EBOOK - Screw refrigerant compressor MAYEKAWA N2016MSC & LLC & MMC & LMC (Instruction Manual) | Cộng đồng Kỹ thuật cơ điện Việt Nam EBOOKBKMT

EBOOK - Máy nén lạnh trục vít MAYEKAWA N2016MSC & LLC & MMC & LMC (Hướng dẫn sử dụng).

About This Manual.

 This product may be modified without prior notice. Therefore, the appearance of actual machine may differ from the descriptions in this manual. If you have any questions, contact our sales offices or service centers. For each sight of MAYEKAWA, refer to "Contact Information" in this manual or followingURL. http://www.mayekawa.com/about/network/
 This manual is in English. If any other language is required, it is the customers responsibility to prepare a manual for safety education and operation instructions.

 This manual is copyrighted. Drawings and technical references including this manual shall not, in whole or part, be copied, photocopied, orreproduced into any electronic medium or machine-readable formwithout prior permission from MAYEKAWA.
 Photographs or drawings included in this manual may differ from the appearance of actual product.
 If this manual is lost or damaged, immediately request our local sales offices or service centers for a new manual. Using this product without the manual may result in safety issues.
 If you resell this product, never fail to attach this manual to this product.

CONTENTS:

Chapter 1 Safety
1.1 Strict Requirements and Prohibitions ........................................................ 1-1
1.1.1 Strict Requirements (Do’s)................................................................................... 1-1
1.1.1.1 Do’s on Operation ........................................................................................ 1-1
1.1.1.2 Do’s on Maintenance ................................................................................... 1-1
1.1.1.3 Do’s on Lockout/Tagout after Shutting Off the Power ................................. 1-1
1.1.1.4 Do’s about PersonalProtective Gear .......................................................... 1-2
1.1.1.5 Do’s about Handling of Hazardous and Toxic Substances .......................... 1-2
1.1.1.6 Do’s about Handling Emergency Situations ................................................ 1-2
1.1.1.7 Do’s about Waste Oil,Fluid, and Materials ................................................. 1-2
1.1.1.8 Other Do’s .................................................................................................... 1-2
1.1.2 Prohibitions (Don’ts)......................................................................................... 1-3
1.2 Warnings ....................................................................................................... 1-3
1.3 Residual Risks ............................................................................................. 1-4
1.4 Safety Devices .............................................................................................. 1-6
1.4.1 Emergency Stop Button ....................................................................................... 1-6
1.4.2 Breakers of Motor Main Power and Control Power
(with Lockout/Tagout Mechanism) ...................................................................... 1-6
1.4.3 Compressor Protective Devices .......................................................................... 1-7
Chapter 2 Compressor Specifications and Structure
2.1 Overview of the 2016**C ............................................................. 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 ................................................................................................... 2-4
2.3.3 Outer Dimensions ................................................................................................ 2-4
2.4 Structure of Compressor .......................................................................... 2-10
2.4.1 Sectional View ................................................................................................... 2-10
2.5 Mechanisms ............................................................................................... 2-11
2.5.1 Basics of the Screw Compressor ...................................................................... 2-11
2.5.2 Suction Process ................................................................................................. 2-11
2.5.3 Compression Process ........................................................................................ 2-12
2.5.4 Discharge Process ............................................................................................. 2-12
2.5.5 About Volume Ratio (Vi).................................................................................... 2-12
2.5.6 Capacity Control Mechanism............................................................................. 2-14
2.5.7 Bearings and Balance Piston ............................................................................ 2-14
2.5.8 Shaft Seal .......................................................................................................... 2-14
2.6 Gas and Oil Flow ........................................................................................ 2-15
Chapter 3 Installation
3.1 General Precautions for Installation .......................................................... 3-1
3.2 Installation Works ........................................................................................ 3-1
3.2.1 Unpacking ............................................................................................................ 3-1
3.2.2 Storage ................................................................................................................ 3-1
3.2.3 Transportation ...................................................................................................... 3-1
3.2.4 Preparation for Installation ................................................................................... 3-4
3.2.5 Installation ............................................................................................................3-5
3.2.5.1 Installation .................................................................................................... 3-5
3.2.5.2 Shaft Alignment between the Compressor and Driving Machine ................ 3-5
3.2.5.3 Piping Connection ....................................................................................... 3-6
3.2.5.4 Equipment and Devices for Protection of the Compressor ......................... 3-6
3.2.6 Airtightness Test .................................................................................................. 3-7
3.2.7 Lubricating Oil Charge ......................................................................................... 3-7
3.2.7.1 Initial Charge of Lubricating Oil ................................................................... 3-7
3.2.7.2 Additional Charge ofLubricating Oil ............................................................ 3-7
