mycom 2016 C Series User manual

2200LZJE-HO-C6-N_2013.12.
Compound 2-stage Screw
Compressor
2016**C Instruction Manual
2016LLC / 2016LMC / 2016LSC
/ 2016MSC / 2016SSC
ATTENTION
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 is subject to change without prior notice.

2200LZJE-HO-C6-N_2013.12.
Preface
Compound 2-stage Screw Compressor 2016**C i
Preface
Thank you for purchasing the compound 2-stage screw compressor 2016**C
(hereinafter referred to as "this product").
This Instruction Manual (hereinafter referred to as "this manual") provides safety information and
operation and maintenance procedures, so that users correctly understand how to handle this product
and, as a result, can use it safely and efficiently. This manual is applicable to the following models:
2016LLC-*B*-51, 2016LMC-*B*-51, 20162LSC-*B*-51, 2016MSC-*B*-51, 2016SSC-*B*-51
2016LLC-*B*-61, 2016LMC-*B*-61, 20162LSC-*B*-61, 2016MSC-*B*-61, 2016SSC-*B*-61
* -51 (-61) may not be written. For more information, see 2.2 "Model designation of the compressor"
in this manual Chapter 2.
Before installing or using this product, make sure you read this manual.
Keep this manual in a safe place near this product for quick reference.
Revision History
Title Document No. First edition issue
date
2016**C Instruction Manual 2200LZJE-HO-C6-N_2013.12. Dec. 16, 2013
Revision
No. Issue date Contents of revisions (modified clause, page, and details) Created / approved by:
- Jun. 30,1974 Issuance of 2016C first edition S. Yamamoto
- Oct.01,1983 Newly issued as 1612**C/2016**C edition. S. Yamamoto
- Jun. 30, 1993 Revision of 1612**C/2016**C (correction of errors,
etc.) S. Yamamoto
- Jun. 30,1996
Reviewed pursuant to the Product Liability Law,
established June 1994 Ikehara / Shozu
00 Dec. 16, 2013 Overall review associated with reissue as
electronic document, document No. change Ikehara, kawamoto / Hirao

2200LZJE-HO-C6-N_2013.12.
Warranty and Disclaimer
Compound 2-stage Screw Compressor 2016**C 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.
Disclaimer Clauses (Exclusion of Warranty Clauses)
In no event will Mayekawa be liable to you for any of the following damages or claims arising out of the
use or inability to use this product:
Malfunction or damage caused by acts of nature (storms, heavy rains, floods, high tides,
earthquakes, subsidences, lightnings, fires, etc.)
Malfunction, damage or deterioration caused by misuse or improper use of this product
(outdoor storage or storage under high temperature and humidity, excessively frequent liquid
flow-back operation, extreme start-stop repetition, 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 the use of refrigerant (or gas) or lubricant that is not
applicable to this product
Malfunction or damage caused by maintenance or inspection not recommended by
MAYEKAWA
Malfunction or damage caused by parts that are not Mayekawa genuine
Malfunction or damage caused by remodeling this product without approval of MAYEKAWA
Lost profits or other incidental or consequential damages arising directly or indirectly out of the
malfunction or damage of this product

2200LZJE-HO-C6-N_2013.12.
Important Information
Compound 2-stage Screw Compressor 2016**C iii
Important Information
Intended Use of This Product
This product is a general-purpose screw compressor for refrigeration and cold storage. Do not use this
product for any other purposes that are not intended for or which depart from the specifications. For
specifications of this product, refer to "2.3 Compressor Specifications".
Please perform the maintenance items described in this manual by using safe and assured procedures.
Important Information for Safe Use of This Product
Although MAYEKAWA has paid a lot of attention to safety measures for this product, all hazards
including potential hazards caused by human errors, or due to environmental conditions can not be
anticipated.
As there are too many items to be strictly observed or prohibited when using this product, it is
impossible to inform all of them through this manual or warning labels. Therefore, when operating this
product, pay extreme caution on personnel safety as well as on items described in this manual.
Important rules for safety work with this product that apply to all workers including managers and
supervisors are listed below.
Please read this manual before using this product. Fully understand the instructions provided there,
and be sure to perform the safety procedures described in this manual.
Operation, maintenance, and inspection of this product should be performed by qualified
personnel educated about the fundamentals of this product and trained about hazards
involved and measures to avoid danger.
Do not allow any person other than those educated on the fundamental expertise of this
product and trained about hazards involved and measures to avoid dangers to approach this
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. Do not use this product for any purpose other than intended.
Replace the parts with genuine parts.
Not only workers but also managers should actively participate safety and health activities in
the workplace to prevent accidents.
When closing or opening a valve during work, make sure to apply lockout/tagout to prevent
the valve from being accidentally closed or opened 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.

