection

a) If the alignment pin is bent or worn, replace it with a new one. b) The bearing cover gasket must be replaced with a new one.

Photo 007 Removing Bearing Cover

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5.4.3 Balance Piston

5.4.3.1 Disassembly

The balance piston sleeve [33] and the balance piston [30] can be removed just by removing the snap ring [32].

Photo 008 Removing the Snap Ring

Photo 009 Removing the Balance Piston Sleeve

Photo 010

Removing the Balance Piston

5.4.3.2 Inspection

a) If there are defects such as extrem e wear, galling or chipping o n the outer circumference of th e

balance piston or on the inner circumference of the balanc e piston sleeve, replace the def ective

component with a new one. b) Measure the large and small outer diameters of the balance piston at four locations each.

If either of the maximum values indicates that the part is worn dow n to or beyond the replac ement

criteria sho wn in Table 5-9, the part should be replaced with a new one.

When replacing with new ones replace the balance piston and balance piston sleeve in a set.

Table 5-9 Balance Piston Replacement Criteria

5.4.4 End Cover

a) Remove two hexagon socket head cap s cr e ws (i125* [2-2], i160* [2]) symmetrically, and inser t s tu d

bolts. In the case of i160* , attach lifting tools to the end cover before proceeding to the next step. b) Pull out remaining bolts, and remove the end cover [22]. At this mom ent, lubricating oil remaining

inside the end cover will flow out. Prepare a container to catch oil.

measurement point

i125*

i160*

Balance Piston diameter

(mm)

Large diameter 112.89 134.85

Small diameter

74.91

64.85

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5.4.5 Thrust Bearing Block

The thrust bearings [38-1] [38-2] are face-to-face angular contact ball bearings. This bearing only recei ves thrust load and does not receive the radi al load perpendicu lar to the shaft

because there is a ga p between the outer ring of the thrust be aring and t he bearing h ead. Apart from receiving the thrust load, the bearing has the important role of securing the position of the gap between the rotor and the discharge side of the bear ing head. This gap (end clearance) is significantly linked with performance.

5.4.5.1 Disassembly

Though part sizes differ between the M rotor side and F rotor side, the same work procedure is applied to both.

a) Remove hexagon head bolts [45] holding thrust bearing glands [43-1] [43-2], and remove the thrust

bearing glands. A spring washer [46] is attached to the hexagon head bolt. Be careful not to lose the

washer.

As O-rings [150-1] [150-2] are mounted to the thrust bear ing glands use d for the i160-s eries, the y

are slightly tight. b) Extend the bent claw of lock washers [40-1] [40-2]. c) Loosen lock nuts [39-1] [39-2] by using a dedicate d lock nut socket. If, at this m oment, the rotor

shaft rotates, attach dedicated rotation stoppers 1 a nd 2 (refer to Section 7.2 i n t hi s manual) during

work. d) Remove lock nuts, torsional slip washers [237-1] [237-2] and thrust washers [250-1] [250-2]. e) Take out thrust bearings [38-1] [38-2]. Since the in ner race of the bearing is s lide fit on the rotor

shaft, bend the tip of a aluminum wire with diameter of 1 to 2 mm , insert it betw een the outer ring

and the ball retainer, and hook it onto the thrust bearing to pull it out. f) Remove thrust bearing outer race spacers [41-1] [41-2] and thrust bearing alignment spacers [42-1]

[42-2].

Photo 011 Extending the Claw of Lock Washer Photo 012 Removing the Thrust Bearing

5.4.5.2 Inspection

a) Repl ac e th e thrus t b ear i ng with a ne w one during regular inspect ion , r egard les s of whether or not it

is defective. If there is an extreme problem, find the cause and review the operating state or periodic

inspection interval to prevent recurrence of such problem. b) If there is a problem such as extreme deformation in the notch of the lock nut, replace the part with a

new one. c) Be sure to replace lock washers and torsional slip washers with new ones. d) O-rings [150-1] [150-2] attached to the i160-series compressor must be replaced with new ones.

2203M4JE-MY-iS2-N_2017.04.

Chapter 5 Maintenance and Inspection

Screw Comp ressor i-series

5.4 Disassembly and Inspection

5-17

Photo 013 Attach Lifting Tool

Photo 014 Pulling Out the Rotor

5.4.6 Bearing Head

Though the case dividing method differs between i125* and i160*, the work flow is the same.

5.4.6.1 Disassembly

a) Attach lifting to ols, remove all bolts [2-1] that hold the part to the

main rotor casing, and separate the part from the main rotor

casing. If bearing head gasket [12] is stuck, use a jack bolt to

remove it. b) Remove bearing head [11] while taking care not to let it be hit and

damaged by the rotor shaft. Also take care not to let the rotor fall

off the main rotor casing.