3.2.8 Charge of Refrigerant .......................................................................................... 3-7
3.2.9 Check after Installation ........................................................................................ 3-7
Chapter 4 Compressor and Package Unit Operation
4.1 Lubricating Oil (Refrigerant Oil) ................................................................. 4-1
4.1.1 Precautions for Selecting the Lubricating Oil....................................................... 4-1
4.1.2 Recommended Lubricating Oils .......................................................................... 4-1
4.1.2.1 Recommended Lubricating Oils for Ammonia Refrigerant .......................... 4-1
4.1.2.2 Oils for systems using Hydrofluorocarbon (HFC) refrigerants .................... 4-2
4.1.3 Change of Lubricating Oil Brand ......................................................................... 4-3
4.1.4 Precautions for Handling lubricating Oil .............................................................. 4-4
4.1.4.1 Precautions for Handling Polyalkylene Glycol (PAG) .................................. 4-4
4.1.4.2 Precautions for Handling Polyolester (POE) Oil .......................................... 4-4
4.1.5 Lubricating Oil Management Criteria ................................................................... 4-5
4.1.6 Lubricating Oil Replacement Timing .................................................................... 4-6
4.1.6.1 After Starting the Initial Operation ............................................................... 4-6
4.1.6.2 During NormalOperation............................................................................. 4-6
4.2 Precautions for Operation ........................................................................... 4-7
4.2.1 Prevention of Liquid Flow-back Operation ........................................................... 4-7
4.2.2 Purging of Non-Condensable Gases ................................................................... 4-7
4.3 When Stopping the Compressor for a Long Time .................................... 4-8
Chapter 5 Maintenance and Inspection
5.1 Precautions for Maintenance and Inspection ............................................ 5-1
5.2 Maintenance and Inspection List................................................................ 5-3
5.2.1 Daily Management ............................................................................................... 5-3
5.2.2 Periodic Inspection .............................................................................................. 5-5
5.2.3 Guidelines for the Timing of Compressor Overhaul ............................................ 5-6
5.3 Compressor Disassembly Preparation ...................................................... 5-7
5.3.1 Disassembly Tools and Workplace ..................................................................... 5-7
5.3.2 ReplacementParts .............................................................................................. 5-7
5.3.3 Refrigerant Gas Recovery................................................................................. 5-10
5.3.4 Removal of Connections to the Unit .................................................................. 5-11
5.3.5 Removal and Lifting the Compressor ................................................................ 5-12
5.3.6 Draining Oil from the Compressor ..................................................................... 5-12
5.4 Disassembly and Inspection ..................................................................... 5-13
5.4.1 Shaft SealBlock ................................................................................................ 5-15
5.4.1.1 Disassembly .............................................................................................. 5-15
5.4.1.2 Inspection .................................................................................................. 5-16
5.4.2 Unloader Indicator ............................................................................................. 5-18
5.4.2.1 Disassembly .............................................................................................. 5-18
5.4.2.2 Inspection .................................................................................................. 5-20
5.4.3 Unloader Cover .................................................................................................. 5-21
5.4.3.1 Disassembly .............................................................................................. 5-21
5.4.3.2 Inspection .................................................................................................. 5-22
5.4.4 Unloader Piston and Unloader Cylinder ............................................................ 5-22
5.4.4.1 Disassembly .............................................................................................. 5-22
5.4.4.2 Inspection .................................................................................................. 5-23
5.4.5 Bearing Cover .................................................................................................... 5-24
5.4.5.1 Disassembly .............................................................................................. 5-24
5.4.6 Separating High-stage and Low-stage .............................................................. 5-25
5.4.6.1 Disassembly .............................................................................................. 5-25
5.4.7 Gear Coupling .................................................................................................... 5-25
5.4.7.1 Disassembly .............................................................................................. 5-26
5.4.7.2 Inspection .................................................................................................. 5-26
5.4.8 Balance Piston Cover ........................................................................................ 5-27
5.4.9 Balance Piston ................................................................................................... 5-27
5.4.9.1 Disassembly .............................................................................................. 5-27
5.4.9.2 Inspection .................................................................................................. 5-28
5.4.10 High-stage Suction Cover and Side Bearings ................................................... 5-29
5.4.10.1 Disassembly .............................................................................................. 5-29
5.4.10.2 Inspection .................................................................................................. 5-30
5.4.11 Low-stage Suction Cover and Side Bearings .................................................... 5-31
5.4.11.1 Disassembly .............................................................................................. 5-31
