mycom SCV Series Instruction Manual
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mycom SCV Series Instruction Manual

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SCV-series
Instruction Manual
Read this manual carefully and thoroughly before operating, maintaining or inspecting this
product. It is important to fully comprehend the contents of this manual. Keep the operation
manual in a safe, designated place for future reference whenever the need arises.
Specifications of this product are subject to change without prior notice.
Screw Compressor
160VLD／160VMD／160VSD
200VLD／200VMD／200VSD
250VLLD／250VLD／250VMD／250VSD
320VLD／320VMD／320VSD
160VLG／160VMG／160VSG
200VLG／200VMG／200VSG
250VLLG／250VLG／250VLG／250VSG
CAUTION
2205Q2JE-HO-S6-N_2020.01.

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  • Page 1 2205Q2JE-HO-S6-N_2020.01. SCV-series Screw Compressor Instruction Manual 160VLD／160VMD／160VSD 200VLD／200VMD／200VSD 250VLLD／250VLD／250VMD／250VSD 320VLD／320VMD／320VSD 160VLG／160VMG／160VSG 200VLG／200VMG／200VSG 250VLLG／250VLG／250VLG／250VSG CAUTION Read this manual carefully and thoroughly before operating, maintaining or inspecting this product. It is important to fully comprehend the contents of this manual. Keep the operation manual in a safe, designated place for future reference whenever the need arises.

  • Page 2: Preface

    2205Q2JE-HO-S6-N_2020.01. Preface Preface Thank you for purchasing the SCV-series/screw compressor (hereinafter referred to as "this product"). This instruction manual (hereinafter referred to as "this manual") describes safety information, operational and detailed maintenance procedures for safe and effective use of this product、It is applicable to the following compressor types 160VSD, 160VMD, 160VLD, 200VSD, 200VMD, 200VLD, 250VSD, 250VMD, 250VLD, 250VLLD, 320VSD, 320VMD, 320VLD...

  • Page 3: Warranty And Disclaimer

    2205Q2JE-HO-S6-N_2020.01. Warranty and Disclaimer Warranty and Disclaimer Warranty Clauses If malfunctions or damages occur under proper usage and conditions following documents such as specifications or instruction manual of this product, or, if MAYEKAWA judges that malfunctions or damages are related to design or manufacture of the product, and if the malfunctions or damages are within the warranty period, MAEKAWA will repair this product or replace parts without any charges.

  • Page 4: Important Information

    2205Q2JE-HO-S6-N_2020.01. Important Information Important Information Intended Use of this Product This product is a screw compressor intended use for freezing and refrigeration. Do not use this product for any other purposes for which it is not intended or deviate from the specifications which are described in Chapter 2, Article 2.3 “Compressor Specifications”.

  • Page 5: Construction Of This Manual

    2205Q2JE-HO-S6-N_2020.01. Important Information prohibited. The sole purpose of the tag plates such as prohibition of operation or commissioning is to warn others that it is prohibited to operate the locked out product. It should always be accompanied by a suitable lockout device to make operation impossible. Observe the following precautions when performing maintenance work on electrical control.
  • Page 6 2205Q2JE-HO-S6-N_2020.01. Important Information T i t l e o f s e c t i o n a n d D e s c r i p t i o n d e t a i l s c h a p t e r Describes sections and period for inspecting, disassembly and 5.

  • Page 7: Table Of Contents

    2205Q2JE-HO-S6-N_2020.01. Table of Contents Table of Contents Preface ........................i Revision history..................... i Warranty and Disclaimer ................... ii Warranty Clauses....................ii Disclaimer Clauses(Exclusion of Warranty Clauses) ..........ii Important Information ....................iii Intended Use of this Product ................iii Important information for Safe Use of this Product ..........iii About this Manual ....................

  • Page 8: Table Of Contents

    2205Q2JE-HO-S6-N_2020.01. Table of Contents 2.3.3 Outer Dimensions ....................2-7 Compressor Structure and Mechanism ..........2-10 2.4.1 Overview of SCV-series Screw Compressor ............ 2-10 2.4.2 Refrigerant Gas Compression Mechanism ............2-11 2.4.2.1 Gas Suction Phase ..................2-11 2.4.2.2 Compression Phase .................. 2-12 2.4.2.3 Discharge Phase ..................
  • Page 9 2205Q2JE-HO-S6-N_2020.01. Table of Contents 4.2.3 Change of Lubricating Oil Brand................. 4-8 4.2.4 Precautions for Handling lubricating Oil ............. 4-8 4.2.4.1 Precautions for Handling Polyalkylene Glycols (PAG)........ 4-9 4.2.4.2 Precautions for Handling Polyolesters (POE) Oil ........4-9 4.2.5 Lubricating Oil Control Criteria ................4-9 4.2.6 Lubricating Oil Replacement Timing ..............
  • Page 10 2205Q2JE-HO-S6-N_2020.01. Table of Contents 5.4.7 Suction Cover and Side Bearings ..............5-26 5.4.7.1 Disassembly .................... 5-26 5.4.7.2 Inspection ....................5-27 5.4.8 Thrust Bearing Block ..................5-28 5.4.8.1 Disassembly .................... 5-28 5.4.8.2 Inspection ....................5-29 5.4.9 Rotors and Main Rotor Casing ................. 5-30 5.4.9.1 Disassembly ....................
  • Page 11 2205Q2JE-HO-S6-N_2020.01. Table of Contents Chapter 7 Related Documents Exploded Views and Sectional Views ............7-1 Parts Configuration Table ................7-6 Table 7-1 Parts Configuration Table of 160V** models ........... 7-6 Table 7-2 Parts Configuration Table of 200V** models ..........7-10 Table 7-3 Parts Configuration Table of 250V** models ..........

  • Page 12: Chapter 1 Safety

    2205Q2JE-HO-S6-N_2020.01. Chapter 1 Safety Chapter 1 Safety Observation/Prevention 1.1.1 Observance (Do's) 1.1.1.1 Do’s on Operation  Always use the MAYEKAWA specified or recommended controller designed for this product.  The controller protects this product based on the sensor output values. ...

  • Page 13: Do's On Lockout/Tagout After Shutting Off The Power

    2205Q2JE-HO-S6-N_2020.01. Chapter 1 Safety 1.1.1.3 Do's on Lockout/Tagout after Shutting off the Power  Prepare lockout / tag-out devices for the main breakers in the power lines to the main motor and control cabinet.  By applying the lockout/tag-out procedure after turning off the power, you can prevent any other personnel from restoring the power inadvertently.

  • Page 14: Other Do's

    2205Q2JE-HO-S6-N_2020.01. Chapter 1 Safety 1.1.1.8 Other Do’s  Keep the floor around the freezing, refrigeration, and/or air conditioning packages clean and provide a safety aisle.  Use the safety aisle only to move around the equipment. Keep the safety aisle free under all circumstances to ensure safe passage when required.

  • Page 15: Warnings

    2205Q2JE-HO-S6-N_2020.01. Chapter 1 Safety Warnings To alert workers about possible dangers, the following information is always provided with the compressor.  Warnings described in this manual  Safety labels on the compressor 1.2.1 Types and Meanings of Warnings This manual uses the following four types of warnings to emphasize potential hazards during operation or maintenance of the compressor: Neglecting the warnings may cause damage to the compressor or its auxiliary equipment.
  • Page 16 2205Q2JE-HO-S6-N_2020.01. Chapter 1 Safety  Types of Safety Labels Table 1-2 Safety Label S af et y l ab el Re ma r ks SCV-series Screw Compressors 1.2 Warnings...

  • Page 17: Residual Risks

    2205Q2JE-HO-S6-N_2020.01. Chapter 1 Safety Residual Risks The following information is provided on the assumption that this product is operated, inspected, and maintained while being used in freezing, refrigeration, and air conditioning packages. Note that all hazardous sources cannot be predicted for the applications mentioned. Foresee appropriate countermeasures for hazardous sources applicable to your systems.
  • Page 18 2205Q2JE-HO-S6-N_2020.01. Chapter 1 Safety Measures to be taken Measures to be taken when cleaning, Danger source Predicted hazard in operation inspecting, and replacing parts I Oil drains from Contact with hazard- Sufficient ventilation Sufficient ventilation compressor unit ous substances 7) Avoid contact Wear protective gear caused by leakage Keep away and do not...
  • Page 19 2205Q2JE-HO-S6-N_2020.01. Chapter 1 Safety Figure 1-1 Hazardous Sources (Compressor: V*D type i.e. discharge port facing sideways) Figure 1-2 Hazardous Sources (Compressor: V*G type i.e. discharge port facing down) Figure 1-3 Hazardous Sources Figure 1-4 Hazardous Sources (Compressor: V*D type) (Compressor: V*G type) SCV-series Screw Compressors 1.3 Residual Risks...