2200LZJE-HO-C6-N_2013.12.
Important Information
Compound 2-stage Screw Compressor 2016**C 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 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", this product may be turned on if
the power is supplied from outside the refrigeration system or cold storage unit. Make sure the power
supply on the power source side is shut off, and perform lockout/tagout to prevent the 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 in your area.
This manual is in English. If any other language is required, it is the customers 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 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 actual
product.
If this manual is lost or damaged, immediately request our local sales offices or service
centers for a new manual. Using this product without the manual may result in safety issues.
If you resell this product, never fail to attach this manual to this product.
Construction of This Manual
Title of section and chapter Description details
Preface Describes the outline of this manual and how to read this manual.
Warranty and Disclaimer Describes what Mayekawa 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 safety information for the worker, safety rules for this
product, and management details regarding the work safety that
is required for handling this product.
2. Configuration and
Specifications of Compressor Describes the main components of this product, functional information, specification, and operating limits.
3. Installation Describes the installation procedure of this product.
4. Operation of compressor and
unit Describes the precautions for operating this product.
5. Maintenance Describes sections and period for inspecting, and assembly and
disassembly of this product.
6. Troubleshooting Describes troubleshooting methods for this product in case
problems occur during operation of this product.
7. Related Documents Describes documents such as development views and parts list.
8. Contact Information Describes contact information for our local sales offices or service
centers, which are for ordering genuine parts.

2200LZJE-HO-C6-N_2013.12.
Table of Contents
Compound 2-stage Screw Compressor 2016**C v
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 This Manual..................................................................................................ⅳ
Table of Contents................................................................................................... ⅴ
Chapter 1 Safety
1.1 Observation/Prevention (DOs and DON'Ts) ..............................................1-1
1.1.1 DOs......................................................................................................................1-1
1.1.1.1 DOs on Operation........................................................................................ 1-1
1.1.1.2 DOs on Maintenance...................................................................................1-1
1.1.1.3 DOs on Lockout/Tagout after Shutting Off the Power ................................. 1-1
1.1.1.4 DOs about Personal Protective Gear..........................................................1-2
1.1.1.5 DOs about Handling of Hazardous and Toxic Substances .........................1-2
1.1.1.6 DOs about Handling Emergency Situations................................................1-2
1.1.1.7 DOs about Waste Oil, Fluid, and Materials.................................................1-2
1.1.1.8 Other DOs ................................................................................................... 1-2
1.1.2 DON'Ts................................................................................................................ 1-2
1.2 Warnings.......................................................................................................1-3
1.2.1 Types and Meanings of 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 of motor main power and control power
(with Lockout/Tagout Mechanism) ......................................................................1-6
1.4.3 Compressor Protective Devices ..........................................................................1-7
Chapter 2 Configuration and Specifications of Compressor
2.1 Features of the Compound 2-stage Screw
Compressor 2016**C....................................................................................2-1
2.2 Model Designation of the Compressor ...................................................2-2
2.3 Compressor Specifications ........................................................................2-2
2.3.1 Specifications....................................................................................................... 2-2
2.3.2 Operation Limits................................................................................................... 2-3
2.3.3 External Dimensions............................................................................................2-4

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Compound 2-stage Screw Compressor 2016**C vi
2.4 Configuration of Compressor.....................................................................2-9
2.4.1 Sectional View..................................................................................................... 2-9
2.5 Mechanisms ...............................................................................................2-10
2.5.1 Basics of the Screw Compressor ......................................................................2-10
2.5.2 Suction Process................................................................................................. 2-10
2.5.3 Compression Process........................................................................................2-11
2.5.4 Discharge Process.............................................................................................2-11
2.5.5 About Volume Ratio (Vi)....................................................................................2-11
2.5.6 Capacity Control Mechanism............................................................................. 2-13
2.5.7 Bearing...............................................................................................................2-13
2.5.8 Seal....................................................................................................................2-13
2.6 Gas and Oil Flow........................................................................................2-14
Chapter 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 Transfer................................................................................................................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 Piping Connection ....................................................................................... 3-5
3.2.5.3 Equipment and Devices for Protection of the Compressor.........................3-5
3.2.6 Airtightness Test..................................................................................................3-6
3.2.7 Lubricant Charge.................................................................................................3-6
3.2.7.1 Initial Charge of Lubricant............................................................................ 3-6
3.2.7.2 Additional Charge of Lubricant....................................................................3-7
3.2.8 Charge of Refrigerant.......................................................................................... 3-7
3.2.9 Check after Installation........................................................................................3-7
Chapter 4 Operation of Compressor and Unit
4.1 Lubricant (Refrigerant Oil) ..........................................................................4-1
4.1.1 Precautions for Selecting the Lubricant............................................................... 4-1
4.1.2 Recommended Lubricants...................................................................................4-1
4.1.2.1 Recommended Lubricants forAmmonia Refrigerant ..................................4-1
4.1.2.2 Oils for systems using HFC refrigerants......................................................4-2
4.1.3 Change of Lubricant Brand..................................................................................4-3
4.1.4 Precautions for Handling lubricant.......................................................................4-3
4.1.5 Precautions for Handling JOMO Freol PN46 (Ammonia-inter-soluble Oil) .........4-4
4.2 Precautions for Operation...........................................................................4-5
4.2.1 Prevention of Liquid Flow-back ........................................................................... 4-5
4.2.2 Purging of Non-Condensable Gases...................................................................4-5
4.2.3 Actions for Stopping the Compressor for Long Period of Time...........................4-6

