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2200Q2JE-HO-KHM-N_2015.02. 

Chapter 5 Maintenance and Inspection 

Ammonia Semi-hermetic Motor with K-series Compressor                              5.1 Precautions for Maintenance
 

 

5-14

 

5.4 Reassembly 

 

When replacing a part, check if it is a correct one or not before using it for assembling.   
Start the reassembly work after completing the cleaning of assembly parts and tools. Most of the 
reassembly work will be performed in the reverse order of the disassembly work.   
To tighten the fastening bolts of each section of the semi-hermetic motor, use the respective torque 
specified in Table 5-5.   
Start the tightening work with 50% of the tightening torque of the specified value for each pair of bolts in 
the mutually facing position. Then, tighten all bolts in the clockwise order applying the specified torque. 
As regards the tightening of bolts involving a gasket, the bolt tightened in the first place has a tendency 
to be loosened. Accordingly, perform another round of the tightening with the specified torque with the 
additional aim of checking the last tightening operation. 
 
 

Table 5-5 Tightening Torques of Hexagon Head Bolt / Hexagon Head Cap Screw 

No. 

Name 

Type

 

Qty 

Size 

Torque

(N

･

m) 

609 

Motor Rotor Mounting Bolt for NHM30 

Hexagon Head Cap Screw

1 

M20×450 

260 

Motor Rotor Mounting Bolt for NHM45 

Hexagon Head Cap Screw

1 

M20×550 

260 

Motor Rotor Mounting Bolt for NHM60 

Hexagon Head Cap Screw

1 

M20×580 

260 

602 

Motor Spacer Fastening Bolt 

Hexagon Head Cap Screw

12 

M16×45 

160 

605 

Motor Casing Fastening Bolt 

Hexagon Head Cap Screw

12 

M16×50 

220 

616 

Motor Bearing Retainer Fastening Bolt 

Hexagon Head Bolt 

12 

M16×40 

160 

612 

Motor Jacket Cover Fastening Bolt 

Hexagon Head Bolt 

12 

M12×35 

80 

625 

Motor Sealing Terminal Box Fastening 
Bolt 

Hexagon Head Cap Screw

6 

M12×35 

80 

628 

Motor Terminal Block Fastening Bolt 

Hexagon Head Cap Screw

8 

M12×35 

80 

HKFB  Water Flange Fastening Bolt 

Hexagon Head Bolt, SUS 

4 

M10×20 

10 

622 

Motor End Cover Fastening Bolt 

Hexagon Head Bolt 

8 

M8×25 

30 

631 

Motor Terminal Box Fastening Bolt 

Hexagon Head Cap Screw

6 

M8×15 

10 

619 

Motor Oil Seal Retainer Fastening Bolt 

Hexagon Head Bolt 

6 

M6×25 

10 

 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

Summary of Contents for K Series

Page 1: ...r with the K series compressor Refer and follow to Reciprocating Compressor K series Instruction manual for the compressor section Before conducting the work of operation inspection maintenance of this product read this manual and sufficiently understand Specifications of this product and contents of this manual are subject to change without prior notice due to technical improvements N6KHM45 ...

Page 2: ... procedure disassembling and assembling of the ammonia semi hermetic motor section of this product For details of the compressor section of this product refer to the Reciprocating Compressor K series instruction manual as well as this manual This manual is applicable to the following type products N4KHM N6KHM N8KHM To maintain the initial functions of this product for a long time please read this ...

Page 3: ...ction or damage caused by misusage described below Malfunction damage or defect of this product due to abnormal or improper use such as storing this product for middle to long term outside the building or in locations subject to high temperatures and high humidity unexpected inspections tests operations and excessive repetition start up stoppage of the product Malfunction or damage caused by devic...

Page 4: ... by a qualified person who has been provided with the basic technical knowledge on this product and trained on the potential risks and how to avoid the risks Anyone other than the ones who have been provided with the basic technical knowledge on this product and trained on the potential risks and how to avoid the risks is not allowed to approach this product while it is operating or during mainten...

Page 5: ...c control The work must be performed by a qualified person who has been trained on the electric control of the particular target system as well as on the potential risks inherent to electric control and how to avoid the said risks on top of the generally required knowledge on electrical work Whenever servicing or inspecting electric machinery be sure to cut off the motor main power and control pow...