  • Page 20: Safety Devices

    2205Q2JE-HO-S6-N_2020.01. Chapter 1 Safety Safety Devices For safe use and protection of the compressor, make sure to foresee and install safety devices to the compressor that comply with the regulations and the following descriptions. Safety devices must be properly and periodically maintained and inspected. It is important to include maintenance and inspection of safety devices in the periodical maintenance/inspection schedule.

  • Page 21: Compressor Protection Devices

    2205Q2JE-HO-S6-N_2020.01. Chapter 1 Safety 1.4.3 Compressor Protection Devices  Overview/Function/Purpose To protect the compressor, the following safety functions of the CP4 controller are used.  Protection against High discharge temperature This function stops the compressor when the discharge temperature exceeds the set value. A temperature sensor is installed in the oil separator.
  • Page 22 2205Q2JE-HO-S6-N_2020.01. Chapter 1 Safety  Sensor positions and settings Consult the package instruction manual for the positions and sensor settings for compressor protection. Make sure that the set values of the sensors do not exceed the operating limits indicated in Chapter 2, section 2.3.2 and Table 2-6 in this manual. ...

  • Page 23: Chapter 2 Compressor Specifications And Structure

    The SCV-series has achieved high efficiency by applying " original O-profile screw robes with the minimum leakage". In addition, the SCV series provides economical operations due to its variable capacity control mechanism, which well follows the load variation.  Responding to a Wide Range Condition...

  • Page 24: Model Designation Of The Compressor

    2205Q2JE-HO-S6-N_2020.01. Chapter 2 Compressor Specifications and Structure Model Designation of the Compressor The meaning of the type designation, which is engraved on the MODEL column of the compressor nameplate, is as follows. [10] [1] When there is specification, working fluid is shown by the symbol. This symbol may not be indicated. (Example: N= Ammonia, F=Hydro Fluoro Carbon, P: Propane) [2] Means rotor diameter which is 160, 200, 250 or 320.

  • Page 25: Compressor Specifications

    (load) Rc3/8 Oil drain Note 1: Unless otherwise noted, the pressure unit MPa represents the gauge pressure in this manual. Note 2: MYK flange is the standard flange for MYCOM single screw compressor. SCV-series Screw Compressors 2.3 Compressor Specifications...
  • Page 26 Rc1/2 Note 1: Unless otherwise noted, the pressure unit MPa represents the gauge pressure in this manual. Note 2: MYK flange is the standard flange for MYCOM single screw compressor. Table 2-3 Standard Specifications of SCV-series 250V*D 2 5 0...
  • Page 27 Oil drain Note 1: Unless otherwise noted, the pressure unit MPa represents the gauge pressure in this manual. Note 2: MYK flange is the standard flange for MYCOM single screw compressor. Table 2-5 Standard Specifications of SCV-series 320V*D 3 2 0...

  • Page 28: Operation Limits

    2205Q2JE-HO-S6-N_2020.01. Chapter 2 Compressor Specifications and Structure 2.3.2 Operation Limits Table 2-6 Operation Limits of SCV-series Screw Compressors I t e m O p e r a t i o n L i m i t Maximum discharge pressure 1.96 (250VLL* is 1.37) Maximum suction pressure 0.59 Minimum suction pressure...

  • Page 29: Outer Dimensions

    2205Q2JE-HO-S6-N_2020.01. Chapter 2 Compressor Specifications and Structure 2.3.3 Outer Dimensions Figure 2-1 Outer Dimensions 160V*D, 200V*D, 250V*D, 250VLLD (Sideways discharge type) Figure 2-2 Outer Dimensions 160V*G, 200V*G, 250V*G, 250VLLG (Down discharge type) SCV-series Screw Compressors 2.3 Compressor Specifications...
  • Page 30 2205Q2JE-HO-S6-N_2020.01. Chapter 2 Compressor Specifications and Structure Figure 2-3 Outer Dimensions 320V*D Table 2-7 Outer Dimensions (1/2) (mm) MODEL 160VS* 1027 +0.011 +0.027 1072 40.5 -0.005 48.5 1117 200VS* 1199 +0.012 +0.027 1256 40.5 -0.007 1311 250VS* 1395 1467 +0.012 +0.027 80.5 1535...
  • Page 31 2205Q2JE-HO-S6-N_2020.01. Chapter 2 Compressor Specifications and Structure Table 2-7 Outer Dimensions (2/2) (mm) MODEL 160VS* 24.5 24.5 200VS* 39.5 39.5 251.5 250VS* 34.5 34.5 VLL* 320VSD MODEL 160VS* 102.5 187.5 162.5 132.5 200VS* 184.5 381.5 224.5 241.5 296.5 250VS* 256.5 314.5 VLL* 349.5...

  • Page 32: Compressor Structure And Mechanism

    2205Q2JE-HO-S6-N_2020.01. Chapter 2 Compressor Specifications and Structure Compressor Structure and Mechanism 2.4.1 Overview of SCV-series Screw Compressor SCV-series Screw Compressors are rotary compressors falling into the category of the positive displacement compressor. The compressor sucks refrigerant gas into a cavity, gradually reduces the volume of the cavity, and discharge the refrigerant as a high-pressure gas.

  • Page 33: Refrigerant Gas Compression Mechanism

    2205Q2JE-HO-S6-N_2020.01. Chapter 2 Compressor Specifications and Structure 2.4.2 Refrigerant Gas Compression Mechanism Inside the main rotor casing, there are the M rotor (number of screw lobes: 4) and F rotor (number of screw lobes: 6), intermeshing and rotating in the opposing directions each other. Together with the rotor casing, these two rotors constitute the essential elements of the compressor for sucking and compressing the refrigerant gas.

  • Page 34: Compression Phase

    2205Q2JE-HO-S6-N_2020.01. Chapter 2 Compressor Specifications and Structure 2.4.2.2 Compression Phase As the rotors rotate further, the volume between the rotor lobes and grooves decreases while the sealing line moves toward the discharge side, which compresses the trapped refrigerant gas. Figure 2-7 Compression Phase 2.4.2.3 Discharge Phase The volume between the rotor lobes and grooves decreases to a level predetermined by the discharge...

  • Page 35: Internal Volume Ratio Vi

    2205Q2JE-HO-S6-N_2020.01. Chapter 2 Compressor Specifications and Structure 2.4.3 Internal Volume Ratio Vi 2.4.3.1 What is the Internal Volume Ratio Vi ? In the case of reciprocating compressors, the refrigerant compression capacity is controlled by setting the pressure attained by piston displacement to an optimum level for the intended application. With screw compressors, on the other hand, the compression capacity is controlled by setting the extent to which the volume of the sucked refrigerant gas is to be reduced.

  • Page 36: Variable Vi Mechanism

    Figure 2-10 compares the discharge ports or the fixed and variable Vi compressors. Conventional compressors (fixed Vi) SCV Series compressors (variable Vi) • Both axial and radial ports fixed • Axial port fixed, radial port variable...

  • Page 37: Why The Vi Needs To Be Changed

    2205Q2JE-HO-S6-N_2020.01. Chapter 2 Compressor Specifications and Structure Figure 2-11 Variable Vi Mechanism of SCV-series 2.4.3.3 Why the Vi Needs to Be Changed? The advantages that can change the Vi settings of the compressor are as follows: [1] You ca set the Vi that is suitable for use refrigerant. Internal volume ratio Vi is expressed as follows with the compression ratio.
  • Page 38 2205Q2JE-HO-S6-N_2020.01. Chapter 2 Compressor Specifications and Structure Conversely, if the same compressor is used for a high compression-ratio application (an application with large difference between suction and discharge pressures), the discharge port will open before the refrigerant gas pressure has risen to the necessary level. This would cause the refrigerant gas in the outlet piping to flow back through the discharge port as shown in the lower left graph of Figure 2-13 unless the flowing-back gas is overcome by driving the compressor using extra power.
  • Page 39 2205Q2JE-HO-S6-N_2020.01. Chapter 2 Compressor Specifications and Structure Figure 2-13 Proper and Improper Adaptation of Vi to Load Condition SCV-series Screw Compressor 2.4 Compressor Structure and Mechanism 2-17...