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Table of Contents
Compound 2-stage Screw Compressor 2016**C vii
Chapter 5 Maintenance
5.1 Precautions for Maintenance......................................................................5-1
5.2 Maintenance List..........................................................................................5-2
5.2.1 Daily Management............................................................................................... 5-2
5.2.2 Periodical Inspection............................................................................................5-4
5.2.3 Guidelines for Compressor Overhaul Frequency................................................ 5-4
5.3 Management of Lubricant ...........................................................................5-6
5.3.1 Lubricant Management Criteria ........................................................................... 5-6
5.3.2 Lubricant Replacement Frequency...................................................................... 5-7
5.3.2.1 First system startup..................................................................................... 5-7
5.3.2.2 During regular operation.............................................................................. 5-7
5.4 Compressor Disassembly Preparation......................................................5-8
5.4.1 Tools for Disassembly and Work Place............................................................... 5-9
5.4.2 Replacement Parts..............................................................................................5-9
5.4.3 Recovering the Refrigerant.................................................................................. 5-9
5.4.4 Removing Parts Connected to the Unit............................................................. 5-10
5.4.5 Removing and Lifting the Compressor..............................................................5-11
5.4.6 Removing Oil from Compressor ........................................................................5-11
5.5 Disassembly Sequence.............................................................................5-12
5.6 Overhaul .....................................................................................................5-14
5.6.1 Mechanical Seal ................................................................................................5-15
5.6.1.1 Disassembly..............................................................................................5-15
5.6.1.2 Inspection ..................................................................................................5-16
5.6.2 Unloader Indicator .............................................................................................5-18
5.6.2.1 Disassembly..............................................................................................5-18
5.6.3 Unloader Cylinder Cover ...................................................................................5-21
5.6.3.1 Disassembly..............................................................................................5-21
5.6.3.2 Inspection ..................................................................................................5-22
5.6.4 Unloader Piston and Unloader Cylinder............................................................5-22
5.6.4.1 Disassembly..............................................................................................5-22
5.6.4.2 Inspection ..................................................................................................5-23
5.6.5 Bearing Cover.................................................................................................... 5-24
5.6.5.1 Disassembly..............................................................................................5-24
5.6.6 Separating High-stage and Low-stage.............................................................. 5-25
5.6.6.1 Disassembly..............................................................................................5-25
5.6.7 High-stage Side Gear Coupling......................................................................... 5-25
5.6.7.1 Disassembly..............................................................................................5-25
5.6.7.2 Inspection ..................................................................................................5-25
5.6.8 High-stage Thrust Bearings............................................................................... 5-26
5.6.8.1 Disassembly..............................................................................................5-26
5.6.8.2 Inspection ..................................................................................................5-27
5.6.9 Balance Piston Cover........................................................................................ 5-28
5.6.10 Balance Piston................................................................................................... 5-28
5.6.10.1 Disassembly..............................................................................................5-28
5.6.10.2 Inspection ..................................................................................................5-29