Page 6: ...the copy to one of our sales or service offices The use of this product without this manual can be a cause of possible accidents When you sell this product be sure to transfer this manual to the next owner Structure of this Manual Chapter Section Title Description Introduction Describes the outline and usage of this manual Warranty and Disclaimer The scope of warranty by the Company is described P...

Page 7: ...n Lock out Tag out Procedures after Power is Off 1 2 1 1 1 5 Do s on Personal Protective Gear 1 2 1 1 1 6 Do s in Handling of Hazardous and Toxic Substances 1 2 1 1 1 7 Do s on the Response to Emergency Situations 1 3 1 1 1 8 Do s on the Disposal of Waste Oil Waste Liquid Scraps etc 1 3 1 1 1 9 Other Do s 1 3 1 1 2 Prohibitions Don ts 1 3 1 2 Warning Notices in This Manual 1 3 1 3 Residual Risks 1...

Page 8: ... and Details 5 3 5 2 3 1 Overhauling the Motor Jacket 5 3 5 2 3 2 Overhauling the Entire Motor 5 4 5 3 Disassembly 5 5 5 3 1 Refrigerant Gas Recovery 5 5 5 3 2 Draining the Lubricating Oil 5 5 5 3 3 Motor Jacket Cover 5 6 5 3 4 Motor End Cover 5 8 5 3 5 Motor Bearing Retainer 5 8 5 3 6 Motor Bearing Outer Race and Motor Oil Seal 5 9 5 3 7 Motor Casing 5 10 5 3 8 Motor Rotor 5 11 5 3 9 Compressor O...

Page 9: ...o an unknown cause immediately contact your supervisor Before restarting the system you must seek the decision and instruction of the supervisor Be sure to continue sufficient ventilation of the machine room especially while the machine is operated Regarding the characteristics of the ammonia refrigerant and lubricating oil e g corrosiveness degradability and toxicity be sure to obtain the latest ...

Page 10: ... 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 let the workers perform the lock out tag out procedures after the motor main power and control power has been shut off Because the workers may neglect to perform the lock out tag out procedures or cut off the power in the following situation...

Page 11: ...on ts Never remove or reposition any safety device based on your own judgment including any modification of electrical interfaces Never disable the function of safety devices by short circuit connections or bypassing the circuits without prior permission Never leave this product in an unsafe condition by removing a safety cover etc Do not touch clean or lubricate any moving part of this product Wh...

Page 12: ...rsonal protection gear Perform the work only when the temperature is 40 C or less B Discharge Elbow of compressor Getting a burn by touching it when it is hot Installation of a guard or other protection Do not touch with bare hands directly Wearing a personal protection gear Wearing a personal protection gear Perform the work only when the temperature is 40 C or less C Unloader Solenoid Valve of c...

Page 13: ...ection gear Sufficient ventilation Wearing a personal protection gear Sufficient ventilation H Oil Drain Burn Contact with hazardous material Do not touch while in operation Wearing a personal protection gear Perform the work only when the temperature is 40 C or less I Motor Getting a burn by touching it when it is hot Electric shock Do not touch with bare hands directly Wearing a personal protect...

Page 14: ...Reciprocating Compressor K series instruction manual Section 1 4 The motor of this product is equipped with a thermostat that operates at 130 C but not with any other protective devices Therefore be sure to install an overload protection device In addition it is recommended to install a unit such as ground fault circuit interrupter reversed phase protection device and single phase protection devic...

Page 15: ...t by docking semi hermetic water cooled motor to allow this product to serving as a dedicated compressor to the use for ammonia refrigerant 2 2 Model Designation of the Compressor The meaning of the type designation stamped on the nameplate of the compressor MODEL column is as follows 1 2 3 4 5 N 6 K HM 45 1 Working fluid refrigerant 2 Number of cylinder 3 Series name 4 Series name additional entr...

Page 16: ...nsion method Motor jacket Water cooled Cooling water system of this product Series Oil cooler Motor jacket Head cover Amount of cooling water L min 35 at 30 C of cooling water temperature Pressure loss kPa 24 36 44 Capacity control Method Hydraulic pressure controlled solenoid valve Loading at energized to the solenoid valve Power source V 100V 110V 200V 220V Range 100 50 100 66 33 100 75 50 25 Sa...