  • Page 40: Bearings And Balance Piston

    2205Q2JE-HO-S6-N_2020.01. Chapter 2 Compressor Specifications and Structure 2.4.4 Bearings and Balance Piston The M rotor and F rotor are supported at their both ends by the side bearings in the suction cover and the main bearings in the bearing head. These bearings use sleeve type white metal lined bearings. In addition, the thrust bearings located outside the main bearings support the thrust loads working on the rotors, which result from both the rotation of the rotors and the difference in refrigerant gas pressure that takes place during the compression process.
  • Page 41 2205Q2JE-HO-S6-N_2020.01. Chapter 2 Compressor Specifications and Structure Figure 2-14 Oil Supply Route of Forced Oil Supply System Figure 2-15 Oil Supply Route of Differential Pressure Oil Supply System SCV-series Screw Compressor 2.4 Compressor Structure and Mechanism 2-19...
  • Page 42 2205Q2JE-HO-S6-N_2020.01. Chapter 2 Compressor Specifications and Structure Figure 2-16 Oil Supply Route SCV-series Screw Compressor 2.4 Compressor Structure and Mechanism 2-20...

  • Page 43: Chapter 3 Installation

    2205Q2JE-HO-S6-N_2020.01. Chapter 3 Installation Chapter 3 Installation General Precautions for Installation  This chapter (Installation) assumes that the compressor is installed to a standard refrigeration / cold storage package unit. If the unit you are actually using is not the standard type refrigeration/cold storage package unit, prepare a proper installation manual by referring to the description in this chapter and paying due consideration to safety, before installing the compressor.
  • Page 44 2205Q2JE-HO-S6-N_2020.01. Chapter 3 Installation Always check the wire ropes before using them. Thoroughly check the wire ropes for problems such as kinks, knots and broken strands. Do not perform lifting before confirming the safety of the wire ropes. If you cannot make a correct evaluation or judgment, entrust an expert to check. To lift the compressor, attach the wire ropes to the appended eye bolts by using appropriate shackles and hooks.

  • Page 45: Preparation For Installation

    2205Q2JE-HO-S6-N_2020.01. Chapter 3 Installation 3.2.4 Preparation for Installation  Installation Space Secure sufficient working space for easy operation, cleaning, maintenance, and inspection.  Illumination Prepare illumination devices which allow easy operation, cleaning, maintenance, and inspection.  Ventilation If natural ventilation is insufficient, install ventilation fans according to the relevant regulations. ...
  • Page 46 2205Q2JE-HO-S6-N_2020.01. Chapter 3 Installation □ 2-M12×P1.75 □ 4-M12×P1.75 □ 4-M12×P1.75 □ 4-M12×P1.75 □ 4-M16×P2 □ 4-M20×P2.5 □ 100A 4-M22×P2.5 100CD 4-M22×P2.5 125A 8-M20×P2.5 125CD 8-M20×P2.5 150A 8-M22×P2.5 150CD 8-M22×P2.5 200CD 12-M20×P2.5 250A 12-M24×P3 350A 16-M24×P3 Figure 3-2 Dimensions of the MYK Flange Joint Part (Compressor) SCV-series Screw Compressor 3.2 Installation Works...

  • Page 47: Installation

    2205Q2JE-HO-S6-N_2020.01. Chapter 3 Installation 3.2.5 Installation 3.2.5.1 Placement Check that the surface of the package unit, where the compressor is to be installed, is even and horizontal. If it is uneven and non-horizontal, tightening the bolts may lead to compressor deformation, which may prevent normal operation.

  • Page 48: Piping Connection

    2205Q2JE-HO-S6-N_2020.01. Chapter 3 Installation 3.2.5.3 Piping Connection  Refrigerant Piping Observe the following when connecting the refrigerant piping to the compressor.  The compressor is one of the few devices installed within the package unit that have moving components. These moving components are adversely affected by foreign substances within the system (scale, dust, spatter, etc.).

  • Page 49: Airtightness Test

    2205Q2JE-HO-S6-N_2020.01. Chapter 3 Installation 3.2.6 Airtightness Test Perform an airtightness test on the package unit before starting commissioning. To prevent water entry in the package unit, use nitrogen gas or dry air for the airtightness test. 3.2.7 Vacuuming  Do not turn the compressor rotor shaft during vacuuming. Vacuuming involves discharging the air in the unit before the refrigerant and oil are charged in the unit.

  • Page 50: Chapter 4 Compressor And Package Unit Operation

    2205Q2JE-HO-S6-N_2020.01. Chapter 4 Compressor and Package Unit Operation Chapter 4 Compressor and Package Unit Operation Adjustment of Vi 4.1.1 Overview The internal volume ratio Vi of SCV-series screw compressors has been adjusted as H port (5.8) at the time of shipping. Before starting the commissioning of the package unit, confirm the appropriate Vi of the compressor for customer’s operating conditions and change the Vi setting if necessary.
  • Page 51 2205Q2JE-HO-S6-N_2020.01. Chapter 4 Compressor and Package Unit Operation b) From the table 4-1 “Number of Turns of Vi Adjusting Rod for Individual Models”, determine how many turns the adjusting rod [444] should be rotated in order to set to the port selected in Step a) above.
  • Page 52 2205Q2JE-HO-S6-N_2020.01. Chapter 4 Compressor and Package Unit Operation e) Remove the domed cap nut [522] at the end of the Vi adjusting rod, then loosen the hexagon nut [453] used as a lock nut. On the compressors produced after March in 2005, a conical spring washer is provided between the hexagon nut and domed cap nut to prevent detachment of the cap nut.
  • Page 53 2205Q2JE-HO-S6-N_2020.01. Chapter 4 Compressor and Package Unit Operation o) Adjust the position of micro switch cam No.2. Remove the cover and loosen the micro switch cam set screw. p) Turn counterclockwise until the micro switch lever is raised. q) Slowly turn clockwise, and stop turning when the micro switch lever is lowered.
  • Page 54 2205Q2JE-HO-S6-N_2020.01. Chapter 4 Compressor and Package Unit Operation Figure 4-3 Vi Changing Sequence from H port to M port SCV-series Screw Compressor 4.1 Adjustment of Vi...

  • Page 55: Lubricating Oil (Refrigerant Oil)

    2205Q2JE-HO-S6-N_2020.01. Chapter 4 Compressor and Package Unit Operation Lubricating Oil (Refrigerant Oil) Selecting and managing lubricating oil (refrigerant oil) is very significant to keep the compressor in a good operating condition. Take the following notes when selecting and managing lubricating oil. 4.2.1 Precautions for Selecting the Lubricating Oil ...

  • Page 56: Oils For Systems Using Hydrofluorocarbon (Hfc) Refrigerants

    2205Q2JE-HO-S6-N_2020.01. Chapter 4 Compressor and Package Unit Operation  Mineral Oils (incompatible oils) Kinematic viscosity Brand Manufacturer Type (40 °C) mm SUNISO 3GS Sun Oil Naphthenic base SUNISO 4GS Sun Oil REFOIL NS 3GS GARGOYLE ARCTIC C HEAVY Exxon Mobil GARGOYLE ARCTIC 300 Exxon Mobil CAPELLA WF46...

  • Page 57: Change Of Lubricating Oil Brand

    2205Q2JE-HO-S6-N_2020.01. Chapter 4 Compressor and Package Unit Operation  Polyolester Synthetic Oil (POE) for R134a (incompatible synthetic oil) Kinematic viscosity Brand Manufacturer Type (40 °C) mm JOMO Freol α100  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.

  • Page 58: Precautions For Handling Polyalkylene Glycols (Pag)

    2205Q2JE-HO-S6-N_2020.01. Chapter 4 Compressor and Package Unit Operation 4.2.4.1 Precautions for Handling Polyalkylene Glycol (PAG) PAG oil is much more hygroscopic than mineral oils and any moisture mixed in the oil may lead to rust, corrosion and wear within the package. When handling PAG oil, pay special attention to the following points.

  • Page 59: Lubricating Oil Replacement Timing

    2205Q2JE-HO-S6-N_2020.01. Chapter 4 Compressor and Package Unit Operation The analysis items and the criteria are shown in the following tables. Please note that these control criteria may be changed without notice. Table 4-3 Synthetic Oil (PAG) Item Criteria (a) Color phase ASTM color scale: 4.0 or less (b) Total acid number (TAN) 0.1 mg KOH/g or less (c) Kinematic viscosity...

  • Page 60: Precautions For Operation

    2205Q2JE-HO-S6-N_2020.01. Chapter 4 Compressor and Package Unit Operation Precautions for Operation If the package unit is used in the refrigeration cycle, please keep in mind the contents of this section in particular. 4.3.1 Prevention of Liquid Flow-back Operation Liquid flow-back is a phenomenon where refrigerant that did not completely evaporate with the gas reaches the compressor.