5.4.6.2 Inspection

a) If the alignment pin is bent or worn, replace it with a new one. b) The bearing head gasket must be replaced with a new one.

5.4.7 Rotors

Rotors [25] [26] are heavy, precisely machined components, which are the heart of the compressor. Care must be taken not t o get them damaged b y dropping or in other ways. Using dam aged rotors m ay lead to d eterioration in performance or damage to the compressor.

5.4.7.1 Disassembly

a) W hen using the i125*, rem ove snap ring [29-3] from the F

rotor. b) As it is heavy in weight, be careful when handling. A s the

i160* r otor weighs m ore than 30 kg, use lifting to ols such as chain bloc ks and nylon belts. Pull out

about two thirds of the rotor, attach a belt around its outer circumfer ence, and then pull out the

remaining part of the rotor. c) After pulling out the rotor, place it on V-blocks or the like to prevent damage to the outer

circumference. d) Remove slotted set screw [31].

5.4.7.2 Inspection

Check that the rotor is not extremely worn or damaged. Rotors stay almost free from wear during normal operation. If the rotor is found worn, check the cause and review the operating state to prevent recurrence of the problem.

If the part wears beyond the replacement standard shown in Table 5-10, performance will be deteriorated. Replacement of the rotor is recommended.

measurement point

i125*

i160*

Rotor's outer diameter (mm) 127.475 163.175

Table 5-10 Rotor Replacement Standards

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Chapter 5 Maintenance and Inspection

Screw Comp ressor i-series

5.4 Disassembly and Inspection

5-18

Photo 015

Removing i125-series Suction Adapter

5.4.8 Radial Bearings

Two pairs of large and small radial bearings are used. Put the disassembled parts in order to distinguish which bearing has been used where.

5.4.8.1 Disassembly

a) Put the radial bearing with the side containing the bearing for bearing head [11] faced upward. b) Remove stop rings [29-1] [29-2], and pull out the outer rings of radial bearings [27-1] [27-2].

* For the i125*, the snap ring is attached to the main rotor casing side. c) Pull out the outer ring of the radial bearing from the main rotor casing.

d) Rem ove the inner ring of the radial bearing from the rotor after inspection. As the inner ring is

shrink-fitted to the rotor, pull it out by heating it with a tool like a burner. Beforehand, remove oil such as lubricating oil sufficiently. Set the rotor with its inner ring (which is to

be pulled out) faced downward and heat the inner ring only. Then the inner ring will come off.

5.4.8.2 Inspection

Replace the radial bear ing with a new one duri ng regu lar insp ecti on, regar dless of whet her or not it is found defective. However, if there is an extreme pr oblem, find the cause and review t he operating state or periodic inspection interval to prevent recurrence of such problem.

5.4.9 Suction Strainer and Check Valve

The structure of the suction strainer and check valve differ between i125 and i160.

5.4.9.1a Disassembly (i125*)

a) Remove strainer cover [5-2]. Remove wave washer

[546], strainer element [480] and O-ring [7].

b) Check that the main body of the check valve moves

smoothly. c) Of the bolts securing s uction adapter [5-1], rem ove all

but the two on the opposing sides. Attach two M12 eye

bolts and lifting to the suction adapter, remove the

remaining bolts, and remove the suction adapter. d) La y the suction adapter on the work bench. Remove

hexagon nut [486], plain washer [46-2], valve plate [490], valve seat [489], seat stopper (1) [488-1],

seat stopper (2) [488-2] and O-ring [495]. Pull out the check valve shaft [491] and c heck valve

spring [485].

5.4.9.1b Disassembly (i160*)

a) Rem ove the R1/ 8 plug from strainer cover [5]. At this moment, lubricating oil remaining ins ide may

flow out. Prepare a container to catch oil. b) Remove the strainer cover. If gasket [6] is stuck, use a jack bolt to remove it. c) Remove strainer el ement [480] and strai ner m ounting seat [481]. Remove O-rings [7-1] [7-2] from

the strainer cover and the strainer mounting seat. d) Observe the main body of the check valve from the strainer cover side. Check that it moves

smoothly.

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Chapter 5 Maintenance and Inspection

Screw Comp ressor i-series

5.4 Disassembly and Inspection

5-19

Photo 016 Removing Unloader

Piston and Spring

e) Remove Φ10 piping [557]. f) Remove the R1/2 plug from check valve cover [8], and pull out check valve spring [485]. g) Remove the check val ve cove r. Be sure to use a jac k bolt for t his r em oval. Be c aref ul not t o let th e

check valve main body fall at the inside. h) Remove the check valve main body. i) Remove hexagon nut [486] from check valve shaft [491]. Remove plain washer [46-2], seat stopper

[488], valve seat [489], valve plate [490] and O-ring [495].