Page 17: ...r of pole P 4 Rating voltage V 200 200 220 400 400 440 Rating frequency Hz 50 60 60 Rating current A 107 105 96 53 52 48 158 155 140 78 78 71 217 206 190 106 102 95 Rating speed min 1 1479 1772 1777 1474 1766 1773 1482 1767 1774 1483 1778 1783 1481 1774 1778 1488 1766 1781 Insulation class Equal to F class insulation Thermostat C 130 working temperature Starting method Star delta starting or inver...

Page 18: ...erature at oil cooler inlet port Minimum supply oil temperature C 30 Maximum speed min 1 1800 Minimum speed min 1 900 Maximum cooling water outlet temperature C 50 Head jacket cover and oil cooler outlet temperature Allowable temperature of blade hose for cooling water Maximum cooling water pressure MPa 0 5 Allowable pressure of blade hose for cooling water Degree of superheat SH C 20 or less Liqu...

Page 19: ...hapter 2 Product Specifications and Structure Ammonia Semi hermetic Motor with K series Compressor 2 3 Product Specifications 2 5 2 3 3 Outer Dimensions Figure 2 2 Outer Dimensions of the K series Ammonia Semi hermetic Compressor ...

Page 20: ...fications and Structure Ammonia Semi hermetic Motor with K series Compressor 2 4 Structure of Semi hermetic Motor 2 6 2 4 Structure of Semi hermetic Motor 2 4 1 Sectional View of the Motor Figure 2 3 Sectional View of the K series Semi hermetic Motor ...

Page 21: ...HM30 and 45 for NHM60 605 Fastening Bolt Motor Casing 12 Hexagon Head Cap Screw M16 50 605 1 Fastening Bolt Washer Motor Casing 12 Conical spring washer CW 1L 16 606 Motor Stator 1 for NHM30 for NHM45 for NHM60 607 Motor Rotor 1 for NHM30 for NHM45 for NHM60 608 Bushing Motor Rotor 1 for NHM30 for NHM45 for NHM60 609 Mounting Bolt Motor Rotor NHM30 1 Hexagon Head Cap Screw M20 450 NHM45 1 Hexagon ...

Page 22: ...ver 1 634 Fastening Screw Motor Terminal Box Cover 6 Cross recessed hexagon head screw with captive washer M5 15 635 Aluminum Terminal V shaped type 4 Φ16 v 08 636 Aluminum Terminal H shaped type 2 Φ16 h 08 637 Mounting Nut Aluminum Terminal 6 M16 637 1 Mounting Washer Aluminum Terminal 6 Nominal 16 637 2 Mounting Spring Washer Aluminum Terminal 6 Nominal 16 638 Teflon Parts 1 for Aluminum Termina...

Page 23: ...elivered to Carefully read and sufficiently understand the content of this chapter and other related materials before actually performing the installation work Wiring work and or other electrical work must be performed by a qualified electrical technician Never get into or put any part of your body into an area immediately below this product being lifted up 3 2 Installation Work 3 2 1 Unpacking Ch...

Page 24: ... the hook is positioned above the center of gravity of this product 8 Before starting to lift up this product instruct all the workers to be sufficiently away from the lifting area 9 Just before starting to lift up provide the coworkers with a sign such as a call hand signal etc of starting the lifting action Do not start to lift up unless the sign such as a call hand signal etc has been fully ack...

Page 25: ... product For slinging up this product the use of belt slings or wire ropes hooking wire facilitates the lifting in an equalized load at each of the four eye bolts If no hook is attached to each of the belt slings or wire ropes hang the load by using each of the eye bolts and the eye ring of the lifting tools via a shackle Figure 3 1 Positions of Eye Bolts ...

Page 26: ...ooling the compressor head cover and ammonia semi hermetic motor Closed type cooling tower facility should be employed to cool down the water used in this product Ensure that a sufficient amount of cooling water is provided as required by the customer s system 3 2 5 Installation For more information about the installation of this product refer to the Reciprocating Compressor K series Instruction M...