  • Page 61: When Stopping The Compressor For A Long Time

    2205Q2JE-HO-S6-N_2020.01. Chapter 4 Compressor and Package Unit Operation When Stopping the Compressor for a Long Time Before stopping the compressor for a long time, make sure to perform the following steps.  Turn off the motor main power.  Turn off the oil heater power and the control power. ...

  • Page 62: Chapter 5 Maintenance And Inspection

    2205Q2JE-HO-S6-N_2020.01. Chapter 5 Maintenance and Inspection Chapter 5 Maintenance and Inspection Precautions for Maintenance and Inspection When reading this Section, also refer to Section 1.1 in this manual Chapter 1.  When entering the machine room for maintenance services, ensure that sufficient ventilation has been started and measure the oxygen concentration so that there is no risk of oxygen deficiency.
  • Page 63 2205Q2JE-HO-S6-N_2020.01. Chapter 5 Maintenance and Inspection  When checking the operation data of units and executing other daily maintenance services, pay particular attention to avoid touching the area heated to a high temperature causing skin burns or inadvertently moving the handle of a valve leading to an erroneous operation.

  • Page 64: Maintenance And Inspection List

    2205Q2JE-HO-S6-N_2020.01. Chapter 5 Maintenance and Inspection Maintenance and Inspection List 5.2.1 Daily Management For the purpose of daily maintenance, check the items listed in Table 5-1 "Daily Inspection Items" and record the results. 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 any abnormal condition of the compressor and prevents possible compressor failures.
  • Page 65 2205Q2JE-HO-S6-N_2020.01. Chapter 5 Maintenance and Inspection Table 5-1 Daily Inspection Item (continued) Inspection item Inspection details Checkpoints and actions  Compressor failure Motor current Whether it is higher than the  Motor failure current at test run  Oil loss Oil level of oil separator Oil level ...

  • Page 66: Periodic Inspection

    2205Q2JE-HO-S6-N_2020.01. Chapter 5 Maintenance and Inspection 5.2.2 Periodic Inspection Inspect the following points at specified intervals. Table 5-3 Periodic Inspection Items Item Inspection interval Remarks Pressure sensors Annually Temperature sensors Annually Protection devices and Annually safety valves Suction strainer Inspection after the first 500h of If the differential pressure between operation the front and back of the suction...
  • Page 67 2205Q2JE-HO-S6-N_2020.01. Chapter 5 Maintenance and Inspection 5.2.3 Guidelines for Compressor Overhaul Frequency When servicing or overhauling the compressor, follow the instructions and guidelines described below. The compressor inspection frequency significantly differs depending on the operating conditions, refrigerant in use, type and condition of lubricant, and the system in which the compressor is operated. The table below indicates the overhaul frequency recommended by based on the operating conditions of the compressor.

  • Page 68: Compressor Disassembly Preparation

    2205Q2JE-HO-S6-N_2020.01. Chapter 5 Maintenance and Inspection Compressor Disassembly Preparation Although screw compressors are very reliable machines, it is still necessary to perform overhaul to inspect internal parts after a certain period of operation. This chapter 5 explains the essential points of disassembly methods, where to inspect on parts, and reassembly procedure.

  • Page 69: Replacement Parts

    2205Q2JE-HO-S6-N_2020.01. Chapter 5 Maintenance and Inspection 5.3.2 Replacement Parts Prepare the genuine parts for replacement. Parts listed in Table 5-5, we recommend to be replaced on the occasion of each compressor overhaul. For each part size and code No. of each compressor model, refer to Section 7.2 "Parts Configuration Table"...
  • Page 70 2205Q2JE-HO-S6-N_2020.01. Chapter 5 Maintenance and Inspection Q’ty. Part Name Remarks abnormality is found. O-ring, Thrust Bearing Gland 320 for 320V*D Gasket, Lubricating Oil Inlet Flange Journal inlet Gasket, Oil Injection Inlet Flange for 320V*D for Sideways Gasket, Discharge Flange Spacer discharge type Torsional Slip Washer Gasket, Liquid Injection Inlet Flange...

  • Page 71: Refrigerant Gas Recovery

    2205Q2JE-HO-S6-N_2020.01. Chapter 5 Maintenance and Inspection 5.3.3 Refrigerant Gas Recovery At the time the compressor operation is stopped, the pressure inside the compressor is still high. As such, it is necessary to drop the pressure down to the atmospheric pressure before starting the disassembly process.
  • Page 72 2205Q2JE-HO-S6-N_2020.01. Chapter 5 Maintenance and Inspection When removing the compressor from the mounting base frame, the following parts must be disconnected beforehand in numeric order of Figure 5-1: Figure 5-1 Disconnecting Parts (1) Coupling to connect the compressor to the driving machine; (2) Suction piping of the compressor.

  • Page 73: Removal Of The Compressor From Base Flame

    2205Q2JE-HO-S6-N_2020.01. Chapter 5 Maintenance and Inspection 5.3.5 Removal of the Compressor from Base Frame  The work to lift up or move the compressor must be performed by a qualified operator. If the work is done by an unqualified operator, it may result in a dropping accident. ...

  • Page 74: Compressor Disassembly Order

    2205Q2JE-HO-S6-N_2020.01. Chapter 5 Maintenance and Inspection Alternatively, place wooden blocks high enough to provide the flange with clearance from the workbench surface below the legs of the suction cover and bearing head and lower the compressor on the wooden blocks as shown in below picture to the right. 5.3.6 Compressor Disassembly Order The disassembly order of the SCV-series compressor is general as described below.

  • Page 75: Disassembly And Inspection

    2205Q2JE-HO-S6-N_2020.01. Chapter 5 Maintenance and Inspection Disassembly and Inspection 5.4.1 Unloader Indicator Block The SCV-series unloader indicator has been changed to the new type indicator (right picture) with the protection grade IP66 by improving the performance of the dust and water proof from December 2014 Moriya factory production.

  • Page 76: Disassembly

    2205Q2JE-HO-S6-N_2020.01. Chapter 5 Maintenance and Inspection 5.4.1.1 Disassembly ■ In the Case of Removing the Wiring only When removing the wiring of the unloader indicator upon removing the compressor, it is necessary to remove the cover as the indicator has a terminal block for the wiring. Perform the work according to the following procedure, and after removing the wires, attach the cover to them for protection.

  • Page 77: Inspection

    2205Q2JE-HO-S6-N_2020.01. Chapter 5 Maintenance and Inspection ■ For Further Disassembly (In the case of Removing as Unloader Indicator Assembly) As the indicator is an assembly to be removed as a whole, no further disassembly should be made unless the purpose of the disassembly is to disassemble this part. a) As a result of the previous disassembly process, the micro switch base plate [121], which is mounting the potentiometer [129], micro switches [125], and micro switch cam [127], can be removed.

  • Page 78: Shaft Seal Block

    2205Q2JE-HO-S6-N_2020.01. Chapter 5 Maintenance and Inspection 5.4.2 Shaft Seal Block Part Name Mating ring Stationary Insert lock pin rings O-ring Seal collar Rotating Seal collar set screw rings O-ring Oil seal sleeve Note Set screw for oil seal sleeve Note O-ring Note Retainer, oil seal...

  • Page 79: Inspection

    2205Q2JE-HO-S6-N_2020.01. Chapter 5 Maintenance and Inspection f) After the seal cover has been removed, wipe clean the shaft and then check its surface. If any flaw is found, use a fine sandpaper to smoothen the surface. This correction is intended to prevent possible damage of the internal O-ring when the mechanical seal is pulled out.

  • Page 80: Unloader Cover

    2205Q2JE-HO-S6-N_2020.01. Chapter 5 Maintenance and Inspection 5.4.3 Unloader Cover The unloader cover [74] is mounted with the indicator cam [77] which converts the linear motion of the unloader slide valve to a rotational motion, and their mounting parts. The indicator cam is supported by the ball bearing [78] and fixed to the cover with a bearing gland [80]. To make it airtight, the V-ring [82], spring [83], and spring retainer [84] are also attached.

  • Page 81: Inspection

    2205Q2JE-HO-S6-N_2020.01. Chapter 5 Maintenance and Inspection Removing the Unloader Cover Ball Bearing for the Indicator Cam Indicator Cam Mounting Parts V-ring (The black part is NBR/FKM) 5.4.3.2 Inspection a) Check the packing of the indicator cam shaft for any flaw. If the refrigerant leaks without any flaw observed in this part, it should be due to a defect of the V-ring or installing the V-ring without sufficient oil.

