MYCOM 2520C, 3225C Compound Type Two-stage Screw Compressor Instruction Manual MAYEKAWA MEG. CO., LTD.Contents Refrigeration Screw Compressor 1 General Description of etrigeration Screw Compressor 1 Compound Type Two-stage Reftgeraton Screw Compressor Parts List Longitudinal Assembly Drawing Hand Too! Kt “ 2 3 4 Exploded Views + 5 ce ‘Compound Type Two-stage Refrigeration Screw Compressor Mechanisms 2.41 Gas Flow 2-2 Capacty Conta 2.3 OllFlow S888 Preparations for Disassembly of Compound Type Two-stage Refrigeration ‘Screw Compressor 8-1 Hand Tools and Work Site 3-2 Disconnecting Compressor Unit rom the System rrnvnvemeniesnsnnn 3-8 Recovering Retigorant Gas in the Unit {8-4 Removing Retrigeration Compressor from the Unit gee eee 3-5 Hanging the Retigeration Compressor Disassembly Sequence illustration 8 Disassembly and Inspection «+ 5-1 Mechanical Shat Seal (100) 5-2 Unload Indicator ~ 52-1 Stucure 5-2-2 Disassembly 5:2-3 Inspection 5-9 Unloader Cover 0 53-4 Stucture eee 0 5:3-2 Disassombly jis fernenemnenes 5.3.3 Inspection 4“54 Unloader Psion and Cylinder 4 5-41 Structure « 42 5-42 Dieassombly 2 15-43 Inepection 4s 155 High-stage side Balance Piston Cover and Bearing Cover 5-5-1 Disassembly 5-5-2 Inspection 5-5-9 Structure of Bearing Cover 5-5-4 Disassombly » 5-55 Inspection 5-6 Separation of Highstage and Low-stage Components 5-6-1 Disassembly - 5-62 Inspection 5-7 Gear Coupling 5:74 Diassoniyo Highgate Sha 5-7-2 Inspection 5:7 Distro Lomstage side ear Coping ant ectn Pe 57-4 Inspection « 56 Thrust Beating ar 5-8-1 Structure ar 5-8-2 Disassembly of High-stage side Thrust Bearing srr 8 5-6-3 Inspection 0 5-8-4 Low-stage Sido Thrust Bearing 50 5-8-5 Disassembly of Low-stage side Thrust Boating “ 50 5-8-6 Inspection - 50 5.9 Balance Piston ~ 5t 59-1 Stucture —— 284 5-9-2 Disassembly of Balance Piston 81 59-3 Inspection « 52 {5-10 Suction Cover and Side Bearing 82 5101 Dannembiyo Hghatge sso in tattisvr I 5510-2 Inspection — {5-108 Disassembly of Lowrstage side ~ ‘5410-4 Inspection svntnnnnseeenn “58541 Rotors and Rotor Casing 5:11-1 Disassembly of High-stage side {5211-2 Ingpecton essen 511-8 Lowestage side Rotors and Rotor Casing ‘512 Bearing Heed end Main Bearing ‘51241 Disassembly of High-stage side 5412-2 Inspection 5-12. Disassemby of Low-stage side 5:12-4 Inspection = asags aeeg (louwuounbly ootciseefouesssenrtery {641 Unioader Sie valve 62 Bearing Head ard Main Bearing {63 Bearing Head ard Rotor Casing «+ {64 Rotor Assombly 65 Surtion Cover ard Side Bearing 66 Balance Piston Slaeve 6-7 Suction Cover ard Rotor Casing 68 Thrust Bearing Assembly and Adjustmont 169 High-stage side Sear Coupling Hub and Balance Piston Cover 6-10 Assembing High-siage side and Low-slage sides 6-11 Lowestage side Bearing Cover ~~ 6-12 Unlosder Cylinder 6-13 UnloaderIndicstor 16-14 Mechanical Shaft Seal» VISREGLARASEEAA Reference ++++++--+ Fastening Torque Values and Bol Sizes os cy Lock Nut Locations and Torque Values we ing List1. Refrigeration Screw Compressor 1. General Description of Rettigeration Screw Compressor The compound two-stage screw comp- ressor Incorporates two standard screw ‘compressor info a single unit Before attempting disassembly and Inspection, a thorough knowledge of the structure ‘and characteristics of this machine is essential. Read the following carefully before undertaking any work on the system. A variety of compressors are used for refrigeration purposes. Among them, the screw compressor is classified as a positive displacement rotary type. It ‘compresses gas continuously by the ratating-motion of two screw-shaped rotors in contrast tothe reciprocating compressor, ‘which compresses gas by the reciprocating motion of a piston in a cylinder. Fig STD. Serow Comprecer, Cross