Page 27: ... Instruction Manual Chapter 4 Requirements for the lubricating oil refrigerating oil of this product Precautions for selecting the lubricating oil Changing the brand of the lubricating oil Management criteria of the lubricating oil Lubricating oil replacement timing Replenishment of lubricating oil Precautions for initial operation Initial operation method Operating precautions Management contents...

Page 28: ...ssure of this product is at the atmospheric pressure before starting the work When using lifting devices e g a crane etc and or lifting tools ensure that they can sufficiently withstand the load When lifting a heavy load object do not allow anyone s body to put under it The work to turn each power supply ON OFF or operate a lifting unit must be exclusively performed by qualified personnel Be sure ...

Page 29: ...uding inside the compressor to cause its damage Parts are slippery with oil Fully watch out for the risk of any object falling down Pay attention to any parts falling down which could lead to personal injury Before disassembly inspections and handling of the compressor and the semi hermetic motor sufficiently understand the disassembly and assembly procedures When removing a part be careful not to...

Page 30: ...ideline for the Semi hermetic Motor Overhaul Timing and Details The required frequency of overhaul will vary depending on the compressor model refrigerant rotating speed usage condition state of system and type of oil The cost of parts replacement will be charged to the customer even if the part failure occurs before reaching the overhaul time listed in this section The recommended overhaul timing...

Page 31: ... seal retainer to inspect the internal parts Table 5 1 Inspection Parts and Action when Overhauling the Entire Motor No Inspection Part Action 617 Motor Oil Seal Replace if any abnormality is found 613 Motor Bearing Replace if any abnormality is found 32 Compressor Oil Seal Replace if any abnormality is found Other Each Part Replace if any abnormality is found Inspect the O ring 610 1 of the motor...

Page 32: ...e to check and communicate the work details and procedures among all coworkers and carry out hazard prediction activities based on the information shared Neglecting to do this will increase the risk of on the job accidents and injuries to a considerable level All the valves that have been opened or closed during the work must be prevented from accidental operation through proper lock out and tag o...

Page 33: ...crane or chain block and the eye bolts hanging bolts provided at two spots on top of the jacket cover Table 5 2 Mass of the Motor Jacket Cover Motor Model Name NHM30 NHM30 NHM30 Mass kg 52 68 80 b Before starting the work close the valve at the inlet and outlet of compressor water cooling system and drain the cooling water remaining in the compressor c Remove the bolts of the hose elbow flange loc...

Page 34: ... be deposited with considerable amounts of water stain and scale If this is the case the water stain and scale are deposited in the gap between the jacket cover and motor casing causing it hard to take out the jacket cover Pull out the jacket cover by using the jacking bolts while giving light knocks to the body of the jacket cover with a somewhat larger soft hammer After moving it for about 15 mm...

Page 35: ...g out from the inside by using a container 5 3 5 Motor Bearing Retainer approx 16 6 kg a After removing the two bolts 616 in the upper area of the motor bearing retainer 614 and screwing two stud bolts for safety the two bolts in the upper area in the picture at left below take off all the remaining bolts b Screw in the bolts the two bolts in the lower area of the picture at left below into each o...

Page 36: ...motor bearing retainer while it is mounted in the motor oil seal retainer 618 and tightened with six bolts 619 The oil seal retainer can be taken off by removing the bolts picture to the right c As long as no fault is found in the lip in contact with the shaft of the motor oil seal following picture to the left the oil seal need not be taken off When the replacement of the oil seal is required tak...

Page 37: ...g is mounted on the motor spacer 600 by using 12 bolts 605 Remove the bolts and take the casing off by pulling it toward yourself First remove the two fastening bolts for the motor casing and screw in the stud bolts picture at middle above These bolts can be used as guides in the initial stage of pulling out d Remove the remaining bolts for tightening the motor casing while slightly lifting up the...

Page 38: ...tor the joint of compressor shaft and motor rotor bushing is disengaged Since the compressor shaft is tapered once the tapered section is disengaged the shaft can be readily withdrawn e Take off the pulley extractor and try to lift up the motor rotor liberated from the compressor shaft Pull off the motor rotor mounting bolt and pull the motor rotor toward yourself to pull it off picture to the rig...