  • Page 82: Unloader Cylinder And Balance Piston Cover

    2205Q2JE-HO-S6-N_2020.01. Chapter 5 Maintenance and Inspection 5.4.4 Unloader Cylinder and Balance Piston Cover Inside the unloader cylinder [60] is an unloader piston [64] around which the cap seal [66] and O-ring [65] are fitted. The unloader piston is assembled to the unloader push rod [67], which operates the unloader slide valve, with the lock nut [69].

  • Page 83: Inspection

    2205Q2JE-HO-S6-N_2020.01. Chapter 5 Maintenance and Inspection f) Screw in two M8 eye bolts to the two jacking bolt threads on the balance piston cover, and separate the balance piston cover with unloader cylinder from the suction cover. g) Remove two fastening bolts [61], and separate the unloader cylinder and balance piston cover. h) In case of SCV-series 320 models, i.e., VL* type, VM* type and VS* type are installed the unloader piston spacer [420] with two O-rings [421].

  • Page 84: Balance Piston Block

    2205Q2JE-HO-S6-N_2020.01. Chapter 5 Maintenance and Inspection 5.4.5 Balance Piston Block Figure 5-10 Exploded View of Balance Piston Block 5.4.5.1 Disassembly a) Remove the snap ring [32] that secures the balance piston [30] on the M rotor shaft using external snap ring pliers. b) Screw in two M8 eye bolts to the hole in the balance piston and pull out the piston in parallel with the axis of the shaft (see right...

  • Page 85: Inspection

    2205Q2JE-HO-S6-N_2020.01. Chapter 5 Maintenance and Inspection With the balance piston sleeve [33] locked using the Type 1 method, the sleeve has a notch using which it is locked by screwing two hexagon socket head cap screws into a threaded hole, one from the notch side (M rotor side) and the other from the opposing side (F rotor side).

  • Page 86: Bearing Cover

    2205Q2JE-HO-S6-N_2020.01. Chapter 5 Maintenance and Inspection 5.4.6 Bearing Cover The bearing cover differs in shape between the D type models (with a bearing head for sideways discharging) and the G type models (with a bearing head for downward discharging). The discharge port is in an unsymmetrical location with the D type models, so the bearing cover has imbalanced weight distribution between the right and left;...

  • Page 87: Suction Cover And Side Bearings

    2205Q2JE-HO-S6-N_2020.01. Chapter 5 Maintenance and Inspection 5.4.7 Suction Cover and Side Bearings If the work sequence is such that the thrust bearing block is disassembled first and then the suction cover is removed, there is a risk that, when the suction cover is separated from the rotor casing, the rotor may also be pull out and dropped.

  • Page 88: Inspection

    2205Q2JE-HO-S6-N_2020.01. Chapter 5 Maintenance and Inspection f) The O-ring and O-ring gland [326] are mounted in the unloader push rod passes part of the suction cover. Remove them. At this time, take care not to lose the four fastening screws for O-ring gland due to their smallness (M5).

  • Page 89: Thrust Bearing Block

    2205Q2JE-HO-S6-N_2020.01. Chapter 5 Maintenance and Inspection 5.4.8 Thrust Bearing Block [160 to 250V**] [320V*D] Figure 5-12 Exploded Views of Thrust Bearing Block Table 5-7 Parts Configuration of Thrust Bearing Block Part Name 160V 200V 250V 320V Thrust bearing Lock nut Lock washer Spacer, Thrust bearing outer race Spacer, Thrust bearing alignment...

  • Page 90: Inspection

    2205Q2JE-HO-S6-N_2020.01. Chapter 5 Maintenance and Inspection c) The whole thrust bearing will be removed helped by the surface tension of the oil on the side face. If you have failed to remove the whole bearing at once, put the components in the order of the removal.

  • Page 91: Rotors And Main Rotor Casing

    2205Q2JE-HO-S6-N_2020.01. Chapter 5 Maintenance and Inspection 5.4.9 Rotors and Main Rotor Casing 5.4.9.1 Disassembly a) The rotor can be easily pulled out. While you can pull out the rotor either from the M or F side, you should be very careful in the work as either rotor is very heavy. When pulling out the M rotor (or F rotor) first, pull out about 2/3 of the full length of the rotor by holding the shaft upward and turning it in the CW (or CCW) direction.

  • Page 92: Variable Vi Auxiliary Slide Valve And Unloader Slide Valve

    2205Q2JE-HO-S6-N_2020.01. Chapter 5 Maintenance and Inspection 5.4.10 Variable Vi Auxiliary Slide Valve and Unloader Slide Valve Figure 5-13 Variable Vi Auxiliary Slide Valve, Unloader Slide Valve and Vi Adjusting Rod 5.4.10.1 Disassembly a) Remove the hexagon head socket cap screws [454] fastening the lock washer [445] on the tip of the suction cover side of Vi adjusting rod [444] and remove the spring washer [455] (following picture to the left).

  • Page 93: Inspection

    2205Q2JE-HO-S6-N_2020.01. Chapter 5 Maintenance and Inspection Pulling out the Unloader Slide Valve Separating the Unloader Slide Valve and Variable Auxiliary Slide Valve and Variable Auxiliary Slide Valve 5.4.10.2 Inspection a) With the unloader slide valve and variable Vi auxiliary slide valve mounted in position, check the step height between the slide valves and the rotor casing surfaces.

  • Page 94: Bearing Head And Main Bearings

    2205Q2JE-HO-S6-N_2020.01. Chapter 5 Maintenance and Inspection 5.4.11 Bearing Head and Main Bearings 5.4.11.1 Disassembly a) Unscrew and remove all the hexagon socket head cap screws [2] fastening the main rotor casing [1] and bearing head [11] . b) Screw in two removed hexagon head cap screws to the jacking threads on the main rotor casing flange, and evenly screw them little by little.

  • Page 95: Reassembly

    2205Q2JE-HO-S6-N_2020.01. Chapter 5 Maintenance and Inspection 5.5 Reassembly  During the reassembly work, be very careful in selecting the correct replacement O-rings of the specified standard, not to make a mistake regarding the size, material, for fixed use, for sliding use, etc. Using a wrong O-ring can lead to oil leak or other problems.

  • Page 96: Bearing Head And Main Bearings

    2205Q2JE-HO-S6-N_2020.01. Chapter 5 Maintenance and Inspection 5.5.1 Bearing Head and Main Bearings The main bearing (O-ring type) [27] is installed by a light press fit. a) Align the notch on the main bearing [11] with the spring pin [14] that is driven in into the bearing head [11], and then drive it in with a pad.

  • Page 97: Unloader Slide Valve

    2205Q2JE-HO-S6-N_2020.01. Chapter 5 Maintenance and Inspection 5.5.2 Unloader Slide Valve a) Check that the O-ring [523] fitted in the Vi adjusting rod hole of the unloader slide valve has replaced, and check that the Teflon bushing [448] for the Vi adjusting rod has no defects. b) Check that all removed plugs for oil injection circuit, etc.

  • Page 98: Installing The Rotors

    2205Q2JE-HO-S6-N_2020.01. Chapter 5 Maintenance and Inspection 5.5.3 Installing the Rotors The rotor must be sufficiently reworked. If any slight flaw is observed on the shaft surface in the area of attaching the bearing or seal, use a sand paper to correct and finish the surface. After finishing the surface to attach the seal, apply protective tape on the surface.

  • Page 99: Suction Cover And Side Bearings

    2205Q2JE-HO-S6-N_2020.01. Chapter 5 Maintenance and Inspection 5.5.4 Suction Cover and Side Bearings a) Similarly to the main bearing, the side bearing (O-ring type) [28] is machined to the size that will allow light press fitting to the suction cover. Press fit the bearing by aligning the notch position of the bearing with the spring pin [8] for positioning the bearing driven-in on the suction cover.

  • Page 100: Installing The Suction Cover

    2205Q2JE-HO-S6-N_2020.01. Chapter 5 Maintenance and Inspection 5.5.6 Installing the Suction Cover a) Turn the Vi adjusting rod counterclockwise to set it to the L port position. b) Apply oil on both sides of the gasket [6], and attach it to the main rotor casing [1] while carefully checking the position of oil supply holes.

  • Page 101: Thrust Bearing Block

    2205Q2JE-HO-S6-N_2020.01. Chapter 5 Maintenance and Inspection 5.5.7 Thrust Bearing Block [160 to 250V**] [320V*D] Note: 250V** models do not use the No.41. Figure 5-15 Exploded View of the Thrust Bearing Block  The torsional slip washer [237] and lock washer [39] must be replaced with new ones. ...
  • Page 102 2205Q2JE-HO-S6-N_2020.01. Chapter 5 Maintenance and Inspection c) After installing the thrust bearing, attach the thrust washer [250], lock washer [40], and torsional slip washer [237]. Then, tighten the lock nut [39] at the specified torque or within the specified range of the tightening angle (refer to Chapter 7, Section 7.3 "Tightening Torques for Bolts and Nuts"...