5.4.9.2 Inspection

a) If the main bod y of the c heck valve does n ot m ove smooth ly, the check valve shaft may be worn or

bent. Replace it with a new one. b) Strainer element, check valve s pr ing and hexagon nut must be replaced if t here are problem s s uc h

as extreme deformation or chipping.

* With i160*, the inner cylinder of the strainer element may be deformed, but this is normal. c) The gasket, O-ring and valve seat must be replaced with new ones.

5.4.10 Unloader

5.4.10.1 Disassembly

a) Attach lifting tools to the motor-side end face of the main

rotor casing, and lay down the unloader horizontally. b) Remove Φ8 piping [538]. c) Of the bolts securing unloader cover [393], rem ove all but

the two on the opposing sides. Loosen the remaining two

bolts alternately, and remove the unloader cover. At this moment, the unloader cover is being pushed from

inside by spring. Remove the bolts carefully. d) Pull out unloader piston [391]and spring [392] (Photo 016).

5.4.10.2 Inspection

a) Moun t an M8 bolt of the max imum allowed l ength to the u nloader pist on, insert it in the main r otor

casing, and check the operat ion. If it does no t m ove sm oothl y, the piston or casing ma y be worn or

damaged, or have burr formed. If removal of the burrs and damages cannot improve the movement,

replace the unloader piston with a new one. b) If the spring is extremely worn or deformed, replace it with a new one. c) Unloader cover gasket [395] must be replaced with a new one.

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Chapter 5 Maintenance

Screw Compressor i-series 5.5 Reassembly

5-20

5.5 Reassembly

 When reassembling, ensure that the replaced O-rings are of the correct standard

(size, material, use for fixed portion or sliding portion, etc.). Incorrect replacement can lead to defects such as oil leakage.

 Some gaskets are asymmetrical. In that case, ensure that the assembly direction

is correct. If the assembly direction is not correct, problems such as blocking of oil passages machined in the casing may occur, resulting in serious defects.

After completing the disassembly and inspection procedures, start the assembly process. First, read again Section 5.1 "Precautions for Maintenance and Inspection" 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 reassembl y sequence is mostly the re verse of the disassem bly sequence. First of al l, clean the

work bench and the tools to be used. Immediately prior to t he assembly, use washing agent (e.g., keros ene, parts cleaner) oil to c lean the

parts to be assembled, dry them with compressed air, and sufficiently apply lubricating oil, etc. For this, prepare a sufficient am ount of clean lubr icating oil for the r eassem bly. Also, apply oil on both sides of the gasket.

Table 5-11 Tightening Torques for Hexagon Socket Head Cap Screws

Unit

M10

M12

M14

M16

N·m 10 25 50 90 140 240

kgf·cm 100 250 500 900 1400 2400

Tighten each hexagon socke head cap screw by referring to the torque shown in the above table.

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Chapter 5 Maintenance

Screw Compressor i-series 5.5 Reassembly

5-21

Photo 017 Installing Φ8 Pipe

5.5.1 Unloader

a) In the same way as for disassembly, lay main rotor

casing [1] on its side (horizontally). b) Set unloader cover gasket [395], unloader piston [391]

and spring [392] to unloader cover [393].

You can install the unloader piston and spring first. c) Insert this into t he main rotor casing, and tighten the

unloader cover. d) Screw an M8 bolt of the maximum allowed length

through the Rc1/4 hole of the unloader cover and

screw it to the unloader piston.

Check that the piston moves properly. e) Remove the M8 bolt, and install Φ8 piping [538]. f) Raise (set vertical) the main rotor casing.

5.5.2 Rotor and Inner Race of Radial Bearing

Make the rotor sufficien tly adj usted. B y using f ine emery paper, remove over an y damage o n t he shaft surface of the bearing and seal.

Both the M and F rotors have a certain engagement positions which are indicated by stamp marks.

Photo 018

M Rotor Mating Mark Photo 019 F Rotor Mating Marks

a) Shrink-fit the inner race of radial bearings [27-1] [27-2] to both the M and F rotors.

The inner race may move upward as it cools down and gets tightened. Hold it in p osition until it cools down completely. Make the combination of the inner and outer races, which have been

packaged together, recognizable. b) Screw the slotted set screw [31] fully into the M rotor. c) Insert the M rotor into the main rotor casing. As it is heavy, be careful when handling.

As the i160* rotor weighs more than 30 kg, use lifting too ls such as chain b locks and nylon belts. After pushing about ha lf of the rot or into the m ain rotor c asing, rem ove the lifting tools and push in the remaining portion of the rotor.

d) B y following the s ame procedur e as for the M rot or, push the F rotor into the m ain rotor casing. At

this moment, engage the M rotor tooth, which has stamped mark 1, between the F rotor teeth having stamped marks 1 and 2.