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Table of Contents
Compound 2-stage Screw Compressor 2016**C viii
5.6.11 High-stage Suction Cover and Side Bearings...................................................5-30
5.6.11.1 Disassembly..............................................................................................5-30
5.6.11.2 Inspection ..................................................................................................5-30
5.6.12 Pulling out High-stage Rotor.............................................................................. 5-31
5.6.12.1 Disassembly..............................................................................................5-31
5.6.12.2 Inspection ..................................................................................................5-32
5.6.13 High-stage Bearing Head and Main Bearings...................................................5-33
5.6.13.1 Disassembly..............................................................................................5-33
5.6.13.2 Inspection ..................................................................................................5-33
5.6.14 Low-stage Thrust Bearings................................................................................5-34
5.6.14.1 Disassembly..............................................................................................5-34
5.6.14.2 Inspection ..................................................................................................5-34
5.6.15 Low-stage Gear Coupling..................................................................................5-35
5.6.15.1 Disassembly..............................................................................................5-35
5.6.15.2 Inspection ..................................................................................................5-35
5.6.16 Low-stage Suction Cover and Side Bearings....................................................5-36
5.6.16.1 Disassembly..............................................................................................5-36
5.6.16.2 Inspection ..................................................................................................5-36
5.6.17 Low-stage Rotor and Rotor Casing................................................................... 5-37
5.6.18 Low-stage Bearing Head and Main Bearings....................................................5-37
5.6.18.1 Disassembly..............................................................................................5-37
5.6.18.2 Inspection ..................................................................................................5-37
5.6.19 Low-stage Unloader Slide Valve and Guide Block............................................ 5-38
5.6.19.1 Disassembly..............................................................................................5-38
5.6.19.2 Inspection ..................................................................................................5-38
5.7 Reassembly................................................................................................5-39
5.7.1 Low-stage Unloader Slide Valve and Guide Block............................................5-41
5.7.2 High-stage Rotor Casing ...................................................................................5-41
5.7.3 Bearing Head and Main Bearings (High/Low-stage).........................................5-42
5.7.4 Bearing Head and Rotor Casing (High/Low-stage)...........................................5-43
5.7.5 Attaching Rotors (High/Low-stage).................................................................... 5-44
5.7.6 Suction Cover and Side Bearings (High/Low-stage)......................................... 5-45
5.7.7 Thrust Bearings (High/Low-stage)..................................................................... 5-48
5.7.7.1 End Clearance Measurement.................................................................... 5-49
5.7.7.2 Procedure for End Clearance Adjustment................................................. 5-51
5.7.7.3 Tightening after End Clearance Adjustment.............................................. 5-52
5.7.8 Bearing Cover.................................................................................................... 5-52
5.7.9 Attaching High-stage and Low-stage.................................................................5-53
5.7.10 Balance Piston Cover and High-stage Unloader Cylinder................................. 5-55
5.7.11 Low-stage Unloader Cylinder............................................................................ 5-57
5.7.12 Mechanical Seal ................................................................................................5-59
5.7.13 Unloader Cylinder Cover ...................................................................................5-62
5.7.14 Unloader Indicator .............................................................................................5-63
5.7.14.1 Micro-switch and Micro-switch Cam..........................................................5-63
5.7.14.2 Potentiometer............................................................................................5-64

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Table of Contents
Compound 2-stage Screw Compressor 2016**C ix
Chapter 6 Troubleshooting
Table 6-1 Troubleshooting................................................................................... 6-1
Chapter 7 Related Documents
7.1 Development Views, Assembly Sectional Views......................................7-1
Figure 7-1 2016C Development View (Low-stage Side)....................................... 7-1
Figure 7-2 2016C Development View (High-stage Side)......................................7-2
Figure 7-3 2016LLC Assembly Sectional View (Vertical) .....................................7-3
Figure 7-4 2016LLC Assembly Sectional View (Horizontal).................................7-4
Figure 7-5 2016LMC Assembly Sectional View (Vertical) .................................... 7-5
Figure 7-6 2016LMC Assembly Sectional View (Horizontal)................................ 7-6
Figure 7-7 2016LSC Assembly Sectional View (Vertical).....................................7-7
Figure 7-8 2016LSC Assembly Sectional View (Horizontal)................................. 7-8
Figure 7-9 2016MSC Assembly Sectional View (Vertical).................................... 7-9
Figure 7-10 2016MSC Assembly Sectional View (Horizontal).............................. 7-10
Figure 7-11 2016SSC Assembly Sectional View (Vertical) ..................................7-11
Figure 7-12 2016SSC Assembly Sectional View (Horizontal)..............................7-12
7.2 Parts Configuration Table.........................................................................7-13
7.3 Tightening Torques for Bolts and Nuts...................................................7-20
7.4 About the O-rings Used.............................................................................7-22
7.4.1 List of O-rings Used...........................................................................................7-22
7.4.2 O-ring Materials Used for Screw Compressor...................................................7-22
7.5 Tools for Disassembly...............................................................................7-23
Chapter 8 Contact Information
8.1 How to Order Genuine Parts......................................................8-1
8.2 Sales Offices/Service Centers....................................................................8-1