  • Page 103: End Clearance Measurement

    2205Q2JE-HO-S6-N_2020.01. Chapter 5 Maintenance and Inspection 5.5.7.1 End Clearance Measurement At this point (i.e., after the thrust bearing block has been fully assembled), measure the end clearance of the rotor on the discharge side. In particular, this measurement must be made when the thrust bearing has been replaced. Even if the same bearing is used, the measurement should be made for verification.

  • Page 104: End Clearance Adjustment Procedure

    2205Q2JE-HO-S6-N_2020.01. Chapter 5 Maintenance and Inspection Figure 5-17 Measurement of the End Clearance 5.5.7.2 End Clearance Adjustment Procedure (1) When the end clearance is less than the specified value In this case, a shim (thrust adjustment liner) must be inserted between the thrust alignment spacer [42] and the inner race of the thrust bearing to increase the end clearance.

  • Page 105: Tightening After Finishing The End Clearance Adjustment

    2205Q2JE-HO-S6-N_2020.01. Chapter 5 Maintenance and Inspection 5.5.7.3 Tightening after Finishing the End Clearance Adjustment (1) In case of 160 to 250V** models: a) Remove a hexagon head bolt [45] which is used to fasten thrust bearing gland [43], and insert the conical spring washer [46] to prevent the bolt loosening.

  • Page 106: Balance Piston Cover And Unloader Cylinder

    2205Q2JE-HO-S6-N_2020.01. Chapter 5 Maintenance and Inspection 5.5.8 Balance Piston Cover and Unloader Cylinder The assembly work of this block will become easier if the unloader cylinder is first installed on the balance piston cover [22] and then the resulting assembly is installed on the suction cover [5]. a) Install the O-ring [63] in the O-ring groove on the machined surface of the balance piston cover along which the unloader cylinder is installed.
  • Page 107 2205Q2JE-HO-S6-N_2020.01. Chapter 5 Maintenance and Inspection Table 5-11 Unloader Positioning Spacer with Model Quantity Model Positioning Spacer【420】 O-ring【421】 250VLL* 160 to 250VL* 160 to 250VM* 160 to 250VS* 1 (PTFE) 320VLD 320VMD 320VSD g) Attach the O-ring [65] without lubricating oil on the unloader piston [64], and then install the cap seal [66] on it.
  • Page 108 2205Q2JE-HO-S6-N_2020.01. Chapter 5 Maintenance and Inspection j) After setting the flanges of the suction cover and balance piston cover together, tighten the hexagon socket head cap screws [24] for the balance piston cover and the same ones [62] for the unloader cylinder, the specified torque respectively.

  • Page 109: Unloader Cover

    2205Q2JE-HO-S6-N_2020.01. Chapter 5 Maintenance and Inspection 5.5.9 Unloader Cover Figure 5-18 Unloader Cover Block a) Use eye bolts to move the unloader piston back and forth to check the normal operation again. b) Assemble the ball bearing [78] on the shaft portion of the indicator cam [77]. When fitting the bearing onto the shaft, push the inner race of the bearing.

  • Page 110: Bearing Cover

    2205Q2JE-HO-S6-N_2020.01. Chapter 5 Maintenance and Inspection 5.5.10 Bearing Cover a) Install the thrust washer [449], as shown a red arrow in following picture to the left, on the Vi adjusting rod. In case of 320V*D models except other models are installed the Vi adjusting rod retainer [600] as shown in following picture to the right.

  • Page 111: Shaft Seal Block

    2205Q2JE-HO-S6-N_2020.01. Chapter 5 Maintenance and Inspection 5.5.11 Shaft Seal Block The BBSE (balance bellows single) type of the mechanical seal assemblies used in current standard screw compressors as standard specification. There are other cases where the BOS (balance O-ring single) type seals are used, according to the specification by the customer.
  • Page 112 2205Q2JE-HO-S6-N_2020.01. Chapter 5 Maintenance and Inspection d) Install the oil seal retainer with the oil seal and sleeve (in case of 160V** models, install the oil seal retainer with the oil seal) along the rotor shaft using two M8 eye bolts. At this time, position the oil escape hole of the oil seal retainer on the upper side of the rotor shaft, and accurately align the notch in the retainer with the position of the spring pin [20] that is driven in into the bearing cover to prevent its rotation.
  • Page 113 2205Q2JE-HO-S6-N_2020.01. Chapter 5 Maintenance and Inspection j) Apply oil on the seal cover gasket [52] and attach it to the seal cover flange by carefully aligning the oil hole position on the gasket and the one on the flange. ◆ In case of the standard internal oil supply system for the shaft seal block, oil is first sent from the bearing cover to the seal cover through the oil supply hole machined on them, then from the notch in the seal cover to the upper part of the seal cover through a groove, and lastly supplied from the oil supply hole in the seal cover to the upper part of the sliding surface of the...

  • Page 114: Unloader Indicator

    2205Q2JE-HO-S6-N_2020.01. Chapter 5 Maintenance and Inspection 5.5.12 Unloader Indicator The specifications of the unloader indicator for SCV-series has been changed from December 2014 Moriya factory production. For details of the new indicator specifications indicator after change, refer to the separately dedicated manual.

  • Page 115: Micro-Switches And Micro-Switch Cam

    2205Q2JE-HO-S6-N_2020.01. Chapter 5 Maintenance and Inspection 5.5.12.2 Micro-switches and Micro-switch Cam The traditional standard unloader indicator uses two micro-switches and one micro-switch cam to detect the indicated 0 % and 100 % capacity control positions of the unloader slide valve. If the micro-switch fails or any of these connections becomes loose for some reason, correct position detection cannot be made, and it causes a problem in the operation control of the compressor.
  • Page 116 2205Q2JE-HO-S6-N_2020.01. Chapter 5 Maintenance and Inspection Figure 5-20 Exploded View of the Unloader Indicator (Traditional standard type) Table 5-13 Component Parts of the Unloader Indicator (Traditional standard type) Part Name Q'ty Part Name Q'ty 121 Micro-switch base plate Hexagon socket set screw, M3×14 122 Hexagon socket head cap screw, M6×20 Dial, SCV 123 Micro-switch base plate...
  • Page 117 2205Q2JE-HO-S6-N_2020.01. Chapter 5 Maintenance and Inspection Figure 5-21 Sectional Views of SCV-series Unloader Indicator (Traditional standard type) SCV-series Screw Compressor 5.5 Reassembly 5-56...