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Chapter 5 Maintenance

Screw Compressor i-series 5.5 Reassembly

5-22

Photo 020

M Rotor Assembly Photo 021 F Rotor Assembly

5.5.3 Bearing Head

a) Sc rew two stud bolts symm etrically. Affix the bearing head gasket [31] to the flange surface of the

main rotor casing, and apply sufficient oil. (Photo 022)

b) While lifting bearing head [11] with lifting tools,

temporarily tighten it with the 4 bolts.

c) After driving the alignment pin in position, tighten the

bolts and remove the lifting tools.

Photo 022

Affixing Gasket Photo 023 Installing Bearing Head

5.5.4 Outer Race of Radial Bearing

a) Attach the outer race of the radial bearing to the main rotor casing and bearing head, in such a way

that the inner and outer races are combined in the same manner as when they have been packaged.

b) To secure the outer race of the bearing, mount sn ap ri ngs [29-1] [29-2] to the bearing head (i160 *)

or main rotor casing (i125*).

c) Install snap ring [29-3] to the F rotor.

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Chapter 5 Maintenance

Screw Compressor i-series 5.5 Reassembly

5-23

Figure 5-2 Suction Adapter pa rt

(i125*)

5.5.5 Suction Strainer and Check Valve

The structure differs between the i125 series and i160 series.

5.5.5.1 i 125*

a) Set O-ring [495] and check valve spring [485] to check valve

shaft [491], and insert it to suction adapter [5-1].

b) While holding the check valve shaft w ith a hand to pre vent it

from coming off, insert s eat stoppers [488-1] [488-2], valve seat [489], val ve plate [490] and plain washer [46-2] in this order. Tighten hexagon nut [486].

c) Install suction adapter gasket [6-1] and suction adapter to

main rotor casing. Check that the check valve functions properly.

d) Assemble O-ring [7], strainer element [480] and wave

washer [546]. Install strainer cover gasket [6-2] and the strainer cover [5-2].

5.5.5.2 i 160*

a) Install O-ring [495], v alve plate [490], valve s eat [489], seat

stopper [488] and plain washer [487] to check valve shaft [491]. Tighten hexagon nut [486].

b) Ins ert the check valve shaft to the side of main rotor casing. Install strainer cover gasket [6] and

check valve cover [8]. c) Insert check valve spring [485], and attach a plug [10-4] to secure it. d) From the strainer cover [5] side, confirm that the check valve operates properly. e) Install O-rings [7-1] [7-2] to stainer element retainer [481]. f) Assemble stainer e lement retainer [481] and strainer el ement [480]. Install stra iner c ov er gas ket [6]

and strainer cover [5]. g) Install R1/8 plug [10-1] to the plug hole in the 6 o’clock position of the strainer cover.

Figure 5-3

Suction Strainer and Check Valve (i160*)

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Chapter 5 Maintenance

Screw Compressor i-series 5.5 Reassembly

5-24

5.5.6 Adjustment of Thrust Beari ng a nd End Cl e a rance

Figure 5-4

Thrust Bearings Block

Table 5-12

Thrust Bearing Components

 When assembling the disassembled thrust bearing without replacing any parts,

check the M and F stamp marks on the thrust bearing outer race spacer and thrust bearing alignment spacer, and reassemble them in the same way as before disassembly. This is essential to control the end clearance of the rotor discharge side.

 Even when assembling t he same beari ng, dim en sions m ay becom e inc or rect i f fl akes

of paint or di rt are caught bet ween outer race spacers and alignment spacers.

 Regarding the direction of thrust bearing assembly, there may or may not be a

V-sh aped mark for asse m bl y on the outer side o f the bearing. Follow the instruction s below for each case of assembl ing.

P/N

Part name

i125*

i160*

P/N

Part name

i125*

i160*

38-1 Thrust Bearing M 1 set 1 set 43-1 Thrust Bearing Gland M 1 1 38-2 Thrust Bearing F 1 set 1 set 43-2 Thrust Bearing Gland F 1 1 39-1 Lock Nut 1 1 45 Hexagon Head Bolt 8 8 39-2 Lock Nut 1 1 46 S pring Was her 8 -

40-1

Lock Washer

1 1 46-1

Spring Was her

40-2 Lock Washer 1 1 46-2 Plain Washer - 8 41-1

Spacer, Thrust Bearing Outer Race M

1 1 237-1 Torsional Slip Wa s her M 1 1

41-2

Spacer, Thrust Bearing Outer Race F

1 1 237-2 Torsional Slip Washer F 1 1

42-1

Spacer, Thrust Bearing Alignment M

1 1 250-1 Thrust Washer M 1 1

42-2

Spacer, Thrust Bearing Alignment F

1 1 250-2 Thrust Washer F 1 1

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Chapter 5 Maintenance

Screw Compressor i-series 5.5 Reassembly

5-25

a) The procedure for assembling this block is described in Figure 5-4.

