mycom 1612LSC series User manual

2202L5JE-DA-C5-N_2015.05.
Compound 2-stage Screw Compressor
1612LSC Speed Increaser Type
Instruction Manual
1612LSC-52 ／1612LSC-62
1612LSC-53 ／1612LSC-63
1612LSC-54
CAUTION
Before operating, servicing, or inspecting this product, read this manual thoroughly to
fully understand the contents.
Keep this Instruction Manual in a safe, designated place for future reference whenever
the manual is needed.
Specifications of this product and contents of this manual are subject to change
without prior notice due to technical improvements, and the like.

2202L5JE-DA-C5-N_2015.05.
Preface
Compound 2-stage Screw Compressor 1612LSC Speed Increaser Type
i
Preface
Thank you for purchasing this compound two-stage screw compressor 1612LSC speed
increaser type (hereinafter indicated as “this product”).
This instruction manual (hereinafter indicated as “this manual”) describes safety information,
operational and maintenance procedures in detail for safe and effective use of this product, and applies
to the following types.
1612LSC-*B*-52/62、1612LSC-*B*-53/63、1612LSC-*B*-54
Before installing or using this product, make sure you read this manual.
Keep this manual in a safe place near the product for quick reference.
Revision History
Title Document No. First Edition Issue Date
1612LSC Speed Increaser Type
Instruction manual 2202L5JE-DA-C5-N_2015.05. 2013.05.30
Revision
No. Issue Date Major Contents of Revisions Created / Approved by:
－1974.06.30 Issuance of 1612C first edition Yamamoto
－1983.10.01 New issuance as 1612C/2016C edition Yamamoto
－1993.06.30 Revision of 1612C/2016C (correcting editing
errors, etc.) Yamamoto
－2006.06.30 2004.07 Re-examination by constitution of Product
Liability Act Ikehara / Shozu
00 2013.05.30 Overall re-examination by reissuance as an
electronic edition, its document No. change Ikehara / Hirao
01 2014.01.15 1.1.1「MSDS」change to 「SDS」, etc. Ikehara / Hirao
02 2015.05.12 Modified the constitution of Chapter 4 and
Chapter 5. Correction of describing, etc. Ikehara / Muta

2202L5JE-DA-C5-N_2015.05.
Warranty and Disclaimer
Compound 2-stage Screw Compressor 1612LSC Speed Increaser Type
ii
Warranty and Disclaimer
Warranty Clauses
MAYEKAWA shall repair or replace parts of this product for no charge if any failure resulting from
defects in design or manufacture occurs, under normal use with the purpose and method that are in
accordance with the specifications of this product and this manual, within the warranty period.
The warranty period is "12 months from factory shipment of this product". If there is a separate
agreement, that agreement shall prevail in principle.
MAYEKAWA is not liable for production or man-made disaster compensation due to malfunction or
damage of this product.
Disclaimer of Warranty
Although MAYEKAWA warrants the clauses mentioned above, the following clauses are exempted.
Malfunction or damage of this product caused by natural disaster, or other accidental forces
(such as fire, thunderbolt, windstorm, intense rainfall, flood, tidal wave, earthquake, land
subsidence, etc.).
Malfunction or damage caused by misusage described below.
Malfunctions, damage, or deterioration of this product due to abnormal or improper use
(including improperly storing this product outdoors or under too hot/humid conditions,
unexpected inspections, tests, operations, too frequent liquid flow-back operation*, and
too frequent start-stop cycles, etc.).
Malfunction or damage caused by devices or equipments not provided by MAYEKAWA
including operation control methods of those devices.
Malfunction or damage caused by refrigerants, gases, or refrigerant oils, and operating
conditions (design conditions) not approved for this product.
Malfunction or damage caused by maintenance or inspection not recommended by
MAYEKAWA.
Malfunction or damage caused by parts that are not genuine.
Malfunction or damage caused by remodeling the product without approval of
MAYEKAWA.
Malfunction or damage caused by unexpected misusage
"Liquid flow-back operation" is ･･･
Normally, while the compressor sucks in the refrigerant liquid only after vaporizing it in the
evaporator, it may directly sucks it in because of the faulty adjustment or failure of the
expansion valve. We call this state of compressor operation "liquid flow-back operation".
No compressor can compress a liquid. The compressor may be damaged should the liquid be
sucked in.