Page 39: ...er As long as no fault is found in the lip part in contact with the shaft the compressor oil seal need not be taken off When replacement of the oil seal is required remove the four bolts 32 2 that are tightening the compressor oils seal gland 32 1 following picture to the left and take off the oil seal gland c To remove the compressor oil seal while allowing the edge of a flat blade screwdriver to...

Page 40: ... the gasket mount the motor spacer a Remove the bolts in two spots on the top of motor spacer and screw two stud bolts safety bolts into the appropriate bolt holes b After loosening the remaining bolts remove every bolt while supporting the motor spacer by hand following picture to the left Pulling the motor spacer toward yourself allows it to be removed c After removing the old gasket and cleanin...

Page 41: ...ening with the specified torque with the additional aim of checking the last tightening operation Table 5 5 Tightening Torques of Hexagon Head Bolt Hexagon Head Cap Screw No Name Type Qty Size Torque N m 609 Motor Rotor Mounting Bolt for NHM30 Hexagon Head Cap Screw 1 M20 450 260 Motor Rotor Mounting Bolt for NHM45 Hexagon Head Cap Screw 1 M20 550 260 Motor Rotor Mounting Bolt for NHM60 Hexagon He...

Page 42: ...ting hole position of the oil seal retainer following picture to the right b Place a disk like inserting jig which is slightly larger than the oil seal onto the oil seal While holding the jig by hand lightly hit it in the top bottom right and left with a hammer to insert the oil seal gradually see the following picture to the right Such a steel disk with a diameter of Φ85 to 90 mm and thickness of...

Page 43: ...lt holes to match the oil holes picture to the right b Apply oil on the lip in contact with shaft of the oil seal and the sealing area of the compressor crank shaft While keeping the oil seal retainer in the right angle with the shaft fit it in the crank case Mount the oil seal retainer so that the oil hole of the crank case matches that of the oil seal retainer c While holding the oil seal retain...

Page 44: ...with the key slot on the compressor crank shaft facing upward c While keeping the key slot on the motor rotor shaft facing upward lift up the motor rotor While lifting the motor rotor so that the center of shaft hole matches the center of crank shaft mount it on the shaft by pushing the motor rotor following picture to the left d Tighten the motor rotor with the motor rotor mounting bolt 609 attac...

Page 45: ...r rotor while allowing the motor casing is aligned with the motor rotor in parallel When the rotor is lifted up so that the center of the motor casing matches that of the motor rotor gradually move the motor casing toward the motor spacer When moving it while visually aiming at the motor rotor through the hole in the motor stator to adjust the rotor comes to the center of the hole gradually push i...

Page 46: ...3 mount the bearing in the motor bearing retainer 614 After inserting the outer race that is in pair with the planetary ring of the bearing following picture to the left attach the snap ring A 613 1 for motor bearing in the groove in front side following picture to the right b Install the oil seal retainer 618 on the motor bearing retainer 614 following picture to the left c Screw in the six bolts...

Page 47: ...unted in the bearing retainer As the shaft is pushed in the bottom end of the spigot section hits the flange hole in the motor casing In that case further push in the spigot section while bring it up it can be mounted onto the flange surface e After slightly tightening the motor oil seal retainer fastening bolts 619 and fit the hexagonal bar wrench to the motor rotor mounting bolt 609 ensure that ...

Page 48: ...ase on the entire surface of the motor jacket cover O ring 610 1 and fit it in the O ring groove in the motor casing following picture to the left After fitting the O ring fill the O ring groove with grease using your finger picture to the right d Apply grease on the O ring fitting face of the motor jacket cover chamfered and uneven edges of the inner end of the groove e Lift up the motor jacket c...

Page 49: ...int located at both ends of the pipe at each joint and tighten them The pipes constitute each system of the oil feeding piping from the joint in the lower area of the motor end cover to another on top of the motor spacer as well as the oil returning piping from the joint in the upper area of the motor end cover to another in the lower area of the motor spacer Connect the pipes cautiously not to co...

Page 50: ... N4KHM30 N8KHM60 ...

Page 51: ...2200Q2JE HO KHM N_2015 02 MAYEKAWA MFG CO LTD 3 14 15 Botan Koto ku Tokyo 135 8482 JAPAN Phone 81 0 3 3642 8181 URL http www mayekawa com ...

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