2200LZJE-HO-C6-N_2013.12.
Chapter 1 Safety
Compound 2-stage Screw Compressor 2016**C 1.1 Observation/Prevention (DOs and DON'Ts)
1-1
Chapter 1 Safety
1.1 Observation/Prevention (DOs and DON'Ts)
1.1.1 DOs
1.1.1.1 DOs on Operation
Make sure to attach safety and protective devices on the unit.
Regularly inspect the safety and protective devices if they function properly.
If the safety or protective devices do not work properly or if this product operates abnormally,
immediately stop the operation and report to the supervisor. Obtain his/her approval and
direction before restarting the compressor.
If this product stops for unknown reasons, immediately inform your supervisor of it. Obtain
his/her approval before restarting the compressor.
Some types of refrigerants emit bad smell or toxic gases when they leak. Make sure to
ventilate the air during operation.
For the properties of refrigerant and lubricant (corrosiveness, decomposability or toxicity), be
sure to obtain the Safety Data Sheet (SDS) and follow the relevant information.
When stopping the operation of this product, close the suction and discharge side shut-off
valves and turn "OFF" the motor (main power), heater power, and control power.
1.1.1.2 DOs on Maintenance
Prepare work procedures based on a work schedule. Be sure to perform danger forecasting
before starting the work.
Before performing the work together with at least one other person, thoroughly confirm each
other's work details and procedures to acknowledge the other worker's movement.
When troubleshooting during operation or before performing setup, cleaning or
maintenance/inspection of this product, always turn OFF the main power to the motor and
control power and other devices. Also, lock and tag out them to prevent the power from being
supplied erroneously during operation.
When troubleshooting during operation or before performing setup, cleaning or
maintenance/inspection of this product, confirm that the pressure inside this product and the
refrigerating/cold storage unit is at atmospheric pressure.
Some refrigerants in use generate bad smell or toxic gases, or may cause deficiency of
oxygen. Before starting work, measure oxygen concentration in the work area as necessary.
Ventilate the area well. Be sure to keep the area well ventilated until the work is finished.
For the properties of refrigerant and lubricant (corrosiveness, decomposability or toxicity), be
sure to obtain the Safety Data Sheet (SDS) and follow the relevant information.
After using tools always restore to designated place and never leave tools in the compressor.
1.1.1.3 DOs on Lockout/Tagout after Shutting Off the Power
Attach lockout/tagout mechanism to the main breakers of motor main power and control power.
Lockout/tagout after power off is a very effective means to secure safety. It can prevent the
power source from being turned on by accident by two or more workers which may cause
injury to other worker(s).
If there are any possibilities of danger during works (especially during cleaning, maintenance
and inspection, and troubleshooting), turn "OFF" the motor main power and control power, and
perform lockout/tagout.

2200LZJE-HO-C6-N_2013.12.
Chapter 1 Safety
Compound 2-stage Screw Compressor 2016**C 1.1 Observation/Prevention (DOs and DON'Ts)
1-2
In the following situations, workers may neglect to perform power source shutoff or
lockout/tagout. Clearly notify the workers of the necessity of lockout/tagout.
It is assumed that workers do not perform lockout/tagout before starting work because it is
troublesome, and only turn "OFF" the main motor and control power.
It is assumed that workers only turn off the main motor and control power and do not
lockout/tagout the main motor and control power, because they judge that there is no
danger.
1.1.1.4 DOs about Personal Protective Gear
Prepare and use protective gear complying with the safety standards of the regulations.
Check the function of each protective gear before using.
Wear designated clothes such as work outfits, with their cuffs tightly closed.
Do not wear any neckties or jewelry as there is a risk of being entangled by a movable part or
rotating part. Put on a helmet as your hair may get entangled.
Do not have anything in your pocket to prevent objects from falling into the machine.
1.1.1.5 DOs about Handling of Hazardous and Toxic Substances
Obtain the Safety Data Sheet (SDS) from manufacturers of hazardous and toxic substances.
Check the SDS and follow the handling instructions recommended by the manufacturers to
handle and store those substances.
1.1.1.6 DOs about Handling Emergency Situations
Formulate an emergency action plan complying with the regulations, and post it on a safe
place.
1.1.1.7 DOs about Waste Oil, Fluid, and Materials
Disposing of refrigerant and oil used for this product are subject to a number of regulations for
the environmental protection purposes. Follow the local, state, federal acts and regulations
and your company's rules when disposing of such waste oil, fluid and materials.
1.1.1.8 Other DOs
Clean the floor around the entire refrigerating/cold storage unit. Provide a safety passage.
Walk only on the areas set up as a work floor. Also, do not leave tools and cleaning solutions
in that area.
If water or oil is spilled on this product or the floor, immediately wipe it off to prevent workers
from slipping and getting injured.
1.1.2 DON'Ts
Do not remove or relocate any safety device, including electrical interfaces.
Do not disable any safety device by short-circuiting or bypassing without any permission.
Do not leave this product unsafe and unattended, by removing a safety cover or some other
measures.
Do not touch, clean or lubricate any part of this product which is moving.
Do not touch relays or electric systems such as terminal block with bare hands when turning
on the power.