2202L5JE-DA-C5-N_2015.05.
Important Information
Compound 2-stage Screw Compressor 1612LSC Speed Increaser Type
iii
Important Information
Intended Use of this Product
This product is a general-purpose screw compressor intended for refrigeration and cold storage.
Do not use the product for any purposes for which it was not intended or which depart from the
specifications. For specifications of this product, refer to “2.3 Compressor Specifications”.
The maintenance items described in this manual should be performed safely and closely following
procedures.
Important Information for Safe Use of this Product
Although MAYEKAWA has thoroughly considered the safety measures for this product, all hazards,
including potential hazards caused by human error or environmental conditions, cannot be anticipated.
There are many guidelines that must be observed for operating this product. However, the warnings in
this manual and the safety labels on the product are not all inclusive. When operating this product,
always pay extreme attention to general safety precautions as well as on items described in this
manual.
Important rules for safe operation that apply to all workers including managers and supervisors are
listed below.
Before using this product, carefully read and fully understand the contents written in this manual and
pay attention to safety.
Operation, maintenance, and inspection of this product should be performed by qualified
personnel educated about the fundamentals of the product and trained about the hazards
involved and measures to avoid danger.
Do not allow anyone other than those educated about the fundamental expertise of the
product and trained about hazards involved and measures to avoid dangers to approach the
product while it is operating or during maintenance.
Observe all related federal/national and local codes and regulations.
To prevent accidents, do not carry out any operation or maintenance other than those
described in this manual, or use the product for any unapproved purpose.
Replace parts with genuine parts.
Not only workers but also managers should actively participate in safety and health activities in
the workplace to prevent accidents.
When closing or opening valves during work, apply lockout/tagout without failure, to prevent
the valves from closing or opening accidentally during the work.
[Lockout] To lock with a key in order to keep people, except the workers involved, from
operating the product.
“Lockout” means disconnecting or keeping disconnected machines and devices by locking their energy
(power) sources. Lockout is not just simply turning off the power switches to stop the supply of power,
but includes immobilizing them with a key or similar device to keep any blocked switches from being
operated.
Lockout devices are devices such as keys, covers, and latches, to immobilize switches, valves,
opening and closing levers, etc., with a state of being locked.
[Tagout] To prevent any inappropriate work by hanging tag plates indicating “work in progress”.
“Tagout” means to clearly indicate, by hanging tag plates, that a device is in lockout and that operation
of the device is prohibited. Tag plates forbidding operation, starting, opening, etc. are warnings clearly
stating to not operate energy (power) sources, and are not for stopping blocking devices.

2202L5JE-DA-C5-N_2015.05.
Important Information
Compound 2-stage Screw Compressor 1612LSC Speed Increaser Type
iv
Observe the following precautions when performing maintenance work on electrical control.
Electrical maintenance of the product must be performed by certified/qualified personnel and
only by those educated about the electrical control of the product.
Before servicing or inspecting the electrical equipment or devices, turn off the motor main
power and control power, and perform lockout/tagout to prevent the power from being turned
on during work.
Even when the motor main power and control power are turned off, the product may be turned on if
power is supplied from outside the package unit in which this product is used. Make sure the power
supply on the power source side is shut off, and perform lockout/tagout to prevent this product from
being turned on during work.
About This Manual
This product may be modified without prior notice. Therefore, the appearance of actual
machine may differ from the descriptions in this manual. If you have any questions, contact
our sales offices or service centers. For each sight of MAYEKAWA, refer to "Contact
Information" in this manual or following URL. http://www.mayekawa.com/about/network/
This manual is in English. If any other language is required it is the customer’s responsibility to
prepare a manual for safety education and operation instructions.
This manual is copyrighted. Drawings and technical references including this manual shall not,
in whole or in part, be copied, photocopied, or reproduced into any electronic medium or
machine-readable form without prior permission from MAYEKAWA.
Photographs or drawings included in this manual may differ from the appearance of the actual
product.
If this manual is lost or damaged, immediately place a purchase order to our local sales offices
or service centers for a new manual. Using the product without the manual may result in safety
issues.
If you resell the product, never fail to include this manual with the product.
Construction of This Manual
Title of section and chapter Description details
Preface Describes the outline of this manual and how to use it.
Warranties and Disclaimer Describes what MAYEKAW
A
warrants and what are covered by the
warranties. Warranty exemption is stated as disclaimer.
Important Information Describes important information related to this product and this
manual.
1. Safety Describes workers' safety information, safety measures taken for this product, and administrative control on industrial safety which is
required when handling this product.
2..Compressor Specifications
and Structure Describes main components of this product and their functions, specifications and operating limits.
3. Installation Describes procedures for installing this product.
4. Compressor and Package
Unit Operation Describes precautions for using this product.
5. Maintenance and Inspection Describes inspection locations & frequency and assembly &
disassembly of this product.
6. Troubleshooting Regarding major troubles that may occur during use of this product, describes how this product will act as well as what actions should
be taken when a trouble may occur.
7. Related Documents Shows materials such as exploded drawings and parts list.
Contact Information Provides contact information for our sales offices and service centers which is to be used for purposes such as
genuine parts ordering.

2202L5JE-DA-C5-N_2015.05.
Table of Contents
Compound 2-stage Screw Compressor 1612LSC Speed Increaser Type
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Table of Contents
Preface .................................................................................................................... ⅰ
Revision History..................................................................................................... ⅰ
Warranty and Disclaimer....................................................................................... ⅱ
Important Information............................................................................................ ⅲ
Intended Use of This Product ...........................................................................................ⅲ
Important Information for Safe Use of This Product ..........................................................ⅲ
About This Manual.............................................................................................................ⅳ
Construction of This Manual..............................................................................................ⅳ
Table of Contents................................................................................................... ⅴ
1 Safety
1.1 Strict Requirements and Prohibitions........................................................1-1
1.1.1 Strict Requirements (Do's)................................................................................... 1-1
1.1.1.1 Do's on Operation........................................................................................1-1
1.1.1.2 Do's on Maintenance...................................................................................1-1
1.1.1.3 Do's on Lockout/Tagout after Shutting Off the Power .................................1-1
1.1.1.4 Do's about Personal Protective Gear..........................................................1-2
1.1.1.5 Do's about the Handling of Hazardous and Toxic Substances....................1-2
1.1.1.6 Do's about Handling Emergency Situations................................................1-2
1.1.1.7 Do's about Waste Oil, Fluid, and Materials .................................................1-2
1.1.1.8 Other Do's....................................................................................................1-2
1.1.2 Prohibitions (Don'ts) ............................................................................................ 1-3
1.2 Warnings.......................................................................................................1-3
1.3 Residual Risks .............................................................................................1-4
1.4 Safety Devices..............................................................................................1-6
1.4.1 Emergency Stop Button.......................................................................................1-6
1.4.2 Breakers for the Main Motor Power and Control Power......................................1-6
1.4.3 Compressor Protection Devices..........................................................................1-7
2 Compressor Specifications and Structure
2.1 Overview of the Compound 2-stage Screw Compressor
1612LSC Speed increaser Type..................................................................2-1
2.2 Model Designation of the Compressor.......................................................2-1
2.3 Compressor Specifications.........................................................................2-2
2.3.1 Standard Specifications.......................................................................................2-2
2.3.2 Operation Limits...................................................................................................2-3
2.3.3 Outer Dimensions................................................................................................ 2-4
2.4 Structure of Compressor ............................................................................2-5

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2.5 Mechanisms .................................................................................................2-6
2.5.1 Basics of the Screw Compressor ........................................................................2-6
2.5.2 Suction Process................................................................................................... 2-6
2.5.3 Compression Process..........................................................................................2-7
2.5.4 Discharge Process............................................................................................... 2-7
2.5.5 About Volume Ratio (Vi)...................................................................................... 2-7
2.5.6 Capacity Control Mechanism............................................................................... 2-9
2.5.7 Bearings and Balance Piston .............................................................................. 2-9
2.5.8 Shaft Seal ............................................................................................................ 2-9
2.6 Gas and Oil Flow........................................................................................2-10
3 Installation
3.1 General Precautions for Installation .........................................................3-1
3.2 Installation Works........................................................................................3-1
3.2.1 Unpacking............................................................................................................3-1
3.2.2 Storage ................................................................................................................3-1
3.2.3 Transportation...................................................................................................... 3-1
3.2.4 Preparation for Installation...................................................................................3-4
3.2.5 Installation ..................................................................................................3-5
3.2.5.1 Installation....................................................................................................3-5
3.2.5.2 Shaft Alignment between Compressor and Driving Machine...................... 3-5
3.2.5.3 Piping Connection ....................................................................................... 3-6
3.2.5.4 Equipment and Devices for Protection of the Compressor.........................3-6
3.2.6 Airtightness Test..................................................................................................3-7
3.2.7 Lubricating Oil Charge.........................................................................................3-7
3.2.7.1 Initial Charge of Lubricating Oil ................................................................... 3-7
3.2.7.2 Additional Charge of Lubricating Oil............................................................ 3-7
3.2.8 Charge of Refrigerant.......................................................................................... 3-7
3.2.9 Check after Installation........................................................................................3-7
4 Compressor and Package Unit Operation
4.1 Lubricating Oil (Refrigerant Oil) .................................................................4-1
4.1.1 Precautions for Selecting the Lubricating Oil....................................................... 4-1
4.1.2 Recommended Lubricating Oils ..........................................................................4-1
4.1.2.1 Recommended Lubricating Oils for Ammonia Refrigerant..........................4-1
4.1.2.2 Oils for Systems using Hydrofluorocarbon (HFC) Refrigerants .................. 4-2
4.1.3 Change of Lubricating Oil Brand ......................................................................... 4-3
4.1.4 Precautions for Handling Lubricating Oil.............................................................4-4
4.1.4.1 Precautions for Handling Polyalkylene Glycol (PAG).................................. 4-4
4.1.4.2 Precautions for Handling Polyolester (POE) Oil..........................................4-4
4.1.5 Lubricating Oil Management Criteria...................................................................4-5
4.1.6 Lubricating Oil Replacement Timing....................................................................4-6
4.1.6.1 After Starting the Initial Operation .............................................................. 4-6
4.1.6.2 During Normal Operation ...........................................................................4-6

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4.2 Precautions for Operation...........................................................................4-7
4.2.1 Prevention of Liquid Flow-back ........................................................................... 4-7
4.2.2 Purging of Non-condensable Gases....................................................................4-7
4.3 When Stopping the Compressor for a Long Time....................................4-8
5 Maintenance and Inspection
5.1 Precautions for Maintenance and Inspection............................................5-1
5.2 Maintenance and Inspection List................................................................5-3
5.2.1 Daily Management...............................................................................................5-3
5.2.2 Periodic Inspection ..............................................................................................5-5
5.2.3 Guidelines for the Timing of Compressor Overhaul............................................5-6
5.3 Compressor Disassembly Preparation......................................................5-7
5.3.1 Disassembly Tools and Work Place....................................................................5-7
5.3.2 Replacement Parts..............................................................................................5-7
5.3.2 Refrigerant Gas Recovery ...............................................................................5-10
5.3.4 Removing Parts Connected to the Unit............................................................. 5-11
5.3.5 Compressor Removing and Lifting....................................................................5-12
5.3.6 Removing Oil from Inside the Compressor........................................................5-12
5.4 Disassembly and Inspection.....................................................................5-13
5.4.1 Shaft Seal Block ................................................................................................5-15
5.4.1.1 Disassembly..............................................................................................5-15
5.4.1.2 Inspection ..................................................................................................5-16
5.4.2 Unloader Indicator .............................................................................................5-17
5.4.2.1 Disassembly..............................................................................................5-18
5.4.2.2 Inspection ..................................................................................................5-19
5.4.3 Unloader Cover..................................................................................................5-20
5.4.3.1 Disassembly..............................................................................................5-20
5.4.3.2 Inspection ..................................................................................................5-20
5.4.4 Unloader Piston and Unloader Cylinder............................................................5-21
5.4.4.1 Disassembly..............................................................................................5-21
5.4.4.2 Inspection ..................................................................................................5-21
5.4.5 Speed increaser Gear Casing Cover................................................................. 5-22
5.4.5.1 Disassembly..............................................................................................5-22
5.4.6 Speed increaser Gear Casing Block .................................................................5-23
5.4.6.1 Disassembly..............................................................................................5-23
5.4.6.2 Inspection ..................................................................................................5-26
5.4.7 Separating High-stage and Low-stage.............................................................. 5-27
5.4.7.1 Disassembly..............................................................................................5-27
5.4.8 Gear Coupling....................................................................................................5-28
5.4.8.1 Disassembly..............................................................................................5-28
5.4.8.2 Inspection ..................................................................................................5-28
5.4.9 Balance Piston Cover........................................................................................ 5-29
5.4.10 Balance Piston...................................................................................................5-29

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5.4.10.1 Disassembly..............................................................................................5-29
5.4.10.2 Inspection ..................................................................................................5-30
5.4.11 High-stage Suction Cover and Side Bearings...................................................5-31
5.4.11.1 Disassembly ..............................................................................................5-31
5.4.11.2 Inspection .................................................................................................. 5-31
5.4.12 Low-stage Suction Cover and Side Bearings....................................................5-32
5.4.12.1 Disassembly..............................................................................................5-32
5.4.12.2 Inspection ..................................................................................................5-33
5.4.13 Thrust Bearings Block........................................................................................ 5-34
5.4.13.1 Disassembly of High-stage Thrust Bearing block......................................5-34
5.4.13.2 Disassembly of Low-stage Thrust Bearing block ......................................5-35
5.4.13.3 Inspection (High-stage/Low-stage)............................................................5-36
5.4.14 High-stage Rotors and Main Rotor Casing........................................................5-37
5.4.14.1 Disassembly..............................................................................................5-37
5.4.14.2 Inspection ..................................................................................................5-37
5.4.15 Low-stage Rotors and Main Rotor Casing.........................................................5-38
5.4.16 High-stage Bearing Head and Main Bearings................................................... 5-39
5.4.16.1 Disassembly..............................................................................................5-39
5.4.16.2 Inspection ..................................................................................................5-39
5.4.17 Low-stage Bearing Head and Main Bearings....................................................5-40
5.4.17.1 Disassembly..............................................................................................5-40
5.4.17.2 Inspection ..................................................................................................5-40
5.4.18 Low-stage Unloader Slide Valve and Guide Block............................................5-41
5.4.18.1 Disassembly..............................................................................................5-41
5.4.18.2 Inspection ..................................................................................................5-41
5.5 Reassembly................................................................................................5-42
5.5.1 Low-stage Unloader Slide Valve and Guide Block............................................5-44
5.5.2 Bearing Head and Rotor Casing........................................................................5-45
5.5.3 Bearing Head and Main Bearings......................................................................5-46
5.5.4 Rotor Assembly .................................................................................................5-47
5.5.5 Suction Cover and Side Bearings......................................................................5-48
5.5.6 Thrust Bearing Block (....................................................................................... 5-50
5.5.6.1 End Clearance Measurement....................................................................5-52
5.5.6.2 End Clearance Adjustment Method........................................................... 5-54
5.5.6.3 Tightening after End Clearance Adjustment ............................................. 5-54
5.5.7 Combining High-stage and Low-stage Blocks................................................... 5-55
5.5.8 Balance Piston Cover........................................................................................ 5-57
5.5.9 Speed Increaser Gear Block..............................................................................5-58
5.5.10 Installation of Speed Increaser Gear Casing to Low-stage Bearing Head........ 5-61
5.5.11 Unloader Cylinder and Unloader Piston............................................................5-63
5.5.12 Unloader Cover..................................................................................................5-65
5.5.13 Shaft Seal Block ................................................................................................5-66
5.5.14 Unloader Indicator .............................................................................................5-69
5.5.14.1 Potentiometer............................................................................................5-70
5.5.14.2 Micro-switch............................................................................................... 5-70
5.5.14.3 Assembly and Adjustment......................................................................... 5-71

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6 Troubleshooting
01: Compressor does not start up................................................................................6-1
02: Compressor stops immediately after startup.......................................................... 6-1
03: Unusually low pressure (decrease of suction pressure)........................................6-2
04: Low oil pressure (low lubricating oil supply pressure)............................................ 6-2
05: Intermediate pressure is unusually high.................................................................6-3
06: Unusually high pressure (abnormal discharge pressure) ...................................... 6-4
07: Discharge temperature is abnormally high.............................................................6-5
08: Leak from mechanical seal.....................................................................................6-6
09: Squeaking of mechanical seal................................................................................6-7
10: Capacity control position is indicated incorrectly....................................................6-7
11: Capacity control malfunction..................................................................................6-8
12: Compressor generates abnormal vibration and/or sound...................................... 6-9
7 Related Documents
7.1 Development Views, Assembly Sectional Views......................................7-1
■Figure 7-1 Development View (Low-stage)...........................................................7-1
■Figure 7-2 Development View of the Parts Assembly (High-stage) ......................7-2
■Figure 7-3 Assembly Sectional View (Vertical)......................................................7-3
■Figure 7-4 Assembly Sectional View (Horizontal) .................................................7-4
7.2 Parts Configuration Table...........................................................................7-5
7.3 Tightening Torques for Bolts and Nuts .....................................................7-9
7.4 O-rings for Use...........................................................................................7-11
7.4.1 List of O-rings for Use........................................................................................7-11
7.4.2 List of O-ring Materials for Screw Compressor..................................................7-11
7.5 Tools for Disassembly...............................................................................7-12
Contact Information
Sales Offices in Japan ...........................................................................................Contact-1
Manufacturing Bases in Japan...............................................................................Contact-1
Global Network.......................................................................................................Contact-2
NORTH AMERICA........................................................................................................Contact-2
EUROPE and AFRICA..................................................................................................Contact-2
ASIA PACIFIC...............................................................................................................Contact-3
LATIN AMERICA...........................................................................................................Contact-5