The important points are explained below. If there is a V-shaped mark for assem bly on the o uter side of th e thrus t bear in g, assem ble with th e

pointed end of the mark on the inner side of the m achine, as there is a s light dir ectional difference

that affects end clearance adjustment.

If there is no V-shaped mark, assembly direction does not affect end clearance adjustment.

However, to clarify the difference between t he inner si de and outer s ide of the m achine, assem ble

the thrust bearing with the bearing number engravings on the outer side and then put down a

V-shaped mark on the machine's inner side by using blue sharpening stone. b) After assembling the thrust bearing, install thr ust washers [41-1] [41-2], lock washers [40-1][40-2]

and torsional slip washers [237-1] [237-2]. c) Attach dedicated shaft rotation sto ppers 1 and 2. Tighten lock nuts [39-1] [39-2] to the s pecified

torque shown in Table 5-13 or to the specified tightening angle shown in Tabl e 5-14 (refer to Section

7.1 "Tightening Angles for Lock Nuts" in this manual f or details), to fix the inner race of th e thrust

bearing to the rotor shaft. Be sure to use a new lock washer.

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 pos

ition between the lock nut wr ench h ooks and l oc k nut gr ooves about four

times when fastening the lock nut.

d) Turn the M rotor shaft by hand, to make sure that rotation of rotors is smooth.

Table 5-13 Tightening Torques for Lock Nuts

i125*

i160*

M rotor

F rotor

M rotor

F rotor

Tightening

torque

N·m

116

166

306

400

kgf·cm

1160

1660

3060

4000

Table 5-14 Tightening Angles for Lock Nuts

Model

Angle range

First turn of tightening

For both M and F rotors (i125* / i160*)

30° to 40°

Second turn of tightening

For both M and F rotors (i125* / i160*)

20° to 30°

 Since the inner race of t he t hr ust bearing is loose fit and is secured by the tighteni ng

force of the nut alo ne , the tightening work is very i mportant.

 If the thrust bearing has been replaced, the difference bet ween t he be arin g inner race

and outer race surfac es will be diff erent even when the p art s are ma nufa ctured within standard values. Therefore, fully tightening the nut from the initial use may lead to a noticeable reduct io n i n the li fe of beari ng, due to a lack of end cleara nce bet ween t he rotor and the bearing head discharge end face, and also due to indentations on the contact surfa ce f ormed by ball pressure. To avoid this, check for end clearance while tightening.

2203M4JE-MY-iS2-N_2017.04.

Chapter 5 Maintenance

Screw Compressor i-series 5.5 Reassembly

5-26

5.5.6.1 End Clearance Measurement

At this point (i.e., after the thrust bearing block has been fully assembled), m easure 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.

In particular, this measurement mus t be made when t he thrust bearing has been r eplaced. Ev en if the same bearing is used, the measurement should be made for verification.

If the measured clear ance does not satisf y the range specified in Table 5-15, proper adjustm ent mus t be made.

Table 5-15

End Clearance

i125*

i160*

End clearance mm

0.03 to 0.05

0.07 to 0.13

Photo 024

Attaching Dial Gauge to Photo 025 Tightening Thrust Bearing Gland

Rotor Shaft End

a) Push the rotor from the suction side (bearing cover side) to the discharge side while the thrust

bearing inner race is secured to the rotor shaft, by using a tool (such as the h andle edge of a soft

hammer). Alternatively, by using a chamfered part of the lock nut, pull out the rotor with the edge of a flat blade

screwdriver. b) W hen the rotor h as been p ushed to the dis charge sid e, prepare to install the thrus t bearing glan d.

Attach a dial gauge on the bearing cover side axial end of the rotor, and match the ne edle to 0

(Photo 024). c) Secure bearing g lands [43-1] [43-2] b y tightening the f our bolts [45] evenly and graduall y to the

specified torque as shown in Table 5-15. Tightening each bolt to the s pecified torque at once will

lead to uneven tightening. Tighten bolts in turn and in several steps. d)

Then, read the dial gauge measurement. This value is the actual end clearance.

If the end clearance is outside the specified value, perf orm the adjustm ent work described in the

next section. If the end clear ance is within the spec ified value, t urn the M rot or shaft by hand and

confirm the smooth tur ning without uneven tighte ning. And then perform the measurement of the

run-out of the rotor shaft described in next section (3).