2200LZJE-HO-C6-N_2013.12.
Chapter 1 Safety
Compound 2-stage Screw Compressor 2016**C 1.2 Warnings
1-3
1.2 Warnings
The following two measures are taken for this product to let workers pay attention to possible dangers.
Warnings described in this manual
Safety labels affixed on the product main body
* No safety labels are affixed to the compressor itself which this manual is intended for.
For details about the warning labels affixed to the unit, refer to the instruction manual of the
unit.
1.2.1 Types and Meanings of Warnings
The warning messages described in this manual warn dangerous situations that may arise during work
by using the following four categories.
Neglecting such warnings may cause accidents, resulting in personal injury or even death.
Also, this product or its auxiliary equipment may be heavily damaged. Therefore, be sure to always
observe the instructions of the warnings.
Table 1-1 Types and Meanings of Warnings
Indicates a hazardous situation which, if not avoided, could very likely cause serious
injury or death.
Indicates a potentially hazardous situation which, if not avoided, may cause serious injury
or death.
Indicates a potentially hazardous situation which, if not avoided, may cause minor or
moderate injury.
Indicates a potentially hazardous situation which, if not avoided, may result in property
damage.

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Chapter 1 Safety
Compound 2-stage Screw Compressor 2016**C 1.3 Residual Risks
1-4
1.3 Residual Risks
The following information assumes that this product is operated or inspected/maintained while being
used in general refrigerating/cold storage units. It is impossible to predict all the risk sources involved in
actual use of the refrigerating/cold storage units.
Devise appropriate countermeasures for hazardous sources in your systems.
Table 1-2 Hazardous Sources
Hazardous sources Predicted hazard Countermeasures in
operation
Countermeasures in
cleaning, inspection,
and parts exchange
A Motor and
compressor coupling Caught in due to contact Install coupling cover
and prohibit opening.
Keep away.
Turn off motor main
power and control power,
and conduct
lockout/tagout.
B Motor terminals Electric shock caused by
contact with live wires or
electrical leakage
Keep away.
Do not open terminal
boxes.
Do not touch terminal
boxes.
Turn off motor main
power and control power,
and conduct
lockout/tagout.
C Compressor
low-stage side
suction casing
Frostbite due to contact
Contact with or inhalation
of hazardous substances
generated by leakage of
refrigerant or the like
Keep away and do not
touch.
Wear protective gear.
Detect gas leakage.
Wear protective gear.
Work under room
temperature.
D Compressor
high-stage side
discharge casing and
discharge piping
Burn injury due to contact
Contact with or inhalation
of hazardous substances
generated by leakage or
spout of refrigerant or the
like
Keep away and do not
touch.
Wear protective gear.
Detect gas leakage.
Wear protective gear.
Work at a temperature of
not higher than 40°C.
E Check valves/service
valves and joints on
each section of the
unit
Contact with or inhalation
of hazardous substances
generated by mishandling
or leakage
Frostbite or burn due to
contact
Sufficient ventilation
Indicate valve
open/close state.
Keep away and do not
touch.
Wear protective gear.
Sufficient ventilation
Wear protective gear.
Tagout for controlled
valve
F Solenoid
valves/motor
operated valves on
each section of the
unit
Electric shock caused by
contact with live wires or
electrical leakage
Pinched due to contact
with driving part
Install protective cover
on terminals, and
prohibit opening.
Keep away and do not
touch.
Wear protective gear.
Turn off each breaker and
the control power, and
conduct lockout/tagout.
Wear protective gear.
G Electric components
in each section of the
unit (oil heater,
protective switch,
etc.)
Electric shock caused by
contact with live wires or
electrical leakage
Pinched due to contact
with driving part
Install protective cover
on terminals, and
prohibit opening.
Keep away and do not
touch.
Wear protective gear.
Turn off each breaker and
the control power, and
conduct lockout/tagout.
Wear protective gear.
H Unit oil drains Contact with hazardous
substances generated by
leakage or spout
Burn caused by contact
with high-temperature
fluid
Sufficient ventilation
Keep away and do not
touch.
Wear protective gear.
Sufficient ventilation
Wear protective gear.
Work at a temperature of
not higher than 40°C.
I Noises Damage caused by noise Wear protective gear. —

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Chapter 1 Safety
Compound 2-stage Screw Compressor 2016**C 1.3 Residual Risks
1-5
Figure 1-1 Locations of Hazardous Sources (compressor)
Photo 001 Locations of Hazardous Sources
A
C
D
A
C
D

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Chapter 1 Safety
Compound 2-stage Screw Compressor 2016**C 1.4 Safety Devices
1-6
1.4 Safety Devices
For safe use and protection of this product, make sure to attach safety devices to this product in
accordance with the regulations and the following instructions.
Safety devices cannot be kept in normal condition unless inspected and maintained at regular intervals.
Their maintenance and inspection need to be performed as an important part of the
maintenance/inspection work project. Provide users of this product with necessary information on the
safety devices, for example, types of the safety devices, installation position, function, and inspection
method of safety related devices.
Check the safety devices after turning on the power and before operation of the
compressor. If they do not operate normally, immediately take repair or replace
safeties before starting compressor.
1.4.1 Emergency Stop Button
Overview/Function/Purpose
The emergency stop buttons are used to stop the compressor operation immediately if an
emergency occurs in this product.
Installation Positions
On the control board and in the operation control room
Stop/Restoration Methods
For information on how to stop or restore the emergency stop button, refer to the instruction manual
of the unit.
Inspection Method/Cycle
The emergency stop buttons must be tested before commissioning and must also be periodically
re-tested after that. For the inspection method and frequency for the emergency stop button, refer
to the instruction manual of the unit.
1.4.2 Breakers of Motor Main Power and Control Power
(with Lockout/Tagout Mechanism)
Overview/Function/Purpose
Turn off the main motor and control power, and if there is any possibility of danger during work
(especially during cleaning, maintenance, inspection, or troubleshooting), lockout/tagout devices
must be used on the breakers of the main motor and control powers to prevent injuries to workers in
case the power is turned on accidentally during work.
Methods of Performing and Releasing Lockout/Tagout
Make sure to clearly notify methods of performing and releasing lockout/tagout referring to the
regulations created by Occupational Safety & Health Administration (OSHA) or local governing
body.
Inspection Method/Cycle
For the inspection method and cycle for the lockout/tagout mechanism, refer to the instruction
manual of the unit.

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Chapter 1 Safety
Compound 2-stage Screw Compressor 2016**C 1.4 Safety Devices
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1.4.3 Compressor Protective Devices
Be sure to adjust the set values and check operation of the protective devices at
the test run.
Overview/Function/Purpose
These protective devices are used to protect this product.
Protecting from discharge temperature rise (DT)
This device stops the compressor operation when the discharge temperature of the
compressor exceeds the set value.
Install a temperature sensing port to the discharge pipe.
Protecting from oil temperature rise (OT)
This device stops the compressor operation when the oil temperature of the compressor
exceeds the set value.
Install a temperature sensing port to the unit's oil supply pipe (after the oil cooler).
Protecting from high pressure (HP)
This device stops the compressor operation when the discharge pressure abnormally rises
due to compressor misoperations or stoppage of cooling water supply to the condenser.
This device prevents explosion of the equipment and components.
Install a pressure sensing port to the discharge pipe.
Protecting from intermediate pressure (IP)
This device controls the compressor appropriately when the intermediate pressure exceeds
the set value. In some cases, this device stops the compressor operation.
Install a pressure output port to the unit's intermediate gas pipe (or compressor's intermediate
gas pressure output port).
Protecting from suction pressure drop (LP)
This device stops the compressor operation when the suction pressure becomes below the
set value.
Install a pressure sensing port to the suction pipe.
Protecting from oil pressure (OP)
This device stops the compressor operation when refrigerant oil supply is not sufficient, the oil
filter is clogged, the refrigerant is mixed into the lubricant, and oil supply pressure difference
(from discharge pressure) becomes below the set value.
This device is to protect the compressor from wear and burnout.
Install a pressure sensing port to the unit's oil supply pump (after the oil pump) and the
discharge pipe.
Protecting from motor overcurrent (OCR)
This device controls the compressor appropriately when the current exceeds the set value. In
some cases, this device stops the compressor operation.
This device is normally installed in the compressor operation controller.