Sectional iw ‘As shown in Figs, 1 and. 2, the rotating portion ofthe scraw compressor consists of two mating helically grooved rotors, one having four lobes and the other having six. These rotors are mounted in bearings located at either end of the compressor casing ip 2 SD. Seen Compressor, ObiqueSoctonal iow The rotor with four lobes is termed the ‘male* rotor while the rotor with six lobes is called the “female” roto. The leading edges ff the male and female rotors correspond to the pitch citcle. The rotors rotate at a rato of 2:3, that is, for every three rotations ‘of the male rotor, the female rotor turns two times. ‘The shaft of the male rotor constitutes the drive shaft of the system. When the ‘compressor is operated at a speed of '3000/8600rpm (SOHZ/60H2), the male rotor turns at a speed of 3000/3600 rpm while the female rotor turns at a speed of 2000/2409. The rotor lobes have an unsymmetric praflie designed to provide maximum compression efficiency. The clearance between the lobes and between the leading edges of the rotors and the casing are sealed by oil injected into the ‘compressor, Tis oll also serves to cool the rotating portions of the compressor. Because there is no direct metal-io-metal ‘contact between the rotors and the casing, rotor wear is negligible.Let's look at the how the compressor functions starting with what is called the “gas compression phase.” Fost DD Fus2e Fig. 2:1 glves a view of the rotor casing Al portions except the dropout sections at the end faces of the casing, termed the *Suction Port’ and the ‘Discharge Port," are enclosed by a wall of the casing Fig, 3-2 illustrates the ‘gas suction phase." When the male rotor is in the position shown in Fig. 3-24, clearance between the rotor causing and the suction side male and female lobes expands ‘gradually (area indicated by hatching). Gas flows into this space from the suction port land expands as shown in Fig. 3-28. Fig. 3-3 ilustrates the "sealing phase." ‘There is an angle at which the clearance between the rotors reaches the maximum as the rotors turn. Whan the rotors reach this angle, as shown in Fig. 3-4, the suction side becomes a seaing wall and the clearance between the lobes is sealed poripherally and at both ends, Fig. 3-5 iilustrates the ‘compression phase.” As the rotors turn further, the lobes ‘mesh from the suction side, the seaing line ‘moves toward the discharge side and the volume between the lobes decreases, resulting in compression of the gas. Fig. 36 illustrates the “discharge phase.” FessFg.31- 36 Compession Pace {As the rotors tur, further decreasing the volume, the chamber formed is linked with the discharge port at a designed volume ratio (explained later) and the compressed gas Is move to the aischarge side where it is completely purged to finish the process. ‘The compressor continuously performs suction, compression and alscharge as the rotor lobes mesh, Since the gas flow in one direction with the motion of rotation, the serew compressor exhibits no vibration. ‘As well, because it Is a positive displacement type machine, stable ‘operation under @ wide range of operating condltons is assured. Note: The volume ratio, indicated as L, M land H in MYCOM catalogues and other publications, represents the ratio of suction volume to volume just before discharge. ‘The following volume ratios are standard at mycom 2.63 Volura of suction gas ‘yja_when comression begins Volume of same amount of 8s at cischarge side “ga sams Fig 4 porary Oring In goneral (VK = «1 = PelPs ‘whore K= Cpl of rtrigerant gas = Design volume ratio. sls Design compression ratio Consequently, selection of tho L, M or H ‘volume ratios should be determined accor- ding to operating pressure requiremonts ‘This must, of course, be decided prior to production of the compressor as no alteration can be carried out to the ‘machine, although in the case of a single- stage compressor, a variable Vi mecha- rism is available Remember that use of a compressor with an inappropriate Vi will result in wasteful power consumption or a shoriage of capacity,‘8} Winen design condtions match operational ‘conctons Ne | Fe. 5 Volare Getacen Latest Meramec Oagam ) When design conditions do not match ‘operational canations.. Fg.6 Naonete Digan Structure of the Screw Compressor The screw compressor consisis of male and female rotors, main, side and thrust bearings which support the rotors, a casing which encloses the rotors, a shaft seal for sealing, the power transmission shaft, a capacity contol slide valve and a capacity ‘control actuating mechanism, @) Bearings ‘The bearings used are a sleeve type lined with, high grade wite metal to absord radial load on the rotors and a face-tortace ‘duplex angular contact ball bearing to absorb axial load. ‘As the male rotor is a helical gear and thrust resulting from discharge pressure acts on ito a greator extent than on the female rotor, a hydraulic piston is incor porated with the ball bearing to handle axial load b) Shaft Seal ‘The shaft seal is composed of a fixed ring of carbon, a rotating ring of sintered alloy and a Teflon V-ing packing, The entire seal rotates in ol for improve sealing and cooling. The standard seal is an unbalan- ced type. ‘A specially constructed balance type seal is also available for applications with large pressure aiflrencas and for helium {gas comprossion (co. 19). Fig7 Sha Seal, Obeve Secon Vow ©) Capacity Control Mechanism ‘A slide valve mechanism is fitted to the ‘compressor to contro load at startup and | 200re* 351 nesinn pe emeuee [| 2500 Th $5) | Ol incon ge E 1] 252008 ot 55) | Of econ Figo z 1] 2sz0ssc 86] | Oving paawoneas [1] ssmor TAs Bet) | Guie Bleck Oy ‘esouroe |_| sore #72) | Geige Black 2) ‘csow7o-e |_| 00% 6:1 Siem, Gude Bose) 1] 2008250 152) | Siem, Gide Boe 2) | 2008250°% 9] [Oring aa401-000 | a] SBD TA aD 91] | Sha ey coer 1) 250 To0| | Meshal Sal asamp | CS1000-FV | tat] 28070 BOSE {oat | Uslade inate Asem) | CSI20.08F [Ist | 200° 120-2| | Under indstrAstrby (2) | 5129.06 [tet | 200° || Se Sere ‘NAssr-00s [2 MAX 41] A| Gia, Una ndieor over | COMIOE | 1 16121SC 151|_| Driven Slee H 152| | Drive Stone n 153| | Driven Heb L 154] | Stops, Drive Skeve cso [2 155] | Stop Ris csisouti | 2 157| | Key. Driven tb esison [1 158| | Key. Drive Hub cesistlt | 1 159] | Set Seren ‘NAgSI2030 | 1 160] | Lock Nut Nas1003 | 1 161 | Lock washer Nos20045 | 1 162] | Henan Sek Head Cap Seow) NB3SI2-085 | | 12>3 163] | O-ing aoae203s | 1 sso 18 35 164] | Retainer Oi njeson Pips | esioiox. | 1 2sa0rsc 165] | Hexagon Sake Head Cp Seow) NBSSUE-O30_| 4 I 168] | Pipe Guide Os njecon 1] as0se t 197] | ing azaoros0_[ 1 smoot Ta Pa 200] | Caving emi Unsrindeeet)| =r] 2520810) 200] A] Casing. UnloierindcsotAl | C3210 | 1] 252018C 200| 8 | Casing Unlode idea) | cSzm0-L8 | 1] 2520L8C Bar| | Tonio lp Water(1) | es23T0# | 2 asaeee 2372| | Torsional lp Water (2) | c82370-E [2 200% 245] | Spring Washer ‘Noss002 | s| iaLs Parts Name code No. oy] Remats be eer sti | Tha Waser Caer [apa 250-2| | That Washer @) csasooe | 2) 2006 257-1| | Spec Spring Wasbr : aya 267-2| | Special Spring Waser E =) M0 278] A| lide, Gude Unloaded = 1) 2s20tse 2715) 6 | Cider, Gide UnlosdenB) E 1) 2201s zo] | O-ang pazwezi30 [1] as 1 Gao) a| | ong a2402-133_| 4] ss TA G8 n2|_[ o-ring aist7-on | a) as wisi 18.2 ‘as | | o-ing a2402-133_| 4] ss IA Gls .2| | Ong aisi7-om | a) ats wisi 14.2 s28| | Seve, i Sal cssaue-v 1) a0vre S29] | serscrew TNARGD6-008 [2 ) MOE si] | Pog