Table 5-16

Tightening Torques for Thrust Bearing Glands

i125*

i160*

Tightening torque

N·m

kgf·cm

300

390

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Chapter 5 Maintenance

Screw Compressor i-series 5.5 Reassembly

5-27

Dial gauge position

(example i125*)

Figure 5-5 Runout Measurement

5.5.6.2 End Clearance Adjustment

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

To deal with this, insert shim material (thrus t adjustment liner) of required thicknes s (difference in thickness from the specified value) between the thr ust bearing alignment spacer [42] and thrust bearing inner race. * The thrust adjustm ent liner is not shown in the exploded view, but availab le from us. Place an order together with a model name.

Or using a highl y accurate surface grinding mac hine or asking professional ser vice vendors to grind, grind the surface of thrust bearing outer race spacer [41] by the difference from the specified value. After grinding the flat surface, measure the whole circumference of the thrust bearing outer race spacer by using a micrometer, and check that the thickness is even.

(2) When end clearance is larger than the specified value

As the end clearanc e is excessive, r emove shim m aterial (thrust adjustm ent liner) of a t hickness equal to the differenc e bet ween the measured value and the specified va lue if t he shim material is used between thrust bearing alignment spacer and thrust bearing inner race. Or if the shim m aterial is not used between t hrust bearing alignment spacer a nd thrust bearing inner race, or even if used but insufficient thickness, grind the s urface of thr ust bearing alignment spacer[42] by the difference between the measured value and the specified value or ask professional vendors to do so. After grinding the flat surface, measure the whole circumference of the spacer by using a micrometer, and check that the thickness is even.

(3) Rotor runout measurement

When the end clearance has been adj usted to within t he specified

range, place a d ial gauge on the sea l attachment portion of t he M

rotor shaft ( FIgure 5-5) . Measure run out by turni ng the rotor shaft.

The tolerance for runout is 0.03 mm or less for all models.

Runout occurs when the th rust bearing alignm ent spacer and outer

race spacer are not parallel or when the thrust bearing mark is not at

the correct side. And it oc curs if fastening the lock nut performed

without changing the position of the lock nut wrench (i.e., the uneven

fastening of the lock nut).

Moreover small partic les of dirt trapped between parts m ay cause excessive runout. If the rotor runout is over the tolerance, even if the end clearance is within the specified range, disassemble and adjust the relative positions of the thrus t bearing outer race spacer, alignment spacer and thrust bearing. This is important because it affects the life of the mechanical seal and its performance. If ax ial ru n out s t il l exc ee ds the to ler a n c e ev en whe n no such assembly problems exist, contact us. The rotor shaft may be bent.

5.5.6.3 Tightening after End Clearance Adjustment

a) Ben d the loc k washer claw to the notc h of the lock nut which is

tightening the thrust bearing inner race,to prevent rotation. b) Remove the hexagon head bolts that are tightening thrust

bearing gland [43] one bye one.

Insert spring washer [46] as rotation stopper, and tighten to the

specified torque again. In case of i160*, us e a f lat was her [46-2] and spring washer

[46-1], and tighten to the specified torque.

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Chapter 5 Maintenance

Screw Compressor i-series 5.5 Reassembly

5-28

5.5.7 Balance Piston

a) W ith the notc h of ba lance piston [30] aligned with the slotted s et scr ew of M r otor shaft [31], install

the balance piston. b) W ith the notch of the balance piston sleeve [33] aligned with the spring pin, install the balance

piston sleeve. c) Install snap ring [32] and O-ring [35].

5.5.8 Bearing Cover

a) Screw two stud bolts symmetrically to the flange surface of the main rotor casing. Apply sufficient oil

to the flange surface (Photo 030), and then place bearing cover gask et [17] (Photo 031).

Take note that the gasket has right/left difference. b) While using lifting tools, temporarily tighten bearing cover [16] with 4 bolts. c) After driving the alignment pin in position (Ph oto 03 2), tighten the bolts and remove the lifting tools.

Photo 030 Applying Oil with Brush Photo 031 Gasket Photo 032 alignment pin

Photo 033

T emporarily Tightening Bolts Photo 034 Final Tightening with Torque Wrench

Photo 027 Installing Balance Piston

Photo 028 Installing Balance Piston Sleeve

Photo 029 Installing Snap Ring

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Chapter 5 Maintenance

Screw Compressor i-series 5.5 Reassembly

5-29

5.5.9 Shaft seal Block

The standard mechanical seal assemblies used in the current shaft seal of standard screw compressors are of the BBSE (balance bellows single) type.

a) Before assembly, clean the portion where the mechanical seal will be installed. b) In particular, recheck immediately before assembly that the stepped portion where the axial seal will

be mounted is free of damage. c) Assemble oil seal [50] to seal retainer [48].