  • Page 118: Chapter 6 Troubleshooting

    2205Q2JE-HO-S6-N_2020.01. Chapter 6 Troubleshooting Chapter 6 Troubleshooting Table 6-1 Troubleshooting Trouble Direct causes Factors Actions Compressor Power source is off. Power source not Prevent oversight by checking a does not turned on after check sheet after inspection. startup inspection. Main motor Most cases are due Refer to the motor instruction malfunction...
  • Page 119 2205Q2JE-HO-S6-N_2020.01. Chapter 6 Troubleshooting Trouble Direct causes Factors Actions Compressor Low pressure Insufficient refriger- If any heat exchange failures as stops imme- protection circuit ant circulation typified by poor defrost diately after activated volume performance, investigate the cause startup. and take measures. For malfunction in pressure regulating valve operation, replace pressure regulating valve, or...
  • Page 120 2205Q2JE-HO-S6-N_2020.01. Chapter 6 Troubleshooting Trouble Direct causes Factors Actions Defect in hydraulic Malfunction in Identify malfunctioning devices, pressure detection hydraulic pressure examine their causes, and take oil-supply divices. protection measures. pressure device(switch), Then, replace malfunctioning pressure sensor, devices. relays, etc. Clogging in the Remove clogging.
  • Page 121 2205Q2JE-HO-S6-N_2020.01. Chapter 6 Troubleshooting Trouble Direct causes Factors Actions Abnormally Excessive Repetitive Adjust refrigerant to proper amount. high refrigerant charge refrigerant charge pressure by mistaking (abnormal insufficient cooking discharge as a lack of pressure) refrigerant in the system. Insufficient capacity If the trouble is caused by change in of heat exchanger operating conditions, re-examine...
  • Page 122 2205Q2JE-HO-S6-N_2020.01. Chapter 6 Troubleshooting Trouble Direct causes Factors Actions Abnormally High oil supply Heat exchange For water-cooled oil cooling, refer to high temperature failure in oil cooler “Heat exchange failure at discharge condenser (heat exchanger)” in temperature item 05. For liquid-injection oil cooling, inspect liquid supply expansion valve, temperature sensor, related relays, wiring, terminals, etc., and...
  • Page 123 2205Q2JE-HO-S6-N_2020.01. Chapter 6 Troubleshooting Trouble Direct causes Factors Actions Leak from Long stoppage Due to user’s If stoppage period becomes more mechanical period (no oil film specific conditions, than one week, manually operate oil seal on sliding surfaces) such as heat load pump as well as manually turn being intermittent.
  • Page 124 2205Q2JE-HO-S6-N_2020.01. Chapter 6 Troubleshooting Trouble Direct causes Factors Actions Faulty Imprecision in Loose screws for Manually tighten screws to the 0 % indication of compressor indicator indication position of compressor capacity indicator capacity control. control posi- Imprecision in Worn groove of Most cases are due to prolonged tion controller capacity...
  • Page 125 2205Q2JE-HO-S6-N_2020.01. Chapter 6 Troubleshooting Trouble Direct causes Factors Actions Capacity Capacity control Maladjustment of oil Readjust it. control hydraulic line defect flow controller valve malfunction Leak and clogging Remove factors. Check oil in solenoid valve contamination level and replace oil gland and oil pipes as necessary.
  • Page 126 2205Q2JE-HO-S6-N_2020.01. Chapter 6 Troubleshooting Trouble Direct causes Factors Actions Abnormal Oil hammer Continuous low During low load operation, lubricant vibration load operation at is poorly discharged. Because of and/or below 30 % of this, the amount of oil that remains noise of capacity control inside rotor mesh increases and oil...
  • Page 127 2205Q2JE-HO-S6-N_2020.01. Chapter 6 Troubleshooting Trouble Direct causes Factors Actions Abnormal Expansion valve Avoid rapid changes in heat load. vibration opening control and/or cannot keep up with noise of rapid changes in compressor heat load on load side. Shortage in heat For frosting (icing), defrost exchanger capacity manually.
  • Page 128 2205Q2JE-HO-S6-N_2020.01. Chapter 6 Troubleshooting Trouble Direct causes Factors Actions Entering of foreign Refer to the Direct cause “Foreign substances substances entering into compressor” above. Excessive thrust Re-examine operating conditions stress and improve them if possible. High suction pres- If it is difficult to improve, sure exceeding re-examine maintenance interval operating...

  • Page 129: Chapter 7 Related Documents

    2205Q2JE-HO-S6-N_2020.01. Chapter 7 Related Documents Chapter 7 Related Documents Exploded Views and Sectional Views Figure 7-1 Exploded View (160 to 250V** model) SCV-series Screw Compressor 7.1 Exploded Views...
  • Page 130 2205Q2JE-HO-S6-N_2020.01. Chapter 7 Related Documents Figure 7-2 Exploded View (320V*D model) SCV-series Screw Compressor 7.1 Exploded Views...
  • Page 131 2205Q2JE-HO-S6-N_2020.01. Chapter 7 Related Documents Figure 7-3 Sectional View (160 to 250V*D model) SCV-series Screw Compressor 7.1 Assembly Sectional Views...
  • Page 132 2205Q2JE-HO-S6-N_2020.01. Chapter 7 Related Documents Figure 7-4 Sectional View (160 to 250V*G model) SCV-series Screw Compressor 7.1 Assembly Sectional Views...
  • Page 133 2205Q2JE-HO-S6-N_2020.01. Chapter 7 Related Documents Figure 7-5 Sectional View (320V*D model) SCV-series Screw Compressor 7.1 Assembly Sectional Views...

  • Page 134: Parts Configuration Table

    2205Q2JE-HO-S6-N_2020.01. Chapter 7 Related Documents Parts Configuration Table Table 7-1 Parts Configuration Table of 160V** models Part Name Code No. Remarks Q’ty. Main Rotor Casing CS00100-160VXS 160VS* 1 (VS*) Main Rotor Casing CS00100-160VXM 160VM* 1 (VM*) Main Rotor Casing CS00100-160VXL 160VL* 1 (VL*) Hexagon Socket Head Cap Screw...
  • Page 135 2205Q2JE-HO-S6-N_2020.01. Chapter 7 Related Documents Part Name Code No. Remarks Q’ty. Thrust Bearing CS03800-160P 7212B Lock Nut NG31-012 AN12 Lock Washer NG32-012 AW12 Spacer, Thrust Bearing Outer Race CS04100-160 160*** Spacer, Thrust Bearing Alignment CS04200-160 160*** Thrust Bearing Gland CS04300-160 160*** Hexagon Head Bolt NB15510-030...
  • Page 136 2205Q2JE-HO-S6-N_2020.01. Chapter 7 Related Documents Part Name Code No. Remarks Q’ty. Shaft Key CS09100-160 160*** Suction Flange CS71400-125MK MYK125A Gasket, Suction Flange CR72000-125N MYK125A Hexagon Head Bolt NB12020-055 M20 x 55 MYK100A Discharge Flange with hole CS74100-100 Female Discharge Flange without hole CS74100-100CDMK MYK100CD Discharge Flange without hole...
  • Page 137 2205Q2JE-HO-S6-N_2020.01. Chapter 7 Related Documents Part Name Code No. Remarks Q’ty. Vi Square Washer, Teflon Bushing CS44600-160VD Teflon Bushing CS44800-160VD Thrust Washer CS44900-160VD O-ring PA11-025 JIS B 2401 P25 O-ring PA11-025 JIS B 2401 P25 Hexagon Socket Head Cap Screw NB35404-010 M4 x 10 Hexagon Nut...
  • Page 138 2205Q2JE-HO-S6-N_2020.01. Chapter 7 Related Documents Table 7-2 Parts Configuration Table of 200V** models Part Name Code No. Remarks Q’ty. Main Rotor Casing CS00100-200VXS 200VS* 1 (VS*) Main Rotor Casing CS00100-200VXM 200VM* 1 (VM*) Main Rotor Casing CS00100-200VXL 200VL* 1 (VL*) Hexagon Socket Head Cap Screw NB35416-050 M16X50...
  • Page 139 2205Q2JE-HO-S6-N_2020.01. Chapter 7 Related Documents Part Name Code No. Remarks Q’ty. Snap Ring (Internal) NG11-130 H130 Thrust Bearing CS03800-200P 200*** PPS Lock Nut NG31-013 AN13 Lock Washer NG32-013 AW13 Spacer, Thrust Bearing Outer Race CS04100-200 200*** Spacer, Thrust Bearing Alignment CS04200-200 200*** Thrust Bearing Gland...
  • Page 140 2205Q2JE-HO-S6-N_2020.01. Chapter 7 Related Documents Part Name Code No. Remarks Q’ty. V-ring CS08200-200B 20X10X12 Spring CS08300-200 200V** Retainer, Indicator Cam Spring CS08400-200 200*** Shaft Key CS09100-200 200*** Suction Flange with hole CS71400-P150MK MYK150A(6") Gasket, Suction Flange CR72000-150N MYK150A Hexagon Head Bolt NB12120-055 M22X55 Discharge Flange with hole...
  • Page 141 2205Q2JE-HO-S6-N_2020.01. Chapter 7 Related Documents Part Name Code No. Remarks Q’ty. O-ring PA62-022 AS568A-244 O-ring PA62-022 AS568A-244 Vi Adjusting Rod CS44400-200VSD 200VS* 1 (VS*) Vi Adjusting Rod CS44400-200VMD 200VM* 1 (VM*) Vi Adjusting Rod CS44400-200VLD 200VL* 1 (VL*) CS44500-200VD 200V** Lock Washer, Variable Vi Auxiliary Slide Valve Vi Square Washer, Teflon Bushing CS44600-200VD...
  • Page 142 2205Q2JE-HO-S6-N_2020.01. Chapter 7 Related Documents  The Code No. of parts shown in parentheses below is applied to the product until the end of November, 2014: (P/N 120 Unloader Indicator Assembly, P/N 125 Micro-Switch, P/N 129 Potentiometer)  For the Code No. of new type indicator part, refer to the separately dedicated Instruction manual for it.
  • Page 143 2205Q2JE-HO-S6-N_2020.01. Chapter 7 Related Documents Table 7-3 Parts Configuration Table of 250V** models Part Name Code No. Remarks Q’ty. Main Rotor Casing CS00100-250VXS 250VS* 1 (VS*) Main Rotor Casing CS00100-250VXM 250VM* 1 (VM*) Main Rotor Casing CS00100-250VXL 250VL* 1 (VL*) Main Rotor Casing 250VLL* 1 (VLLD)
  • Page 144 2205Q2JE-HO-S6-N_2020.01. Chapter 7 Related Documents Part Name Code No. Remarks Q’ty. Main Bearing O-ring type CSH02700-250 250VS*, VM*, VL* Main Bearing O-ring type CSH02700-250 250VLL* Side Bearing O-ring type CSH02800-250 250*** Snap Ring (Internal) NG11-160 H160 Balance Piston CS03000-250H 250**H Key, Balance Piston CS03100-250 250***...
  • Page 145 2205Q2JE-HO-S6-N_2020.01. Chapter 7 Related Documents Part Name Code No. Remarks Q’ty. Lock Nut NG31-008 AN08 Lock Washer NG32-008 AW08 O-ring PA12-035 JIS B 2401 G35 Unloader Cover CS07400-250 250*** 250*** Unloader Cover CS07460-250 Explosion proof O-ring PA12-170 JIS B 2401 G170 Hexagon Socket Head Cap Screw NB35412-030 M12×30...
  • Page 146 2205Q2JE-HO-S6-N_2020.01. Chapter 7 Related Documents Part Name Code No. Remarks Q’ty. Gasket, Lubricating Oil inlet Flange CR72000-025N MYK25A Hexagon Head Bolt NB111012-035 M12×35 Spacer, Discharge Flange FX101-250 250*** 1(V*D) (This spacer is not necessary for CD flange.) Gasket, Discharge Flange Spacer CS23600-250N 250*** 1(V*D)
  • Page 147 2205Q2JE-HO-S6-N_2020.01. Chapter 7 Related Documents Part Name Code No. Remarks Q’ty. Plug NFO6-008 R1/4 Plug NFO6-015 R1/2 Domed Cap Nut NC921-36 O-ring PA11-040 JIS B 2401 P40 Oil Seal Sleeve CS52810-250VD 250V** Oil Seal Sleeve with O-ring CS52809-250VD 250V** Set screw NA83606-008 M6×8 Spring Washer, Hexagon Socket Head Cap...
  • Page 148 2205Q2JE-HO-S6-N_2020.01. Chapter 7 Related Documents Table 7-4 Parts Configuration Table of 320V*D models Part Name Code No. Remarks Q’ty. CS00100-320VXS 320VS* 1(VSD) Main Rotor Casing Main Rotor Casing CS00100-320VXM 320VM* 1(VMD) CS00100-320VXL 320VL* 1(VLD) Main Rotor Casing Hexagon Socket Head Cap Screw NB35424-080 M24×80 Φ25×80...
  • Page 149 2205Q2JE-HO-S6-N_2020.01. Chapter 7 Related Documents Part Name Code No. Remarks Q’ty. CS03300-320H 320**H Sleeve, Balance Piston Φ6×14 NE3206-014 Spring Pin PA12-190 JIS B 2401 G190 O-ring O-ring Spacer CS03600-320 320*** Snap Ring (Internal) NG11-200 H200 Thrust Bearing CS03800-320 320*** Lock Nut NG311-021 AN21 Lock Washer...
  • Page 150 2205Q2JE-HO-S6-N_2020.01. Chapter 7 Related Documents Part Name Code No. Remarks Q’ty. CS07800-200 #6000 Ball Bearing NG12-010 Snap Ring (External) CS08000-200 200V** Bearing Gland Hexagon Socket Head Cap Screw NB35406-015 M6×15 20×10×12 VH10 CS08200-200B V-ring CS08300-200 200V** Spring CS08400-200 200*** Retainer, Indicator Cam Spring Shaft Key CS09100-320 320***...
  • Page 151 2205Q2JE-HO-S6-N_2020.01. Chapter 7 Related Documents Part Name Code No. Remarks Q’ty. Electromizer (Economizer) Flange with hole CR74000-080 MYK80A Male Gasket. Electromizer (Economizer) Flange CR72000-080N MYK80A NB15520-055 M20×55 Hexagon Head Bolt CS71400-050 MYK50A Male Liquid Injection Flange without hole Liquid Injection Flange with hole CR74000-050 MYK50A Male Gasket, Liquid Injection Flange...
  • Page 152 2205Q2JE-HO-S6-N_2020.01. Chapter 7 Related Documents Part Name Code No. Remarks Q’ty. Flange Hexagon Head Bolt NB14012-035 M12×35 Vi Adjusting Rod Washer ND160-036 JIS B 1256 36 NF06-032 R1 1/4 Plug NF06-004 R1/4 A Plug NF06-004 R1/4 B Plug A Conical Spring Washer, Vi Adjusting Rod ND160-036 B Conical Spring Washer, Vi Adjusting Rod ND160-036...
  • Page 153 2205Q2JE-HO-S6-N_2020.01. Chapter 7 Related Documents Tightening Torques for Bolts and Nuts 7.3.1 Hexagon Head Bolts Table 7-5 Hexagon Head Bolts Used and Each Tightening Torque Nominal Designation x Length mm (Qty) Tightening Torque N･m Tightening Location 160V 200V 250V 320V M10x30 (8) M12x35 (8) M16x45 (8)
  • Page 154 2205Q2JE-HO-S6-N_2020.01. Chapter 7 Related Documents 7.3.2 Hexagon Socket Head Cap Screws Table 7-6 Hexagon Socket Head Cap Screw Used Location 160V 200V 250V 320V Main Rotor Casing M12x45 (52) M16x50 (50) M20x60 (44) M24x80 (52) M12x40 (19) D M16x50 (15) D M16x50 (18) D M20x70 (19) 18-1...

  • Page 155: Lock Nuts

    2205Q2JE-HO-S6-N_2020.01. Chapter 7 Related Documents 7.3.3 Lock Nuts Table7-8 Lock Nut Used and Each Tightening Torque Nominal Designation of Lock Nut（Qty） Tightening Torque N･m Location 160V 200V 250V 320V Thrust Bearing AN12 (2) AN13 (2) AN17 (2) AN21 (2) 408/510 522/653 1186/1483 2259/2824...

  • Page 156: Thrust Bearing Gland

    2205Q2JE-HO-S6-N_2020.01. Chapter 7 Related Documents 7.3.4 Thrust Bearing Gland Standard tightening torque of thrust bearing gland bolt and its tightening method 1. Introduction Thrust bearing gland bolts for screw compressors are a very important task in assembling precision thrust bearings. In this work, excessive tightening or partial tightening exceeding the specified torque may affect the bearing life, so be sure to use the specified torque and tightening method below.

  • Page 157: O-Rings Used

    2205Q2JE-HO-S6-N_2020.01. Chapter 7 Related Documents O-rings Used 7.4.1 List of O-rings Used Table 7-10 List of O-rings Used (Quantity in parentheses) Location 160V 200V 250V 320V Suction Cover P46 (1) G60 (1) G65 (1) P58 (1) Balance Piston Sleeve G95 (1) P120 (1) P150 (1) G190 (1)

  • Page 158: Gasket Used

    2205Q2JE-HO-S6-N_2020.01. Chapter 7 Related Documents Gaskets Used Figure 7-7 Gaskets Used Table 7-12 Gasket Size (mm) Location 160V 200V 250V 320V Suction Cover Bearing Head Bearing Cover (D: Sideways discharge) ― Bearing Cover 332.5 ― (G: Downward discharge) Balance Piston Cover Φ...

  • Page 159: Tools For Disassembly

    2205Q2JE-HO-S6-N_2020.01. Chapter 7 Related Documents Tools for Disassembly Table 7-13 List of Tools for Disassembly (example) Parts Center Tool name Illustration size, etc.; Code No. Ratchet wrench 1/4” SG261-08 Adjustable wrench 250 mm SG231-250 75 mm SG112-075 Screwdriver Phillips 125 mm SG112-125 75 mm SG111-075...
  • Page 160 2205Q2JE-HO-S6-N_2020.01. Chapter 7 Related Documents Parts Center Tool name Illustration size, etc.; Code No. 5-25 N･m Torque wrench 20-100 N･m SG132-0900 for assembly 60-420 N･m SG132-4200 160V CS70300-160 Assembly and 200V CS70300-200 Disassembly Tool, 250V CS70300-250 Main/Side Bearing 320VL CS70300-320 SCV-series Screw Compressor 7.6 Tools for Disassembly 7-32...
  • Page 161 2205Q2JE-HO-S6-N_2020.01. MAYEKAWA MFG. CO., LTD. 3-14-15 Botan Koto-ku, Tokyo 135-8482, JAPAN Phone : +81 (0)3-3642-8181 : http://www.mayekawa.com/...

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