ier [05.2] —| roe TPR er] | Pg 2] Ria Sui] | Sion Fang 0) nanos | 1] asm oN) 522| _| Suton Fangs (2) 120.150 | 1) 1520 106) 33-1] | Gasket, Suton Flange) | C8710.250__| 1 820K 080) 932] | Gasket, Suton Fangs 2) | C3712-150 | 1 820K 10016) Hesapor He Bot Norsaess_ [12] waaxss Discharge Fangs ‘Nx20150_[__1/ sS20K 0A) Distnge Fae 2) 'Nx2520-100 [1] S204 104) Gaskes, Disehrge Flange (7) CS7121-150 | 1) JS20K 106%) Gasket, Dish Fangs @) | CS712-100 | 1 S208 100A) Hexagon Head Bok N1s20.055_|_ 8) nauxss ange, Labiton Oi Sopa (| NX232025 | 1 820K 2817) ange, Lub Oi Supls 2) | NX2320-000_| 1] S00K 208 rer) | OBC Lbreaion OF Sippy cS7I2L-2 | 1) sok asa ange) Trea] _| Ssstetubicaion OW Supply | CS7II-O00 [TSAR BOAT ange @) TTI] | Nevagon Hed Bole Naistenes [4] Mioces 2172] | Hesagea Head Blt navat2.035_ || wizxss 28] | Fangs, ijestion OF Seppiy | Nxzxz0-0s | 1 Sank 18AN129 | 219| | ak josion Oil Supply Fags] 87121-0151 SOK 14/12" | 720) | Hexagon Head Bol awaizons | «] Mixaparstin 3225**C 32250 PARTS LIST ‘ae nhime code Na om] Renate [peor aaRSIEcleS ‘Main Ror Casing CD ‘ceuaiaMcT || s0504c oh —L Main Rote Cig @) E 1] ssc ch Mais Ror Casing (1) 1 aassre oo Main Rotor Casing 2) ‘cammiort | 1] 2501-6 z r Mais Rokr Cig 2) ‘csaoio-rw | 1] some i Main Rotor Casing 2) ‘esmo10sFs [1 ose i ran Hagan Socket Feo Cap See NB3S22-00 | 32] M24xa0 1 Hexagon Sookt Fad Cap Sete | NBSS2D060 | «| M060 lagna NExIrso80 | $] 25x00 1 ‘linens Pin NEIILG.70 | 6] 16x70 tT Hanger a Nata | 3] 0 snger Balt —f npoon.ane | a Sosin Cover (I Fs 1 a6. Suetn Cover 2 ‘cosa |r| sasere Gest Sucton Gner(ny | C0061. — [1 sa ‘asks, Suton Ger} | c3006t-n_| 1 5G | | Hanger Bale “N000.016 | 2] m6 72) | Manger Bate 1 DM36 1) Spring in (I) Nemes [2] goxis - 2) f sping in) Nemu6ai2 | 2] 6x12No Part Name codero. joy] remans | onecaal Toa[A Fi ‘Nrnwono || ea 10.3] A Pg ‘0500.20 | —1] Re a] a Pig ‘Nfoaonog [1 eu 2] | ‘Nroan-s | 1] RIB. ct] | Beariag Head ‘csonomi_ [1] sms 1-2] Bea Heat 2) ‘cote [1 ps5 Tal] | Gasket, ewig Head (es0121.G [1 320-6 12-2] | Gas, Bearing Heat 2) esoizi-r [1 2enee 11] | Hanger Bote E 2) M36 152] | Hanger ale ‘Npeowo-oia [1 012 11] | peng Pin NexnG0Is | 2) 66xi8 142] [Spring Pi Nexmsor2 | 2) 66x12 15[ A Plog ‘Neos —[ 1) 8 1s) 8) Pg ‘yraga02 [1 RI 6) | Bearing Cover oie | 1) szasee 1.1] | Gasket, Bening Cori) | esoiriem —|_1| sms 1-2] | Casha. Bering Cover (2) | esra3iam | 1 322566 18-1] | Hexagon Soke Head Cap See | N3S20470 | 30|-M20%<70 18.2) | Hexagon Socket Head Cap See | NBSS204K8 | 24[ MED| 300°, Boose 12.2| | Space Tas Bet Alament (2) C5080-F | 2| 250°" 48:1, | Ths Bering Gand (1 csooG [2] sa $52 [_| Five ening Gand @)A | cxone.r —[ 3] asbeee 5:1 | Hexagon esd Bat ‘Nars20-065_| swans 452 | Heeagon Head Bat INBISI6b65 | 8) Mas 46-1] | tock Waser 01.6 || 20 462) —[ Lack Water 2) ‘Cooter | a] ase 8) | Rewine 01 Seal ‘csows-cv_|_1[ sa0ve" 9) [o-ring pa2on.160_| 1 | tse Gi sa) | ites ccsnso-cv [1 | saussxianein 1 _| Sel Cove (650510068 |_1 | 320°" 52) | Gasket, Seat Cove cesasnt-6 [1 320° 53] | Hexag Socket Hed Cap Seow | NASI6-040 [6] MIBXI0 || Uno abe) Po rfsmsue [a SSH | Uae Sse ate (1) Pet rf amasuec Pe De Sct] | Una Sie We 1} Pt 1] ssc TH St] | Uae Sse ake (1) Pet 1 aswec co ‘|| Uae Se ate (1) Fo, 1] sn2sse 1 Sct] [Und SieWae 1)( Pt 1] n2ssv. rr ‘2] | Uae Sie ate (21 Pot [sau 7 r 542| | Under Sie Va (1-2) Po aso r i ‘42 | Unlaer sie Vake (-2 Pot 1] ass T cp ‘42 — [eer Se ate (2 Po 1] 250s ot 2) | UnadrSieYee (1.2) Pe) 1) ss 7 SS] | Unleade Side Wve 2-1 1] sou oi S61] [Unleaded Wve 2-1 1] 30m" io S51] [Unload Side Wve 2-1) rf suse I Tho $82] | Unleader hide Vive 2-2) 1] asa. Ti r 52) | Unload Side Whe 2-2) 1] 250M" T 5.2) | Unload hide Wine (22) 1 ass z rn 5-1 | WenagonSucet Head Cap Sew) NBRSIOWO | «| MIO s-2| | Wenagon Socket Head Cap See] NDSSIZ-@0 | «| MI2xe0 39] oving a24o1.os2 | 1 ssm01 APD w.1| | Unload ye CD ‘csnaioaw [1 sseec Th 0-1] | UnoaerCyhinde() _s r[-saass5C To 0.2) | Unosder Cyd 2) ‘csoeiar [1] aso H 602) | Unleade Cyne 2) ‘csnauosrs || 0s Ta} aa 61] | Hexagon Socket Head Cap Seem] NOSSI6440 | 2 | MI6XAD || Hexagon Socket Head Cap See] NB3S20470_[#| A070 ‘2-2| [Hexagon Socket fend Cap Serew | Nass16<6 | 6| SOW LNo. Pant Name odo No. |aty) Remarks ei og paaa@-170_ |i) asa A GT 32] | o-rng Pa2402-190 | 1 ssn 14 | ‘1 || Unload ison sou [1 22sec (642) | Unlone Piston 2) cesnotr-r [| asiene 1) | Oring Pa240i-1d0_| 1 vsazir Tari 65.2) | Oring a24otiss| 1] JSB240 IA FSS ‘| | Can Sad ‘esieeoxt | 1 cAP-3BE1a0 62) | Capseat ‘esncsosF | 1] eAPameiss ‘-1| | Pash Ro Under Side ve) | Csneroati |r| 32512, we 67-1] | Pah Ro, Under Side ve (1 fase (61-2) | Pah Uner Se Ve 2) 1p saserc (67-2) | Pah Rd Unader Se Ve 2) = TL amseMe 7-2) | Poh Rv Una Sie ae 2) | C30aTOME [1 | 325°5C 8-1] | Guide Pa ‘oss0-05 | 1) 6x15 8:2) | Guide Pn csoos0-05 [if 3x12 1] | tack Nu CD ‘Nosi00-10 || aNto 2) [tock Nat 2) No3i00-08 | 2] anos: 1 | Lack Waser Naaai0-10 | 1 AWio 702| [back Water Nasaio.0 | 2] Woe [tack Nat) Nau00-12 | 1 ANI 72 [Lack Waser Nos20042 [1 -AWi2 Tat) Orng pa2sol-ose | —1[ sonar Ta BA 32] | Ovi pa2aonis| 1 SSRI 1A GSS 7161 |_| Unlader Cynder Cover) zi n sur) | Wilder Cinder Cover (1) - r {Esplasen- rot Type) 72] Unloader Cynder Cover. | Conan |i a0 ua) | Usoadr Cynder Cover) | CSITAOFB [1] 2506 (Explosion- Pot Type) 7a] [or aa03.190 [1 | asm A a 752) | Osi pano.170 | 1] Jst0 14 GI ee | | Hexagon Soak Head Cp Seow] NBSSI2-005_[ 8] 2x35 762| | Hexagon Socket Heal Cap Sere | NBSS12.030—|_s| M230 Tr] | netor CAM (I) some [if szzstc Tr] | adeaoe CAM (1) 50770. | 1 3225¥ec Tr] | nietoe CAM (1) cesurmues [| s25src 72] | ateatoe CAM 2) cesormew || 250m Tra | ingicsor CAM) ‘esis || 250s Bul Be ‘esrrene | 2 000 ‘Sip Ri ‘No1200010 |2| S10 Dearing Gin cesiaone [2] 200° Heagon Sock Hea Cop See] NUS06. 01S | 6| Maxis ‘sing ‘esi2oe8 [Sua] 20501002 Serine fesnssoe || 20>" Ratiserndor Cam Spring | CSIG40.E [2 | 200° Oi Ijezton Pipe Fi [sao OF jection Pipe - 1 aa0se (Oi Ijin Pipe 1 s2s886 Oi paaan-om [1 aisszan ia a Guide Blok 1320Pars Name Code No. [ay] Remaris | Guide Bock @) rs Se, Guide Blo [over ‘Stn, Gide Blk 2 1] poneaso= Oi pazaoraed_[—2[ nseol 1A at ‘ing azaolsoat| 2 ssa 1420 sia Ke) cesap1046 [1 sa0ver Coupling Assit = [ise 108-0530 Mesa Seal sonbiy | CS1000-G¥ [ee s20"*= BOSE ‘Uloader nea Asser () | CS1209-01F [Ie] 1612 ‘Unoaer iene Asser (2) | CS128-0K [et] 200°" ‘ing ag2-220 | 2) sso A Ga Dive Sens : TTastse Dive Hab E 2 aztstsc ‘Sopp, Div Shave Give [2] arstse Sop Ri sistas |] Fes-130 Key, rien Hab : 2 | an125 Set Seren = Tp Mio Lock Waser ‘Nasa awis Hexagon Soaked Gap Saw] NBBSI2080_[ S| MI2>%S0 Rewer Ol lnjesion pe | CS6s0-M | 1) 3235-0 Oo a2soicoa0_ | 1 usonor Ta a Hevagon Saket Hand Gap Sars NB3s06015 | 4] Maxis Hesagon Socket Head Cp Sree | NBSSOS-2|—#] MSI 168] | Pipe Gus, 01 jesion cesiesoat [1 325% || Oia a24ol-osi_| 1 sson401 TA PS Bt | Torsional Sip Waser (1) | cs2s70.0 [>| sane 2372] | Torsional lp Waker (2) | cS2ar0-e | 2| asaeee 245] | Sing Washer NDS200.12 | s| Mz 2s0-1| [ths Waser reszsuosg [2 sa0-= 3302 | Thr Water cesnsoast || 2500 267-| | Special Seng Waser a a) ans 267.2| | Spel Spins asker : [ia 326:1| | Gland Oving caw [i same 326-2] | Gland O-ing cssa50.m | 1) 2s 25] | Osa PA2401-046 | 1 | 1882401 TAS 0 Spring Fi ‘Neupeoio| 1] 94310 (0 Spas Unload Pon igh Sago) [ 1 awusria To 1] ovrng PAaaDI-686 | 2 | S241 1A aS 23 | Spe ld Powion Low ge) [ 1 [aaswre T faa] onrng paawa-i6s | 4 smu AG 22| | Ong paz7-135 | 4 tse obs fan| | O-ring paoan-t6s | 4 [sant GUS 482| [o-ring paaa0n.135 | 4 nso GS 525] | Seve, Ol Sal csosoav [1 s0ver 25] | sersaew 1NAs606008 | 2 MX as] | Fog - ‘nroaids [1] RY ar] [rug roo | 2] 1 -Parts Name ‘code No Remarks ue SS |_| Seton Fg = soc o7-2| | Seen Fang 2) Neasana00 [asa 2) [se Stn Fane esra0 [1 ak ou) 952 || Ga So Flange @) | €S712-200—| 1 [1S 1] | Heapn He Ba = 6) 080 2] | Hexagon Hed Bt 1a] x60 [951 ose Fg Neasena00_|—1 [ase AR) 952) [Dick Flange 1 Noosa [1 KL Se) | Ges Dias Fege | esrizt-ao [1 sa 62 | eat Dhue Fangs 2) | cS721-130_ [1 sank 06) 1) | Heagn Hed ass 2] wax 72 | Hexagon Hed Bt Nalswoss |i) wes Dist] | Fg. abe OFSapiy | wxaNB_| 1 sSNA) 2182 [| Png aon OF spa | Azan [LS AC ie] |e abe FS pe | CS2- O40 || SNK) 2162) | ce tn gp ge crits 1 nk 207) 217-1 | Heap Had Bat NoIsi6015 [a] Mies 2172] Heepn Hed Bak NBIS16045 | 4] Mi6xas 218) | Fang. scion OF Sly [xa om | [GE 219[ | Gs. loeton Oi Fa | esi2.z0 [1 ak ON 220 [Hea el Bok No1512035_| 3] Mi2x3s so) | Fn sas Piston OF Rea] NXE] 1] 20K aA) cei) Gis als Pion OF Rae] COT) [1] TRO AAGIE) Pie ae 332] | Hoag ea a Nemes | a) was neo] | Hii Betg CoV Ret) NXESENIGE [HOM ATF Spe) | Ste Beng Gone OF Ren] COBO [1] ADAM Pin ge 56 | ge Rove Cain Fe | WR? 1 oS AT - ‘Gast Rte Casing OF Ret | CS712052 [1] 90K 14) ss Bie Fag 358) | Hog Hed Bat Norsicois | 4] wis as5. Longitudinal Assembly Drawing| noose be@@02ee@ ® BE Fig 13 Moshanieal Sol or Helin Compressor and Balanced ype Nesharcel Sel _ig 4 Standard Unator dear ip 19R Uaioatar neo Woutsa0etow sage 8.19.ig 6 25206 Compressor, Cross Sectional ViewSSN SAVANE oe KA UNTER Fi.17 $2050 Compressor Cs Sacer View6. Hand Too! Kit, “abl 4 Hand Too for Model 2520196 Screw Compressor Na Nae tmsrion | Speatestone | OH ee | Reet Saw | corte 2 | Menkay wre J 2sonm | 1 | Gonralpaie 2 | sev aero =| tm 1 fe 4 | semw are ——— a aes | imine > | sox © | vii | 130 x00 x70 | m= SE | voxicoxaiem | 1 | Watts 8 Dove ended wrench es 17x19 2 | Joins 2 sett ws a oo | eco | OP | case cares | Sting is =S_ Medion 1 | Stings 2 ede we Le Be er 1 Ta 16 | do - “ANT 1 | ao | Bae arxai0mm | 1 | Uae a, — ‘Seal retainer 18 | Sorkstwrech eo w 1 | Metering 2 | Tomer mee [1 | sett a Aen rh 2am | 1 | len wn 2 | dam | t [ae |e Le tom [1 | Be es | oe ‘4eum 1 | aoe Le Tem = a“Tobl Hand Too fr Model 225.5 Serew Compressor se ane wisn | speateaore [oy ve 1 | Rahat ne —_ ue | Aausing ges & aves 2 |My ate | | corre 3 [ sewr ait re + | seew ait a 3 | Poste i co) oo | asenionm —[ e a TCD __liséxma vem) 1 | onan 7 | se <= | xiao || Wate | Dowie ened wench ==s xp | 2 | tome 9 | ene fier see | Sede 0 | ommconree | FA | oes | | mee 1 | Septet | 26 | eon 2 | Sepia Seansta | + | Sep eS SS ee le eS e waft fe es ‘oe | eS Toure | + [ores 2 | Be baste | 1) are 2 | ee a z= oe [0 [es 2 | tere —— 2 | Ate an [1 [Ale es fen == ee 29 | do ue ‘sum 1 | do 2 om | es ES 32 | do mm 1 | to2 Compound Type Two-stage Refrigeration Screw Compressor Mechanisms. 244 Gas Flow The structure of a standard screw com pressor is explained in Chaptor 1. With a two-stage machine, the rotor sets of two compressors are aligned along the same axis, with the low-stage side com- pressor atthe shalt drive end. Gas enters a Ccontral suction port @ and is compressed by the low-stage side roiors @. itis then discharged through the low-stage dis ccharge Port @ and via connecting piping fenters the high-stage side suction port as © and @ are connected to each other. Midway along this piping gas from the liquid intercooler enters and is mixed with the low-stage side discharge gas. Gas ‘compressed by the high-stage side rotors @s finally sent to the condenser via the oll separator through the compressor dis- ‘charge port ©. F182 Composer win Expsin poo nda, (esq Seca! View 2-2 Capacity Controt The structure of the capacity control mechanism is explained in Chapter t Unloader devices for reducing load at ‘tarp oF reducing and inereasing load as Fequited during operation are mounted on the high-staga and low-stage sides, Since the high- and low-stage sides ‘commence operation simultaneously and the high-stage side discharges more cil than the low-stage side, a spacer is pro- vvided on the unloader push rod of the high- ‘sage side to ensure that minimum load ‘does not drop below 20% of the slide valve ‘on model 2520C or 30% on model 3225C. Various systems are used for operating the capacity control devices on the com pressor FRefer to the Instruction manual provided for the compressor package. Please note tha intermediate pressure is dependent upon the balance between high- ‘and low-slage side displacements and this pressure changes in the balancing direc- tion when capacity controls actuated. I ie 9.1982.3 01 Flow In principle, oll flow in the two-stage ‘compressor is the same as in a single- stage unit with the exception that high ‘stage side injection is eliminated because oll is entrained in the low-stage side discharge gas already. Also, the balance piston normally provided on the low-stage ‘side is replaced by a coupling and pressure Is tne same as that on the high-stage side thrust bearing. In the case of the Model 320 series, an independent lubrication line is provided for the duplex thrust bearing to ensure proper lubrication. (On some types, external oil piping is ‘arranged for return oil fom the high-stage side to the low-stage side. This is done to prevent too much oll fem passing into the high-stage side compressor, which would ‘otherwise result in oll compression when, for example, the unit s started up after long-term shutdown, el icone i i [oom rt as : om | yu] | =} ——-— | | — Fp 20 Presse Libvcston Sys (Dlg A and res DternceLuneston System (ign 8)3 Preparations for Disassembly of Compound Type Two-stage Refrigeration Screw Compressor Proparations for Disassembly While the screw compressor offers ex: tremely high reliability, tis, after all, com- posed of moving parts subject to friction, damage from foreign matter, otc, It is therefore essential that the machine be disassembled and inspected at specified intorvals. This chapter 2xplains disassem- bly procedures and pcints out the parts which must be inspected. If at all possible, the compressor should bbe disconnected from the system and trens- ported to a fully equipped maintenance ‘shop for disassembly ard inspection. When maintenance work musi be carried out on- site, the procedures explained herein should be closely followed. Periodic Inspection should be czrried out with the ‘compressor removed frem its base. 341 Hand Tools and Work site Be sure to have all the necessary disas: sombly tools for the 2520C or 3225C avalabl (rf. Tables 4 5) Especially, a locke rut wrench should be availabe for remov- ing the bearing, Hand tools such as a hammer, pliors, spatula for removing pecking and gaskets, lc. and supplies such as emery paper, waste cloth, etc., shoud be on hand, as well as a container for catching ol, a pan of kerosene for cleaning parts and lubrication alin Work is best pertormed on a large, solid ‘metal plate of some sort raised about 70cm above the floor. The ideal size of such an iron surface plate is 1,000mm 1,500mm. Be sure to keep the work area dry and {ree from dust, sand or other contaminants. 3-2 Disconnecting Compressor Urit from the System Before commencing disassembly, the compressor unit must be cisconected from the refrigeration system. First, close the gasiliquid stop valves ‘connecting the compressor to the system. Manipulate the suction valve, discharge valve, intercooler liquid supply valve, etc. to ‘seal off the compressor, being sure that no liquid is sealed between valves. TT your system contains only one comp: fessor unit, it need hardly be said that refrigerant should be recovered into the receiver betore commencing repair or main tenance work as well as any mainterance required after long-term stoppage. 3-8 Recovering Refrigerant Gas. in the Unit AA considerable quantly of refrigerant gas will unavoidably be sealed in the com- pressor. This gas must be released 1) fa small refrigerant recovery device is fitted for maintenance purposes. reft gerant in the unit should be recovered Using this device. 2) When two or more compressers are included in the system and are connected with bypass piping, gas in one unit can be recovered by operating the other compressor. '3) When only one compressor is installed, ‘the unit should be stopped only after Fetngerant recovery tor long term siopping has been carried out. Gas in the unit should be released to the low-stage side,4) The above work should be cartied out slowly and deliberately. It pressure in the Unit crops suddenly because operation is too rapid, refigerant dissolved in the oil may vaporize, causing foaming, and an excessive amount of ol may carried by the gas. This wll result in restarting citfcuty 5) Refrigerant gas should be recovered Until the internal pressure of the unit is bolow atmospheric pressure or lower. 6) As somo rorigorants, i released into the atmosphere, contribute to the depletion of the Ozone layer protecting the earth, never discharge refrigerant gas directly into the ‘atmosphere, ‘Ammonia refrigerant poses less serious ‘a danger than Freon but is strongly initant nature contributes to environmental pollu tion. If ammonia must be released into the atmosphere, pipe It into a container of water. Water will absorb up to 600 times its weight in ammonia gas. When purging ‘ammonia into a water container, work slowiy as there is @ possibilty that water may be sucked into the hose and then into the system. 3-4 Removing Refrigeration ‘Compressor from the Unit, 1) Disconnect the suction and discharge piping before removing the compressor from its base, Be careful not to damage the Ingulated suction pipe end, Be eure to cover the exposed ends of all pipes to prevent contamination. ‘The suction strainer mounted on the ‘chack valve is heavy so care should be taken when disconnecting and removing this device. After removing, cover the suction port to prevent contamination Flemeve the flange bolts. 2) Remove the driveshaft coupling. The ‘most commonly used coupling is a mult= plat flexible coupling with spacer. Loosen and remove the bolts holding the plates to the spacer and then loosen the ‘compressor side coupling ub locking ‘screw to remove the hub. '8) Detach the lubrication piping from the oi header and remove the unloader actuating pipings and the connecting pipes between the solenoid valve and the compressor. Do rot forget to record to locations of the individual pipes in order to faciitate reas- sembly. 4) Remove the control wiring of the un- loader indicator (rf. 5-2). 5) Remove the connecting pipe between the low-stage discharge and high-siage suction ports of the branch piping from the liquid sub-cooter. 66) Remove the external oll return piping (it attached) between the low-stage rotor ‘casing and the high-stage suction cover. * When removing the oll system piping, always place a container Under the joint being loosened to catch any oll remaining in the pipe. The unloader oylinder, in particular, will contain a considerable quantity of oil, Also tag or mark all electrical connections and piping joints to prevent misconnection during reas- sembly, 7) Remove all of the bolts from the com- pressor base,