Since the design modification in November 2002, the oil seal attachment direction has been

changed from "facing the atmosphere side" to "facing the opposite side". The purpose of this

change is to improve oil flow from inside the seal box so that the pressure will not rise too high. Place a Teflon or other kind of resin block on the oil seal an d tap on the block to push th e oil seal

into the retainer evenl y until it bo ttoms. When it gets fully pushe d in , you will know by the change in

the tapping sound and feel. After assembly, check that the step formed at the boun dar y betwee n the oi l seal and the r etainer is

even. See from the opposite side, and confirm that they are evenly assembled. d) Using two eye bolts (M8), install the seal retainer with the oil seal along the rotor shaft.

At this time, ensure that the retainer's oil ho le is o n t he upper side of the rotor shaf t, an d ac cur at ely

align the rotation stop s pring p in [20], which has b een sc rewed to the b earing c ov er, with the notch

of the oil seal retainer. After assembly, try to turn the retainer's eye bolts to check that they are secure.

If they are properly aligned, the retainer will not rotate. e) Then, insert the O-ring [49] for the seal retainer.

 Take special care, because users f r equently omit to insert thi s O-ring [49].

Photo 035

Assembling Seal Retainer Photo 036 Inserting O-ring [49]

f) Install the seal col lar [109], which has the O -ring [112] attached to its inner peripher y, to the rotor

shaft. Before assembly, apply sufficient lubricati ng oi l onto the rotor shaft and wash away dirts.

Push in the seal collar, carefully not to damage the O-ring [112] by the step on the rotor shaft. After

installing the seal collar, push it by hand and check it’s normal movement in the axial direction.

2203M4JE-MY-iS2-N_2017.04.

Chapter 5 Maintenance

Screw Compressor i-series 5.5 Reassembly

5-30

g) By using two seal collar set screws [111], tighten the seal collar against the countersunk holes in the

rotor shaft. Tightening the seal collar at other places than the countersunk holes can cause damage

to the rotor shaft which can lead to leakage. h) Attach the O-ring [103] for mating ring and mating ring [101] to seal cover [51].

Photo 037

Tightening Seal Collar Set Screw Photo 038 After Assembly of Mating Ring

i) Apply oil to seal cover gas k et [52], align the gasket oil hole w ith t he be arin g c over oil h ol e, an d affix

gasket to the flange. * The i-series com pres sors em ploy the s tandard int ernal oil sup pl y type. With this type, the bear ing

cover and the seal co ver are connected by drilled oil suppl y holes. Oil flows thr ough the notch in

seal cover to upper side of seal cover, and t hen goes through the drilled oil supply holes to th e

sliding surfaces of mechanical seal assembly. j) Install the seal cover with the gasket, so that the oil removal piping of the seal cover is on the bottom

side. At this tim e, ass emble it car efull y, either at a right angle or by dela ying the upper side s lightl y,

while paying attention not to cause the mating ring inside the seal cover hit against the rotor shaft. The seal collar and mating ring sliding surface will come into contact midway through attachment.

At this moment, c hec k the dimensions bet ween th e s e al c ov er g as ket and the bearing co ver f la ng e

surface by using a taper gauge. This value is called " fastening margin" for seal.

It is used when checking the sliding surface pressure between the rotating ring and stationary ring of

the seal. If this value is not within t he range sho wn in Table 5-17, measures should be taken, s uch

as replacement of mechanical seal assembly or addition of another gasket.

With i-series compressor, the thickness of the seal cover gasket is 0.5 mm. In c as e of B B SE-type seal of the i-ser ies c ompressor, make sure that this value is in the ra nge of 2

to 3 mm.

Table 5-17

Fastening Margin for Seal

Seal Bearing cover Cover

* The hatched portion represents gasket.

Photo 039 Figure 5-6

Checking Fastening Margin

Checking Tightening Allowance

Model BBSE seal

i125* 2.0 to 3.0 mm i160* 2.0 to 3.0 mm

Taper gauge

2203M4JE-MY-iS2-N_2017.04.

Chapter 5 Maintenance

Screw Compressor i-series 5.5 Reassembly

5-31

k) When the seal fas tening m argin is proper, push the seal

cover firmly into the bearing cover.

Since there is repulsion force of the seal bellows, keep

it pushed firmly and tighten the two hexagon socket

head cap screws (for tightening the seal cover) evenly at

positions 180 degrees apart. When the gasket surface gets free of gap, tighten all of

the remaining screws. m) W hen tightening of the seal cover is f inished, supp ly oil

to the seal cover while rotating the shaft. This oil refilling work is very important to maintain the

airtightness in the shaft seal block when vacuuming after

compressor overhauling. n) After supplying oil, be sure to screw in the removed plug

on the seal cover. Photo 040

Supplying Oil

5.5.10 End Cover

a) Screw two stud bolts (i125*:M12/i160*:M16) symmetrically, and then place end cover gasket [23]. b) Install end cover [22].