5.4.11.2 Inspection .................................................................................................. 5-31
5.4.12 Thrust Bearing Block ......................................................................................... 5-32
5.4.12.1 Disassembly of the High-stage Thrust Bearing Block ............................... 5-32
5.4.12.2 Disassembly of the Low-stage Thrust Bearing Block ................................ 5-33
5.4.12.3 Inspection (High-stage and Low-stage) ..................................................... 5-33
5.4.13 High-stage Rotors and Main Rotor Casing ........................................................ 5-35
5.4.13.1 Disassembly .............................................................................................. 5-35
5.4.13.2 Inspection .................................................................................................. 5-35
5.4.14 Low-stage Rotors and Main Rotor Casing ......................................................... 5-36
5.4.15 High-stage Bearing Head and Main Bearings ................................................... 5-37
5.4.15.1 Disassembly .............................................................................................. 5-37
5.4.16 Low-stage Bearing Head and Main Bearings .................................................... 5-38
5.5 Reassembly ................................................................................................ 5-39
5.5.1 Unloader Slide Valve and Guide Block .............................................................. 5-41
5.5.2 Bearing Head and Main Bearings ...................................................................... 5-42
5.5.3 Bearing Head and MainRotor Casing ............................................................... 5-43
5.5.4 Installing Rotors ................................................................................................. 5-44
5.5.5 Suction Cover and Side Bearings...................................................................... 5-45
5.5.6 Balance Piston Sleeve ....................................................................................... 5-46
5.5.7 Installing Suction Cover ..................................................................................... 5-47
5.5.8 Thrust Bearing Block ......................................................................................... 5-49
5.5.8.1 End Clearance Measurement .................................................................... 5-51
5.5.8.2 Procedure for End Clearance Adjustment ................................................. 5-53
5.5.8.3 Tightening after Finishing the End Clearance Adjustment ........................ 5-52
5.5.9 Bearing Cover .................................................................................................... 5-54
5.5.10 Coupling High-stage and Low-stage Blocks ...................................................... 5-55
5.5.11 Balance Piston Cover and High-stage Unloader Cylinder ................................. 5-57
5.5.12 Low-stage Unloader Cylinder............................................................................ 5-59
5.5.13 Shaft Seal Block ................................................................................................ 5-61
5.5.13 Unloader Cover .................................................................................................. 5-64
5.5.15 Unloader Indicator ............................................................................................. 5-65
5.5.15.1 Potentiometer ............................................................................................ 5-65
5.5.15.2 Micro-switches and Micro-switch Cam ...................................................... 5-66
5.5.15.3 Reassembly ............................................................................................... 5-66
Chapter 6 Troubleshooting
01: Compressor does not start up ................................................................................ 6-1
02: Compressor stops immediately after startup .......................................................... 6-1
03: Unusually low pressure (decrease of suction pressure) ........................................ 6-2
04: Low oil pressure (low lubricating oil supply pressure) ............................................ 6-2
05: Intermediate pressure is unusually high ................................................................. 6-3
06: Unusually high pressure (abnormal discharge pressure) ...................................... 6-4
07: Discharge temperature is abnormally high ............................................................. 6-5
08: Leak from mechanical seal ..................................................................................... 6-6
09: Squeaking of mechanical seal................................................................................ 6-7
10: Capacity control position isindicated incorrectly.................................................... 6-7
11: Capacity control malfunction .................................................................................. 6-8
12: Compressor generates abnormal vibration and/or sound ...................................... 6-9
Chapter 7 Related Documents
7.1 Development Views, Assembly Sectional Views ...................................... 7-1
7.2 Parts Configuration Table ......................................................................... 7-13
7.3 Tightening Torques for Bolts and Nuts ................................................... 7-20
7.4 About the O-rings Used ............................................................................. 7-22
7.4.1 List of O-rings Used ........................................................................................... 7-22
7.4.2 O-ring Materials Used for Screw Compressor ................................................... 7-22
7.5 Tools for Disassembly............................................................................... 7-23
Contact Information
Sales Offices in Japan ........................................................................................... Contact-1
Manufacturing Bases in Japan ............................................................................... Contact-1
Global Network ....................................................................................................... Contact-2
NORTH AMERICA ........................................................................................................ Contact-2
EUROPE and AFRICA .................................................................................................. Contact-2
ASIA PACIFIC ............................................................................................................... Contact-3
LATIN AMERICA ........................................................................................................... Contact-5

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