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Chapter 1 Safety
Compound 2-stage Screw Compressor 2016**C 1.4 Safety Devices
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Connection Positions and Settings
For connection position and setting for each compressor protective device, refer to the instruction
manual of the unit.
Make sure that the set values do not exceed the operating limits shown in Chapter 2, section 2.3.2
and Table 2-2 of this manual.
Inspection Method/Cycle
Compressor protective devices require operation tests and confirmation of the settings calibration
before test run as well as at regular intervals. For information on inspecting procedure and
frequency for the compressor, refer to the instruction manual of the unit.
In the operation test, check that alarms and protective devices operate normally
by using devices such as pressure tester. Do not operate the compressor with all
the valves closed, or in any other dangerous conditions.
If the protection from oil pressure (OP), high pressure (HP) activates, do not
restart operation until the cause of activation is removed.

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Chapter 2 Configuration and Specifications of Compressor
Compound 2-stage Screw Compressor 2016**C 2.1 Features of the Compound 2-stage Screw Compressor 2016**C
2-1
Chapter 2 Configuration and Specifications of
Compressor
2.1 Features of the Compound 2-stage Screw
Compressor 2016**C
The 2-stage compression system, which has hitherto required two units of standard-type screw
compressor for its embodiment, can now be realized by a single unit of compound 2-stage screw
compressor.
Generally, screw compressors use oil injection to keep discharge temperature at a low level during
operation without loss of volumetric efficiency even at high compression ratios. It can, therefore, be
operated with a single-stage compression system even at evaporative temperatures near -40°C.
However, for normal use at low temperatures, a 2-stage compression system is applied in order to
improve KW/RT (ratio of power consumption versus cooling ability). If the 2-stage compression system
is configured with standard-type screw compressors, at least two screw compressor units need to be
installed, one on the high-stage and the other on the low-stage, which inevitably requires double
installation of the entire system including machinery, motors, utilities, etc.
This 2-stage screw compressor is produced to solve this problem. It is a single unit that has two
single-stage compressor units combined into one.
The 2016**C model has a capacity control mechanism for startup load reduction on the high-stage, and
a capacity control mechanism for coping with load change on the low-stage.
There are various combinations of machine control methods/capacity control methods. However, as
they are not directly related to the inspection of the compressor, they are omitted here.
2.2 Model Designation of the Compressor
This manual describes 2016**C-*B*-51 and 2016**C-*B*-61 models.
The meaning of the type designation, which is engraved on the MODEL column of the compressor
nameplate, is as follows.
*2016**C-*B*-51/61
5: Power frequency (6: 60Hz)
1: Indicates that it is a motor directly connected type.
* Unless specifically specified, machines manufactured in
September, 2010 or after do not have this indication engraved
on their nameplate.
Vi (volume ratio) specified for the high-stage discharge port,
standard value of which is Lor M
Means a booster (low-stage machine)
Vi (volume ratio) specified for the low-stage discharge port, standard
value of which is Lor M
Stands for Compound (compound 2-stage machine)
Specifications of high-stage rotor length, which is L, Mor S
Specifications of low-stage rotor length, which is L, Mor S
High-stage rotor diameter of 160
Low-stage rotor diameter of 200
Indicates working fluid
(Example: N = Ammonia, F= Freon, P = Propane, HE = Helium)

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Chapter 2 Configuration and Specifications of Compressor
Compound 2-stage Screw Compressor 2016**C 2.3 Compressor Specifications
2-2
2.3 Compressor Specifications
2.3.1 Specifications
Table 2-1 2016**C Screw Compressor Specifications
Items 2016
LLC LMC LSC MSC SSC
Weight kg 1180 1140 1100 1050 1000
Low-stage theoretical
displacement
@3550 rpm /2950 rpm m3/h 1460/1210 1460/1210 1460/1210 1220/1020 975/810
High-stage theoretical
displacement
@3550 rpm /2950 rpm m3/h 749/622 624/519 499/415 499/415 499/415
Refrigerant - NH3, HFC, etc.
Design pressure MPa 2.6
Capacity control (Actual load) - 10 to 100%
Rotation direction - Counterclockwise viewed from motor
Connected
pipe size
Low-stage
suction flange - JIS 20K 150A (6")
Low-stage
discharge flange - JIS 20K 100A (4")
High-stage
suction flange - JIS 20K 100A (4")
High-stage
discharge flange - JIS 20K 80A (3")
Journal
lubrication
(low-stage) - JIS 20K 25A (1")
Journal
lubrication
(high-stage) - JIS 20K 20A (3/4")
Oil injection
lubrication - JIS 20K 15A (1/2")
Low-stage
capacity control - Load: Rc1/4, Unload: Rc3/8
High-stage
capacity control - Load: Rc3/8, Unload: Rc1/4
Unless otherwise noted, the pressure unit MPa represents the gauge pressure
in this manual.
For limits of working temperature and pressure, see "2.3.2 Operation Limits" in
this manual.