In case of i160*, use lifting tools for safety assembly because the mass of end cover is 47 kg.

2203M4JE-MY-iS2-N_2017.04.

Chapter 6 Troubleshooting

Screw Compressor i-series

6-1

Chapter 6 Troubleshooting

Table 6-1 describes typical trouble s ymptoms of compressors, their caus es and actions to be taken. The explanations of this Ch apter are ass um ed that th e c om press or is us ed in the gener al ref riger ation cycle.

Table 6-1

Troubleshooting

Symptom

Direct cause

Root cause

Action

Compressor

does not start up.

Power source is off.

Mostly caused by

forgetting to turn on after inspection.

Use a check sheet for

post-inspection actions and implement finger pointing and call

check to prevent forgetting.

Main motor failure

Mostly caused by

activation of overload protection

circuit.

Refer to the instruction manual of

the motor for details including other causes and actions.

Cooling water

circulation is not confirmed.

Failure of devices

such as cooling water pump and related circuits

Identify defective devices,

investigate causes of failure and take necessary actions. Then, replace failed device(s).

Circulation route is

clogged.

Remove the clogging.

Failure of magnet,

relay, etc. in compressor startup circuit

Aging degradation

Identify defective devices, and replace with a new one.

Poor installatio n

environment

Replace ventilation fans, etc. if

defective. Improve temperature, humidity and ventilation at the installation

site.

Compressor

stops immediately after startup.

Low pressure

protection circuit activates.

Insufficient

refrigerant flow

・ Insufficient

refrigerant

・ Insufficient

liquid supply

・ Heat exchange

failure in heat exchanger

To correct insufficient refrigerant,

check leak, stop leak and then add refrigerant. * Also pay attention to moisture

entering into the system.

To correct insufficient liquid

supply, inspect expansion valve and liquid supply strainer. Take necessary actions. In addition, inspect devices and parameters (set values) of the expansion valve aperture adjusting mechanism, and take

necessary actions.

If there are any problem

(insufficiency) in heat exchange, such as malfunction of defrosting, investigate the cause and take

necessary actions.

In case of malfunction of pressure

adjustment valve, replace the valve or remove the cause.

Failure of low

pressure protection switch, pressure sensor, relay, etc.

Identify defective devices,

investigate causes of failure and take necessary actions. Then, replace failed device(s).

2203M4JE-MY-iS2-N_2017.04.

Chapter 6 Troubleshooting

Screw Compressor i-series

6-2

Symptom

Direct cause

Root cause

Action

Compressor

stops immediately

after startup.

Motor overload

Motor overload that occurs just after startup is mostly

caused not by the refrigeration cycle but by the motor. Refer to the instruction manual of the motor.

Abnormally

low pressure (Low suction pressure)

Refer to direct

cause, "Low pressure protection circuit activates", in

Item 02 above.

Same as left

04 Low oil

pressure (Low oil supply pressure)

Oil filter element is

clogged.

* Pressure

difference between outlet and inlet ports is large.

Contamination of

lubricating oil

Remove clogging, and check oil

for contamination/replace oil.

Internal defects of

compressor

Check for oil contamination and

conduct vibration/noise diagnosis. Overhaul compressor if necessary.

Insufficient oil in oil

separator.

Oil heater is not

functioning, refrigerant dissolves excessively when the machine is stopped, and oil loss occurs at startup.

Inspect oil heater alone, inspect

relays, etc. on related circuits, and replace parts as necessary.

Insufficient oil

return due to insufficient refrigerant circulation

Correct insufficient refrigerant

circulation, and return oil from load-side heat exchanger. * Supply lubricating oil temporarily.

Troubles such as

clogging in oil return passage

Remove causes of the trouble,

and restore the system.

Extensive oil leak

Inspect machine room and around

the compressor, and take necessary actions. Check if there is oil floating in cooling water system.

→If there is, check for oil leak

from heat transmission tube of oil cooler and take necessary actions.

If oil line piping is damaged due to

excessive vibration, take measures to reduce vibration (including measures for resonance vibration).

Oil pressure

detection function is defective.

Failure of oil

pressure protection switch, pressure sensor, relay, etc.

Identify defective device(s),

investigate causes of failure and take necessary actions. Then, replace failed device(s).

Pressure pipe is

clogged.

Remove clogging, and check oil

for contamination/replace oil.

mycom i125S, i160S, i125L, i160L, i160M Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual