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2205B0JE-DA-J-N_2014.05.

1 Safety

Screw Compressor J-series

1.2 Warnings

1-6



Affixing Positions of Safety Labels

The figure below shows the affixing positions of safety labels.

The numbers in the figure correspond to the ones in Table1-2 Safety Label.

Figure 1-1 Safety Label Locations (170J/220J)

Figure 1-2 Safety Label Locations (280J)

Summary of Contents for 170J

Page 1: ...V 220JM V 220JL V 280JS V 280JM V 280JL V CAUTION Before operating maintaining or inspecting this product read the manual thoroughly and fully understand the contents Keep the operation manual in a s...

Page 2: ...nual Keep this manual in a safe place near the product for quick reference Revision History Instruction manual name Document No First edition issue date J Series Instruction manual 2205B0JE DA J N_201...

Page 3: ...e of this product caused by natural disaster or other accidental forces such as windstorm intense rainfall flood tidal wave earthquake land subsidence thunderbolt fire etc Malfunction damage or defect...

Page 4: ...low any person other than those educated on the fundamental expertise of the product and trained about hazards involved and measures to avoid dangers to approach the product while it is operating or d...

Page 5: ...ed in this manual may differ from the appearance of actual product If this manual is lost or damaged immediately place a purchase order to your local sales office or service center for a new manual Us...

Page 6: ...Toxic Substances 1 2 1 1 1 6 Do s about Handling Emergency Situation 1 2 1 1 1 7 Do s about Waste Oil Fluid and Materials 1 2 1 1 1 8 Other Do s 1 3 1 1 2 Prohibition Don ts 1 3 1 2 Warnings 1 4 1 2 1...

Page 7: ...llation Work 3 2 3 2 1 Unpacking 3 2 3 2 2 Storage 3 2 3 2 3 Transfer 3 2 3 2 4 Preparation for Installation 3 3 3 2 5 Installation 3 4 3 2 5 1 Installation 3 4 3 2 5 2 Piping 3 5 3 2 5 3 Equipment an...

Page 8: ...20 5 4 2 Replacement Parts 5 20 5 4 3 Recovering the Refrigerant 5 20 5 4 4 Removing the Compressor 5 21 5 4 5 Removing Oil from Inside the Compressor 5 22 5 4 6 Common Work Items 5 23 5 4 7 Vi Positi...

Page 9: ...Installation 5 59 5 4 18 Suction Cover 5 60 5 4 18 1 Common Precautions for Removal Installation 5 60 5 4 18 2 Precautions for Removal 5 61 5 4 18 3 Precautions for Installation 5 61 5 4 19 Rotors 5 6...

Page 10: ...2 7 3 List of Tools for Disassembly 7 27 7 4 Design Modification Notification follow up 7 28 Appendix 1 Tips for Design Manufacturing and Installation of the Compressor Package Appendix 1 1 Precaution...

Page 11: ...gerant oils and follow their instructions When stopping the compressor for a long time turn OFF the main motor heater and control power Close the suction and discharge side shut off valves 1 1 1 2 Do...

Page 12: ...ontrol power and do not lockout tagout the main motor and control power because they think it is not important After checking that all the work is finished the worker who applied lockout tagout must r...

Page 13: ...r immediately wipe it off to prevent workers from injury caused by slipping 1 1 2 Prohibition Don ts Do not remove or relocate any safety devices including electrical interfaces Do not disable any saf...

Page 14: ...which if not avoided will result in serious injury or death Indicates a potential hazardous situation which if not avoided could result in serious injury or death Indicates a potential hazardous situa...

Page 15: ...2205B0JE DA J N_2014 05 1 Safety Screw Compressor J series 1 2 Warnings 1 5 Types of Safety Labels Table 1 2 Safety Label No Safety label Remarks 1 2...

Page 16: ...nings 1 6 Affixing Positions of Safety Labels The figure below shows the affixing positions of safety labels The numbers in the figure correspond to the ones in Table1 2 Safety Label Figure 1 1 Safety...

Page 17: ...touch terminal box Shut off and lockout tagout of motor s main power and control power C Compressor suction casing Frostbite caused by contact Contact with or inhalation of hazardous substances caused...

Page 18: ...sed by contact Install terminal protective cover and prohibit opening Keep away and do not touch Wear protective gear Shut off each breaker and shut off and lockout tagout the control power Wear prote...

Page 19: ...2205B0JE DA J N_2014 05 1 Safety Screw Compressor J series 1 3 Residual Risks 1 9 Figure 1 3 Hazardous Sources 170J 220J Figure 1 4 Hazardous Sources 280J...

Page 20: ...rating control room Stop Reset Methods To activate and reset the emergency stop buttons refer to the unit instruction manual Inspection Method Cycle The emergency stop buttons must be tested before a...

Page 21: ...ops the compressor when oil supply is not sufficient the oil filter is clogged too much refrigerant in oil or oil supply pressure difference from suction pressure is below the set value This is to pro...

Page 22: ...the compressor and must be periodically inspected For inspection methods and periods refer to the package instruction manual Adjust the set values and check operation of the compressor protection fun...

Page 23: ...e without overhaul because of the following features A new rotor profile that reduces the bearing load radial sleeve bearings specially designed with s original technology and special high load capaci...

Page 24: ...oil supply Rc1 2 Capacity control and Vi control oil supply drain Oil supply Rc1 2 Oil drain Rc1 2 E port ANSI 300 1 I port ANSI 300 3 4 Theoretical displacement 3550 min 1 m3 h 469 610 793 2950 min 1...

Page 25: ...ntrol and Vi control oil supply drain Oil supply Rc1 2 Oil drain Rc1 2 E port ANSI 300 1 1 2 I port ANSI 300 3 4 Theoretical displacement 3550 min 1 m3 h 1030 1340 1741 2950 min 1 m3 h 856 1114 1447 C...

Page 26: ...Oil injection oil supply ANSI 300 1 1 4 Capacity control and Vi control oil supply drain Capacity control Increase Decrease Rc1 2 on each side Vi control Increase Decrease Rc1 2 on each side E port AN...

Page 27: ...but when using in the explosion proof area it is 55 Minimum lubrication temperature C 20 Maximum rotation speed M rotor min 1 4500 280J 3600 Minimum rotation speed M rotor min 1 1450 Refrigerant NH3 H...

Page 28: ...mpressor J series 2 3 Compressor Specifications 2 6 Figure 2 1 Operation Limits Chart NOTE1 The pressure values in the operation limit chart are absolute values MPa A Operation range Pressurized lubri...

Page 29: ...ons of the Compressor Screw Compressor J series 2 3 Compressor Specifications 2 7 2 3 3 Outer Dimensions Outer dimensions of the 170J and 220J series Standard Specification Figure 2 1 Outer Dimensions...

Page 30: ...ANSI 300 3 4 4 M16 ANSI 300 3 4 4 M16 8 F injection Option Rc1 2 Rc3 4 9 Hydraulic cylinder oil supply Rc1 2 10 Hydraulic cylinder oil drain Rc1 2 11 Hydraulic cylinder oil return Rc1 2 12 Unloader in...

Page 31: ...3 Outer Dimensions of the 170J and 220J Series Motor Spacer Table 2 6 170J and 220J series Outer Dimensions Table Motor Spacer Unit mm I t e m 1 7 0 J 2 2 0 J NEMA IEC NEMA IEC 44 D 50 D FF 500 FF 600...

Page 32: ...re and Specifications of the Compressor Screw Compressor J series 2 3 Compressor Specifications 2 10 Outer dimensions of the 170J and 220J series Explosion Proof Figure 2 4 Outer Dimensions of the 170...

Page 33: ...F injection Option Rc1 2 Rc3 4 9 1 Capacity control increase Rc1 2 9 2 Capacity control decrease Rc1 2 10 1 Vi control increase L H Rc1 2 10 2 Vi control decrease H L Rc1 2 11 Capacity control oil re...

Page 34: ...DA J N_2014 05 2 Structure and Specifications of the Compressor Screw Compressor J series 2 3 Compressor Specifications 2 12 Outer dimensions of the 280J series Figure 2 5 Outer Dimensions of the 280...

Page 35: ...1 2 8 M20 7 I port ANSI 300 1 4 M16 8 F injection Option Rc1 1 4 9 1 Capacity control increase Rc1 2 9 2 Capacity control decrease Rc1 2 10 1 Vi control increase L H Rc1 2 10 2 Vi control decrease H L...

Page 36: ...ompressor J series 2 4 Structure of the Compressor 2 14 2 4 Structure of the Compressor For the names and locations of the compressor components refer to 7 1 Development View and Configuration Table o...

Page 37: ...5B0JE DA J N_2014 05 2 Structure and Specifications of the Compressor Screw Compressor J series 2 4 Structure of the Compressor 2 15 2 4 1 Sectional View Figure 2 7 Sectional View of the 170J Series 1...

Page 38: ...2205B0JE DA J N_2014 05 2 Structure and Specifications of the Compressor Screw Compressor J series 2 4 Structure of the Compressor 2 16 Figure 2 8 Sectional View of the 170J Series 2 3...

Page 39: ...2014 05 2 Structure and Specifications of the Compressor Screw Compressor J series 2 4 Structure of the Compressor 2 17 794 ASSY Figure 2 9 Sectional View of the 170J Series 3 3 Liquid Injection Port...

Page 40: ...2205B0JE DA J N_2014 05 2 Structure and Specifications of the Compressor Screw Compressor J series 2 4 Structure of the Compressor 2 18 Figure 2 10 Sectional View of the 220J Series 1 3...

Page 41: ...2205B0JE DA J N_2014 05 2 Structure and Specifications of the Compressor Screw Compressor J series 2 4 Structure of the Compressor 2 19 Figure 2 11 Sectional View of the 220J Series 2 3...

Page 42: ...2014 05 2 Structure and Specifications of the Compressor Screw Compressor J series 2 4 Structure of the Compressor 2 20 794 ASSY Figure 2 12 Sectional View of the 220J Series 3 3 Liquid Injection Port...

Page 43: ...2205B0JE DA J N_2014 05 2 Structure and Specifications of the Compressor Screw Compressor J series 2 4 Structure of the Compressor 2 21 Figure 2 13 Sectional View of the 280J Series 1 3...

Page 44: ...2205B0JE DA J N_2014 05 2 Structure and Specifications of the Compressor Screw Compressor J series 2 4 Structure of the Compressor 2 22 Figure 2 14 Sectional View of the 280J Series 2 3...

Page 45: ...2014 05 2 Structure and Specifications of the Compressor Screw Compressor J series 2 4 Structure of the Compressor 2 23 794 ASSY Figure 2 15 Sectional View of the 280J Series 3 3 Liquid Injection Port...

Page 46: ...profiles The rotor with five lobe sections is called the male M rotor while the one with six lobe sections is called the female F rotor Figure 2 16 Compressor Mechanisms The compressor is driven by a...

Page 47: ...olating the gas from the suction port 1 Start of suction 2 Suction continues 3 Just before suction completion 4 Suction side sealed Figure 2 18 Suction Process 2 5 3 Compression Process As the rotors...

Page 48: ...2205B0JE DA J N_2014 05 2 Structure and Specifications of the Compressor Screw Compressor J series 2 6 Oil Flow 2 26 2 6 Oil Flow Figure 2 21 Oil Flow 170J 220J Series Figure 2 22 Oil Flow 280J Series...

Page 49: ...series can vary capacity continuously using the slide valve capacity control structure This control system offers a wide capacity control range with high efficiency by hydraulic control Figure 2 23 S...

Page 50: ...d Vi is shown as follow Vi Volume of refrigerant gas after suction when compression begins Volume of refrigerant gas when discharge port opens end of compression Vi is the ratio of the volume between...

Page 51: ...acteristics are inevitable for a fixed Vi screw compressor and become obvious when the discharge port Vi does not match the actual operation conditions The J series has a structure that can vary Vi of...

Page 52: ...following three ports L port Vi 2 5 M port Vi 3 5 H port Vi 5 0 Note 1 For the J series a specified controller is always required 2 8 4 Vi Position Sensor Figure 2 27 Vi Sensor Wiring Diagram Table 2...

Page 53: ...mation only Maximum flow rate coefficient Cv value 0 33 0 35 Applicable standard UL and CSA CE Note 1 This pressure represents the gauge pressure Note 2 Proper operation is not possible when the kinem...

Page 54: ...nd Variable Vi Control SV1 1 SV2 1 SV3 1 SV4 1 RV1 1 RV2 1 Load Off On On Off Unload On Off Off On SV1 2 SV2 2 SV3 2 SV4 2 RV1 2 RV2 2 H L Off On On Off L H On Off Off On Note 1 If it is not possible...

Page 55: ...sure See Note 2 0 4 0 6 MPa U P Maximum Flow rate coefficient Cv value 0 53 and over Minimum Flow rate coefficient Cv value 0 10 or less Note 1 In this manual unless otherwise noted pressure units MPa...

Page 56: ...procedure is different from the contents of this manual prepare an installation procedure manual referring to this chapter and considering safety precautions before installing the compressor If there...

Page 57: ...ny problems such as deformation knot wire breakage Do not start lifting unless the lifting slings are verified that they have no problems If you cannot make correct evaluation or judgment entrust an e...

Page 58: ...nt direction and check safety 15 Do not lift the compressor above any safety passage unless in unavoidable case 16 Do not put the compressor in a safety passage Always keep the safety passage free of...

Page 59: ...ety bolts M16 60 to the bearing cover flange face of the compressor 2 Lift the compressor horizontally using lifting equipment such as a crane and align the compressor flange to the motor spacer flang...

Page 60: ...he instructions below The compressor is one of the few equipments with moving components in refrigerating cold storage and air conditioning packages The moving components are adversely affected by for...

Page 61: ...r Make sure to install a protection function thermostat etc to prevent overheating Suction Strainer When miscible oil is used the mesh size of suction strainer should be 200 meshes or more or when non...

Page 62: ...sure to the design pressure of the package and maintain the pressure for at least 30 minutes while checking the flange connections and fittings for any leaks using leak detector fluid such as soapy wa...

Page 63: ...s using a coupling 9 If lubricant flows through the oil supply line normally after the above works the initial lubricant charge is completed After the initial charge of lubricant make sure that the oi...

Page 64: ...Installation Screw Compressor J series 3 3 Documents Related to Installation 3 9 3 3 Documents Related to Installation Lifting Positions Gravity Center Positions Lifted View Figure 3 5 Center of Gravi...

Page 65: ...2205B0JE DA J N_2014 05 3 Installation Screw Compressor J series 3 3 Documents Related to Installation 3 10 Figure 3 6 Center of Gravity and Lifting Points 220J...

Page 66: ...2205B0JE DA J N_2014 05 3 Installation Screw Compressor J series 3 3 Documents Related to Installation 3 11 Figure 3 7 Center of Gravity and Lifting Points 280J...

Page 67: ...2205B0JE DA J N_2014 05 3 Installation Screw Compressor J series 3 3 Documents Related to Installation 3 12 Figure 3 8 Compressor being Lifted...

Page 68: ...check the unloader solenoid valve operation start the oil pump and adjust the pressure Set the oil pump discharge pressure 0 2 MPa 0 05 MPa higher than the oil pump suction pressure 4 Using the contro...

Page 69: ...The lubricant must be selected such that it is supplied to the compressor with appropriate viscosity 13 to 40 mm 2 s in the operating conditions In a system utilizing a screw compressor the lubricant...

Page 70: ...5 70 Refrigeration oil S4 FR V 32 Shell 32 35 65 Refrigeration oil S4 FR V 46 46 45 70 Refrigeration oil S4 FR V 68 68 55 70 PAO AB Gargoyle Arctic NH68 Exxon Mobil 68 55 70 Reflo Synthetic 68A Petro...

Page 71: ...t adopt different package components and refrigeration flow e g type of evaporator with or without oil return line Therefore miscible lubricant must not be changed to non miscible lubricant If you cha...

Page 72: ...entry must be avoided Therefore special attention must be paid as with PAG when handling POE Finish the charging in as short a time as possible after opening the bale can to minimize exposure to air M...

Page 73: ...initial installation or maintenance is insufficient or the suction pressure is lower than the atmospheric pressure to suck air if the suction pipe had a leak non condensable gases accumulate in the c...

Page 74: ...essor inlet If the stoppage period is 1 month or longer perform the following checks every month Measure the package pressure Check for refrigerant leak using a leakage detector Operate the oil pump f...

Page 75: ...ccur Do not modify the compressor or any of its parts without prior permission of Mayekawa It may cause the compressor to be damaged or disabled from maintaining its normal functions To disassemble th...

Page 76: ...Pa represents the gauge pressure in this manual These operation data should be recorded in an operating log book on a daily basis This practice is significantly effective and helpful in finding out an...

Page 77: ...er and lower limits Temperature flow rate etc of the object to be cooled Degree of superheat for suction C Whether degree of superheat is proper Adjust expansion valve Insufficient refrigerant flow Di...

Page 78: ...al period of operation if it is attached At the beginning of operation or just after the periodical maintenance the differential pressure of the suction strainer may increase in a short time If the di...

Page 79: ...e analysis results do not satisfy the management criteria provided in 5 3 Management of Lubricant in this manual replace oil Oil filter Replace annually When the differential pressure between oil filt...

Page 80: ...on Example Recommended Overhaul Frequency Relatively stable operating condition Cold storage and refrigeration Every 5 years or 40 000 operating hours Relatively changing operating condition Ice maker...

Page 81: ...S B 2401 P375 17 1 O ring 1 JIS B 2401 P300 17 2 O ring 1 JIS B 2401 P14 23 O ring 2 JIS B 2401 G115 35 1 O ring 1 JIS B 2401 G90 35 2 O ring 1 JIS B 2401 G115 49 O ring 1 JIS B 2401 G120 52 1 O ring...

Page 82: ...1 AW09 46 Conical spring washer 12 Hexagon socket head cap screw M8 237 1 Torsional slip washer 1 237 2 Torsional slip washer 1 293 Spiral retaining ring 2 FRSN 45 489 Valve sheet 1 485 Spring check v...

Page 83: ...s any damage 79 Retaining ring C type External 1 JISB2804 S10 To be replaced if there is any damage 716 Retaining ring E type 1 JIS B2804 E snap ring 4 To be replaced if there is any damage 78 Ball be...

Page 84: ...there is any damage 250 1 Thrust washer M 1 To be replaced if there is any damage 250 2 Thrust washer F 1 To be replaced if there is any damage 31 Balance piston key 1 To be replaced if there is any...

Page 85: ...2401 P14 23 1 O ring 1 JIS B 2401 G150 23 2 O ring 1 JIS B 2401 G115 35 1 O ring 1 JIS B 2401 P120 35 2 O ring 1 JIS B 2401 G150 49 O ring 1 JIS B 2401 G145 52 1 O ring 1 JIS B 2401 G145 52 2 O ring...

Page 86: ...ck washer 1 AW16 40 2 Lock washer 1 AW12 70 Lock washer 1 AW07 46 Conical spring washer 12 for Hexagon socket head cap screw M12 237 1 Torsional slip washer 1 237 2 Torsional slip washer 1 293 Spiral...

Page 87: ...JIS B 2804 S65 To be replaced if there is any damage 37 Retaining ring C type Internal 1 JIS B 2804 H120 To be replaced if there is any damage 79 Retaining ring C type External 1 JISB2804 S10 To be r...

Page 88: ...is any damage 42 2 Thrust bearing alignment spacer F 1 To be replaced if there is any damage 250 1 Thrust washer M rotor 1 To be replaced if there is any damage 250 2 Thrust washer F rotor 1 To be re...

Page 89: ...JIS B 2401 P580 9 1 O ring 1 JIS B 2401 P85 12 O ring 1 JIS B 2401 P580 17 1 O ring 1 JIS B 2401 P480 17 2 O ring 1 JIS B 2401 P14 23 1 O ring 1 JIS B 2401 G190 23 2 O ring 1 JIS B 2401 G150 35 1 O r...

Page 90: ...washer 1 AW09 46 Conical spring washer 12 Hexagon socket head cap screw M16 237 1 Torsional slip washer 1 237 2 Torsional slip washer 1 293 Spiral retaining ring 2 FRSN 75 711 Spring 1 27 Bearing for...

Page 91: ...ny damage 25 M rotor 1 To be replaced if there is any damage 26 F rotor 1 To be replaced if there is any damage 42 1 Thrust bearing alignment spacer M 1 To be replaced if there is any damage 42 2 Thru...

Page 92: ...mination level Contamination measured by gravimetric analysis millipore filter value is 15 mg 100 mL or less Table 5 9 Mineral oil synthetic oil AB PAO Item Management Standards a Color ASTM color sta...

Page 93: ...he management standards for each oil type detailed in tables 5 8 to 5 10 replace the lubricant 5 3 2 2 During normal operation Lubricant gradually degrades when used for a long term Though the degrada...

Page 94: ...this chapter Perform the work in a dry place with as little sand and dust as possible with a sufficiently wide space around there 5 4 2 Replacement Parts Prepare genuine replacement parts referring t...

Page 95: ...ing 4 Open the capacity control solenoid valve and variable Vi solenoid valve manually and dispose oil and refrigerant inside the cylinder 5 Turn off the control power 6 Disconnect the Vi position sen...

Page 96: ...for 280JS 2450 kg for 280JM 2600 kg for 280JL 5 4 5 Removing Oil from Inside the Compressor While placing the compressor on the work bench remove the drain plug at the bottom of the compressor as sho...

Page 97: ...parts make sure to lubricate them bearing balance piston rotor For the parallel pin and locknut threads apply sticking preventive lubricants molybdenum disulfide a solid lubricant Before hammering in...

Page 98: ...may cause injuries or damage to the compressor Always attach stud bolts before installing or disassembling the casing or cover To disassemble the casing first loosen all bolts and then remove the par...

Page 99: ...23 11 O ring G25 717 4 Potentiometer assembly 12 Retaining ring E type 716 Potentiometer 13 Vi position sensor rod 712 Vi position sensor support 14 Spring 711 Hexagon socket head cap screw M3 10 15 P...

Page 100: ...e Vi position sensor rod may jump out and cause injuries During and after retaining ring removal do not direct the Vi position sensor assembly toward anyone 5 4 7 2 Precautions for Removal Sensor box...

Page 101: ...1 8 O ring G100 657 2 Hexagon socket head cap screw M8 30 53 9 Mechanical seal assembly Mating ring 100 100 2 3 Seal cover assembly 4 O ring G145 52 2 10 Mechanical seal assembly O ring 100 100 1 5 O...

Page 102: ...G120 G140 657 2 Hexagon socket head cap screw M10 35 M12 40 53 8 Mechanical seal assembly Mating ring 100 100 2 3 Seal cover assembly 4 O ring G145 G165 52 1 9 Mechanical seal assembly O ring 100 100...

Page 103: ...ng the seal cover assembly do not damage the male rotor shaft surface and the mechanical seal mating ring Retaining ring The retaining ring may jump out causing injuries Always use retaining ring plie...

Page 104: ...rings are all attached Mechanical seal assembly mating ring 1 Attach the mating ring to the seal cover Shower flushing sleeve 1 Using eyebolts M8 install the shower flashing sleeve Seal cover assembly...

Page 105: ...g 100 4 12 Hexagon socket head cap screw 280J M20 50 18 3 Mechanical seal assembly 100 Hexagon socket head cap screw M12 50 M16 60 18 1 Rotating ring 100 3 Hexagon socket head cap screw M12 70 M16 90...

Page 106: ...al assembly rotating ring Loosen the hexagon socket set screw for at least more than 5 turns and remove mechanical seal assembly from the male rotor shaft If the hexagon socket set screw is not turned...

Page 107: ...Using the lifting equipment remove the bearing cover 5 4 9 3 Precautions for Installation O ring P300 P375 P480 1 After disassembly replace the existing O rings with new ones Oil seal 1 With the lip o...

Page 108: ...M5 75 535 11 Spring lock washer 536 12 Capacity control variable Vi solenoid valve 562 7 Spring lock washer 536 13 O ring 561 1 Remove the parts in the order of the numbers shown in the figure 2 Insta...

Page 109: ...ssure oil dissolved in refrigerant within the variable Vi cylinder and the capacity control cylinder the refrigerant gas or oil may blow off when the capacity control solenoid valve and the variable V...

Page 110: ...O ring G135 G175 75 1 18 Locknut FU05SS AN07 69 6 Hexagon socket head cap screw M6 15 81 19 Plain washer 170J Lock washer AW07 220J 70 7 Bearing gland 80 20 Unloader piston assembly 8 Unloader indicat...

Page 111: ...cket head cap screw M6 15 81 16 Locknut AN09 69 5 Bearing gland 80 17 Lock washer AW09 70 6 Unloader indicator cam assembly 18 Unloader piston assembly 7 Unloader indicator cam 77 19 Unloader piston 6...

Page 112: ...unloader piston when disassembling the 170JS 170JM 220JS 220JM 280JS and 280JM Therefore install the unloader spacer to the unloader push rod before installing the unloader piston when assembling the...

Page 113: ...nloader piston 1 Attach the O ring P130 P170 P225 to the unloader piston 2 Attach the Teflon cap seal to the outside of the O ring 3 Using eyebolts M8 put the unloader piston into the unloader cylinde...

Page 114: ...der cylinder cover spacer to the unloader cylinder cover with the flat face to the atmosphere side Unloader indicator cam assembly 1 Install the ball bearing to the cam shaft with the surface with sta...

Page 115: ...must face upwards when installing into the unloader slide valve push rod pin 2 Install the unloader assembly to the unloader cylinder with the diagonal service holes of the unloader cover horizontal...

Page 116: ...ocket head cap screw M12 70 M16 90 M20 110 61 4 O ring G135 G175 G230 298 Hexagon socket head cap screw M12 110 M16 140 M20 170 62 5 Back up ring for O ring SUN 2BP 32 SUN 2BP 44 SUN 2BP 58 325 2 2 Un...

Page 117: ...3 Remove the two upper hexagon socket head cap screws M12 70 M16 90 M20 110 and attach stud bolts for safety 4 Remove the hexagon socket head cap screws M12 110 M16 140 M20 170 5 Insert the hexagon s...

Page 118: ...between the two back up rings Unloader cylinder partition plate 1 Install unloader cylinder partition plate to the unloader cylinder with the projection side facing out towards the atmosphere Do not...

Page 119: ...ring WG36 G200 63 1 7 Spiral retaining ring FRSN 45 FRSN 56 293 2 O ring P14 63 2 8 Vi piston assembly 3 Bush P14 type O ring 537 9 O ring P52 P65 295 4 Cylinder Vi 296 10 Teflon cap seal SUNR BE 130...

Page 120: ...ion Part No Order Description Part No 1 O ring G260 63 6 O ring P85 295 2 Cylinder Vi 296 7 Piston Vi 294 3 O ring G260 63 8 O ring P225 65 4 Spiral retaining ring FRSN 75 293 9 Teflon cap seal SUNR B...

Page 121: ...piston by holding the hexagon socket head cap screws M12 for 170J M8 for 220J 280J used as service bolts Spiral retaining ring Do not attempt to extend the spiral retaining ring excessively in the axi...

Page 122: ...ion Part No 1 Parallel pin 10 dia 55 16 dia 55 16 dia 70 591 5 O ring G100 G100 G135 299 1 2 Hexagon socket head cap screw M12 50 M16 60 M20 70 24 6 O ring WG36 G200 G260 299 2 3 Balance piston cover...

Page 123: ...upper hexagon socket head cap screws M12 50 M16 60 M20 70 and attach safety bolts 2 Use the slide hammer and remove the parallel pin 3 After pulling out the parallel pin loosen the rest of the hexagon...

Page 124: ...he order of the numbers shown in the figure 2 Install the parts in the reverse order of removing Note According to the design modification notification as of April 9 2012 J series balance piston relat...

Page 125: ...g P120 G150 35 1 3 O ring G150 G190 23 1 11 Housing balance piston 36 4 Spring pin 6 dia 12 34 12 O ring G150 G190 35 2 5 Spring pin 6 dia 12 34 13 Inner cover F assembly balance piston cover 6 Spring...

Page 126: ...is difficult to hold by hand the suction cover separately while loosening the hexagon socket head cap screw Preparation for suction adapter removal is not required for 280J 5 4 15 3 Precautions for R...

Page 127: ...ling into the suction cover Align the large cutout with the oil supplied port on the right side of the suction cover Balance piston 1 Install the balance piston onto the shaft by aligning the keyway t...

Page 128: ...ng gland spacer female rotor 44 2 21 Thrust bearing alignment spacer male rotor 42 1 10 Locknut AN12 39 1 22 Thrust bearing outer race spacer female rotor 41 2 11 Torsional slip washer 160 237 1 23 Th...

Page 129: ...6 Thrust washer female rotor 250 2 6 Thrust bearing gland female rotor 43 2 17 Thrust bearing assembly male rotor 38 1 7 Thrust bearing gland spacer male rotor 44 1 18 Thrust bearing assembly female r...

Page 130: ...s of the thrust bearings 5 4 16 2 Precautions for Installation Thrust bearing When replacing the thrust bearings regarding the direction of thrust bearing assembly there may or may not be a V shaped m...

Page 131: ...d do not tighten the locknut further and replace the thrust bearing alignment spacer or insert a shim of appropriate thickness between the thrust bearing alignment spacer and the inner race of the thr...

Page 132: ...over and Main Rotor Casing 170J 220J 280J Order Description Part No Order Description Part No 1 Parallel pin 13 dia 65 13 dia 65 16 dia 110 3 3 Suction cover 5 2 Hexagon socket head cap screw M16 60 M...

Page 133: ...or Removal Suction cover 1 Using appropriate tools remove the parallel pin 2 Insert bolts into the service holes tighten the bolts and separate the suction cover and the main rotor casing flange face...

Page 134: ...G130 G165 432 2 Retaining ring C type internal H95 H120 H150 29 2 6 O ring G75 G100 G100 433 3 Bearing male rotor 27 7 Spring pin 4 dia 10 14 4 Bearing female rotor 28 1 Remove the parts in the order...

Page 135: ...the radial bearing installing tool 5 4 18 3 Precautions for Installation Spring pin 1 Check for wear and damages If anything wrong is found replace with new spring pin Bearing 1 Lubricate the bearing...

Page 136: ...9 Hexagon socket head cap screw M8 30 M8 35 M10 40 58 3 Female rotor 26 10 Spring lock washer M8 M8 M10 267 4 Unloader slide valve assembly and slide valve assembly Vi 11 Gland push rod for unloader...

Page 137: ...ing capacity the male rotor or female rotor may fall causing injuries and damage to the compressor Before starting the lifting work always check that the lifting equipment and lifting slings have suff...

Page 138: ...the cutout of the push rod gland with the grooved pin No 446 in the unloader slide valve push rod Male rotor and female rotor 1 Inspect the rotors for dents or scratches 2 Using lifting slings lift t...

Page 139: ...n Rotor Casing 170J 220J 280J Order Description Part No Order Description Part No 1 Parallel pin 13 dia 65 16 dia 65 16 dia 110 3 4 Bearing head 11 2 Hexagon socket head cap screw M16 60 M16 75 M20 11...

Page 140: ...170J 270 kg for 220J 520 kg for 280J 1 Using the one eyebolt M20 M30 M36 on the top of the bearing head lift and carry the bearing head with lifting equipment 5 4 20 3 Lifting of Main Rotor Casing We...

Page 141: ...G100 G150 G100 432 2 Retaining ring C type internal H95 H120 H150 29 2 6 O ring G75 G165 G130 433 7 Spring pin 4 dia 10 14 3 Bearing male rotor 27 4 Bearing female rotor 28 1 Remove the parts in the o...

Page 142: ...the radial bearing installing tool 5 4 21 3 Precautions for Installation Spring pin 1 Check for wear and damages If anything wrong is found replace with new spring pin Bearing 1 Lubricate the bearing...

Page 143: ...ription Part No 1 Hexagon socket head cap screw M20 50 493 7 Sheet stopper 488 2 Suction adapter 492 8 Valve sheet 489 3 O ring P155 494 9 Valve disc 490 4 Valve disc assembly 10 Check valve slider 48...

Page 144: ...4 Suction adapter 492 11 Valve disc 490 5 O ring P220 494 12 Check valve slider 481 6 Valve disc assembly 13 Spring check valve 485 7 FU nut FU05SS 486 14 Check valve stem 491 1 Remove the parts in th...

Page 145: ...for Installation FU nut The FU nut has a high friction locking device Turn the FU nut with a locknut wrench when tightening the FU nut Suction adapter 1 Install the suction adapter into the suction c...

Page 146: ...art No Order Description Part No 1 Parallel pin 8 dia 60 8 dia 80 13 dia 100 249 3 Spring lock washer 248 2 Hexagon socket head cap screw M8 70 M8 90 M10 110 247 4 Guide unloader slide valve 246 1 Rem...

Page 147: ...in case of 170 J and the 220 J series using a highly accurate surface grinding machine or asking professional service vendors to grind grind the surface of thrust bearing outer race spacer 41 by the d...

Page 148: ...rinding the flat surface measure the whole circumference of the saucer by using a micrometer and check that the thickness is even 2 When the end clearance is larger than the specified value As the end...

Page 149: ...mes while changing the combination of engagement between tightening tool claw and locknut groove 5 4 26 Inspection for Runout of Seal Cover Mount Face Bearing Cover 1 Mount a dial gauge to the shaft o...

Page 150: ...vices Clogging in connecting pipes Remove clogging Check oil contamination level and replace oil as necessary Unconfirmed cooling water circulation Malfunction in devices such as cooling water pumps a...

Page 151: ...ure Clogging in oil filter element Big difference in outlet inlet pressures Contamination of lubricant Remove clogging Check oil contamination level and change lubricant as necessary Defect inside com...

Page 152: ...ce malfunctioning devices Flow volume adjustment fault for cooling water brine etc If valve is manually adjusted readjust it If an automatic control valve including wax valve is used examine its cause...

Page 153: ...measures Then replace malfunctioning devices Liquid stoppage etc by clogging in connecting pipes Remove clogging Check oil contamination level and replace oil as necessary Closed outlet stop valve for...

Page 154: ...her This happens because of the specific operating conditions of the compressor and unsteadiness in bearing pressure condition of processed sliding surfaces following replacement For initial leak amou...

Page 155: ...f sliding surfaces can be applied Incompatibility between operating conditions working temperature ranges refrigerant etc and lubricant Inappropriate lubri cant or change in operating conditions since...

Page 156: ...aladjustment of zero and span adjustment for E E positioner Readjust it Malfunction of E E positioner or its indicator For aging degradation replace E E positioner For unique causes such as surge curr...

Page 157: ...them 11 Abnormal vibration and or noise of compressor Insufficient axis adjustment with motor side If vibration value is higher in the axial direction this might be the cause Readjust the shaft cente...

Page 158: ...to various factors such as a leak inside the liquid supply solenoid valve on load side insufficient heat exchange refrigerant evaporation in heat exchanger or trapping caused by wrong piping in piping...

Page 159: ...For malfunction of devices specific to defrosting methods remove the cause and replace them For blocked piping routing specific to defrosting methods remove the cause and take measures Especially for...

Page 160: ...o the Direct cause Foreign substances contaminating compressor above Excessive thrust stress other than above High suction pressure exceeding op erating conditions Re examine operating conditions and...

Page 161: ...w Compressor J series 7 1 Development View and Configuration Table of the Parts 7 1 7 Related Documents 7 1 Development View and Configuration Table of the Parts Development View and Configuration Tab...

Page 162: ...2205B0JE DA J N_2014 05 7 Related Documents Screw Compressor J series 7 1 Development View and Configuration Table of the Parts 7 2 Figure 7 2 Development View of 170J 2 2...

Page 163: ...0 PAH80 300 PC11 300 1 17 2 O ring JIS B 2401 P14 PAH80 014 PC11 014 1 18 1 Hexagon socket head cap screw M12 50 NB35412 050 5 18 2 Hexagon socket head cap screw M12 70 NB35412 070 13 19 Parallel pin...

Page 164: ...O ring JIS B 2401 G120 PAH81 120 PC12 120 1 52 2 O ring JIS B 2401 G145 PAH81 145 PC12 145 1 53 Hexagon socket head cap screw M8 30 NB35408 030 8 54 Unloader slide valve S 1 Unloader slide valve M 1...

Page 165: ...emale rotor CS25000 125 1 267 Spring lock washer Hexagon socket head cap screw M8 ND330 08 6 289 Slide valve S Vi 1 Slide valve M Vi 1 Slide valve L Vi 1 292 Push rod S Vi 1 Push rod M Vi 1 Push rod L...

Page 166: ...g R1 8 NF06 004 1 607 B Plug R1 8 NF06 004 1 611 Sleeve shower flashing CS61100 J170 1 657 O ring JIS B2401 G100 PAH81 100 PC12 100 1 658 Retaining ring C type internal JIS B2804 H100 NG11 100 1 709 V...

Page 167: ...ication is FKM For O rings material other than HNBR or FKM the part code No are differ depending on the material For customers using O rings other than the standard material contact before purchasing...

Page 168: ...DA J N_2014 05 7 Related Documents Screw Compressor J series 7 1 Development View and Configuration Table of the Parts 7 8 Development View and Configuration Table 220J Figure7 3 Development View of...

Page 169: ...2205B0JE DA J N_2014 05 7 Related Documents Screw Compressor J series 7 1 Development View and Configuration Table of the Parts 7 9 Figure7 4Development View of 220J 2 2...

Page 170: ...NF06 010 1 16 Bearing cover 1 17 1 O ring JIS B 2401 P375 PAH80 375 PC11 375 1 17 2 O ring JIS B 2401 P14 PAH80 014 PC11 014 1 18 1 Hexagon socket head cap screw M16 60 NB35416 060 5 18 2 Hexagon sock...

Page 171: ...asher Hexagon head screw M12 ND320 012 12 48 Retainer for oil seal CS04800 J220 1 49 O ring JIS B 2401 G145 PAH81 145 PC12 145 1 50 Oil seal SA1J 75 100 13 CS05010 250VD 1 51 Seal cover 1 52 1 O ring...

Page 172: ...r CS25000 J220 1 250 2 Thrust washer female rotor CS25000 160 1 267 Spring lock washer Hexagon socket head cap screw M8 ND330 08 9 289 Slide valve S Vi 1 Slide valve M Vi 1 Slide valve L Vi 1 292 Push...

Page 173: ...e thread NE2313 065A 2 605 Plug R1 2 NF06 015 1 607 A Plug R1 8 NF06 004 1 607 B Plug R1 8 NF06 004 1 607 C Plug R1 8 NF06 004 1 611 Sleeve shower flashing CS61100 J220 1 657 O ring JIS B2401 G120 PAH...

Page 174: ...CS73600 J220 1 744 O ring JIS B2401 G70 PAH81 070 PC12 070 1 745 Rivet 3 dia 6 4 235 1 Motor spacer For NEMA 44 D CS23502 J220NEMA44 1 Motor spacer For NEMA 50 D CS23502 J220NEMA50 Motor spacer For I...

Page 175: ...Name Design Modification Notification first Remarks Registration No Issue Date 33 Balance piston sleeve 674 033 2012 04 09 Design modification notification follow up No C0956 02 34 Spring pin 35 1 O...

Page 176: ...DA J N_2014 05 7 Related Documents Screw Compressor J series 7 1 Development View and Configuration Table of the Parts 7 16 Development View and Configuration Table 280J Figure7 5 Development View of...

Page 177: ...2205B0JE DA J N_2014 05 7 Related Documents Screw Compressor J series 7 1 Development View and Configuration Table of the Parts 7 17 Figure7 6Development View of 280J 2 2...

Page 178: ...6 020 1 16 Bearing cover 1 17 1 O ring JIS B 2401 P480 PAH80 480 PC11 480 1 17 2 O ring JIS B 2401 P14 PAH80 014 PC11 014 1 18 Hexagon socket head cap screw M20 70 NB35420 070 16 19 Dowel pin 16 dia 7...

Page 179: ...01 P14 PAH80 014 PC11 014 1 53 Hexagon socket head cap screw M12 40 NB35412 040 8 54 Unloader slide valve S 1 Unloader slide valve M 1 Unloader slide valve L 1 58 Hexagon socket head cap screw M10 40...

Page 180: ...J280M 1 Push rod L Vi CS29200 J280L 1 293 Spiral retaining ring FRSN 75 NGFR 75 2 294 Piston Vi CS29400 J280 1 295 O ring JIS B2401 P85 PAH80 085 PC11 085 1 296 Cylinder Vi 1 297 Partition plate unloa...

Page 181: ...Hexagon socket head cap screw M6 25 NB35406 025 2 724 Vi position sensor box 1 725 Packing Sensor box 1 726 Hexagon socket head cap screw M5 15 NB35405 015 4 794 Vi position sensor assembly 1 727 I pl...

Page 182: ...Table 7 3b Part No Part Name Design Modification Notification first Remarks Registration No Issue Date 33 Balance piston sleeve 684 037 2012 04 09 Design modification notification follow up No C0956 0...

Page 183: ...agon socket head cap screw M8 30 58 Gland push rod for unloader slide valve 25 250 6 Hexagon socket head cap screw M8 30 61 Unloader cylinder 52 520 2 Hexagon socket head cap screw M12 70 62 Unloader...

Page 184: ...lide valve 25 250 9 Hexagon socket head cap screw M8 35 61 Unloader cylinder 130 1300 2 Hexagon socket head cap screw M16 90 62 Unloader cylinder 130 1300 6 Hexagon socket head cap screw M16 140 76 Un...

Page 185: ...100 3 Hexagon socket head cap screw M6 15 247 Slide valve guide 50 500 4 Hexagon socket head cap screw M10 110 719 Vi position sensor rod housing gland 10 100 4 Hexagon socket head cap screw M6 25 723...

Page 186: ...ws Accordingly the tightening angle range is now added to the rotor shaft lock nut tightening procedure in this manual Tightening Angle Range of Lock Nuts for Rotors a After tightening the lock nut by...

Page 187: ...Philip s screwdriver 1 Screwdriver for cross recessed head screws Eyebolt M8 1 set 2 pcs in 1 set Retaining ring pliers medium size 1 for external Retaining ring pliers large size 1 for internal Hexa...

Page 188: ...al number besides and the follow up information about the big modification of design In the J series the following three are issued at the time of the publication of the this manual In the brackets it...

Page 189: ...es J series to be used under conditions below Use of carbon dioxide as a refrigerant Use of PAO base oil Currently used NBR O rings should be replaced with HNBR on the next upcoming overhaul Applicabl...

Page 190: ...70 220J 108 95 280J 140 127 2 The integration of balance piston P N 30 and balance piston housing P N 36 Balance piston housing is discontinued 3 Associated with above 2 O ring P N 35 1 is discontinu...

Page 191: ...2210040 280JS 2850030 2 280JM 2830022 2 280JL 2810010 2 However the serial numbers indicated below have mounted modified balance pistons in advance 170JS 1751015 1 170JL 1711082 1711087 1711095 171109...

Page 192: ...Thrust bearing gland P N 43 and Thrust bearing gland spacer P N 44 Accordingly thrust bearing gland P N 44 is discontinued When mounted on 170J make the cast out part of the thrust bearing tightening...

Page 193: ...ys use the specified controller to control and protect the compressor Set the following control values for compressor protection in consideration of the compressor operating limits 1 Protection from a...

Page 194: ...is below 10 ppm Consider the gravitational sedimentation method and the types of filter to use 2 Amount of lubricant held The amount of lubricant held in the oil separator must at least be more than 1...

Page 195: ...loader variable Vi system oil lines 1 Lubrication oil line For the lubrication system an inlet port of ANSI 300 1 common in J series is provided on the bearing head and another inlet port of Rc1 2 170...

Page 196: ...lass 8 or ISO 4406 17 15 13 When the package unit requires API 619 4th 5th edition conformity use an oil filter with beta ratio in the range of 10 200 Any contaminants in the lubricant may cause damag...

Page 197: ...alve located below the compressor suction flange is not subjected to excessive force or damaged during installation of the suction pipe If no rustproof and freezing proof coating is applied to the hex...

Page 198: ...ressor side flange diameter 4 Attach two safety bolts M16 60 to the upper two bolt holes on the flange face of the bearing cover motor spacer side 5 Lift the motor spacer with lifting equipment such a...

Page 199: ...mpressor and motor bases In this case the couplings of the motor and the compressor must be aligned For detailed procedure refer to the package instruction manual Suction Gas Line Piping When installi...

Page 200: ...ITY HOKKAIDO 063 0803 TEL 011 631 2052 FAX 011 631 2053 Tohoku Branch 8 72 ROKUTYONO MEMINAMI MACHI WAKABAYASHI KU SENDAI CITY MIYAGI 984 0013 TEL 022 288 5001 FAX 022 288 5155 Kanto Branch 3 14 15 BO...

Page 201: ...A TEL 1 310 328 1362 FAX 1 310 782 6759 MAYEKAWA U S A INC SEATTLE OFFICE 2615 W CASINO ROAD UNIT 3D EVERETT WA 98204 U S A TEL 1 425 645 9400 FAX 1 425 353 3344 MAYEKAWA U S A INC PORTLAND OFFICE 47...

Page 202: ...FLOOR OFFICE 419 EGYPT TEL 20 22 503 2925 FAX 20 22 503 2801 MAYEKAWA MIDDLE EAST FZCO P O BOX 61349 PBU RA08 UC05 JEBEL ALI FREE ZONE DUBAI U A E TEL 971 4 888 6363 FAX 971 4 888 6373 MAYEKAWA TURKEY...

Page 203: ...IA GRAHA PRATAMA BUILDING 9TH FLOOR JL M T HARYONO KAV 15 JAKARTA 12810 INDONESIA TEL 62 21 8370 9484 FAX 62 21 8370 9483 P T MAYEKAWA INDONESIA MEDAN OFFICE JL SUTRISNO No 274 MEDAN 20215 INDONESIA T...

Page 204: ...X 86 21 6920 7719 MAYEKAWA CHINA MFG CO LTD GUANGZHOU BRANCH 266701 RM 1205 BUILDING H R F TIANHE PROSPEROUS PLACE EAST LINHE ROAD TIANHE DISTRICT GUANGZHOU P R CHINA TEL 86 20 8527 6161 FAX 86 20 852...

Page 205: ...710 REP OF KOREA TEL 82 2 796 1766 FAX 82 2 798 7715 LATIN AMERICA MAYEKAWA ARGENTINA S A BUENOS AIRES OFFICE AV VELEZ SARSFIELD 670 74 C1282 AFT CAPITAL FEDERAL BUENOS AIRES REPUBLICA ARGENTINA TEL...

Page 206: ...A ISSAC POVOAS 586 SALA 405 EDIFICIO WALL STREET CENTRO CUIABA MT CEP 78055 560 BRASIL TEL 55 65 3023 7559 FAX MAYEKAWA DO BRASIL EQIPAMENTOS INDUSTRIAIS LTDA CURITIBA BRANCH RUA XV DE NOVEMBRO 2175 6...

Page 207: ...FICINA 3 MARACAY EDO ARAGUA VENEZUELA TEL 58 243 269 4913 FAX 58 243 269 3952 MYCOM VENEZUELA SALES SERVICE C A MARACAIBO OFFICE CALLE 148 CENTRO EMPRESARIAL SAN FRANCISCO NIVEL 1 LOCAL 5 Y 6 ZONA IND...

Page 208: ...MEXICO S A DE C V HERMOSILLO OFFICE CALLE FRAY TORIBIO DE BENAVENTE 38 COL LOS ARCOS CD HERMOSILLO SONORA C P 83250 MEXICO TEL 52 662 216 2047 FAX 52 662 216 2047 MAYEKAWA DE MEXICO S A DE C V IRAPUAT...

Page 209: ...2205B0JE DA J N_2014 05 MAYEKAWA MFG CO LTD 3 14 15 Botan Koto ku Tokyo 135 8482 Japan TEL 03 3642 8181 URL http www mayekawa com...

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