mycom 4032**C Series User manual

2201Q4JE-MY-C9-N_2018.01.
Compound 2-stage Screw Compressor
4032 * * CInstruction Manual
4032XLLLC/4032LLLLC/4032LLLC/4032LLMC/4032LLSC
4032LLC/4032LMC/4032LSC/4032MLC/4032MMC/4032MSC
4032SLC/4032SMC/4032SSC
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.

2201Q4JE-MY-C9-N_2018.01.
Preface
Compound 2-stage Screw Compressor 4032**C i
Preface
Thank you for purchasing the C-series compound 2-stage screw compressor 4032**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:
4032XLLLC-*B*-51
4032LLLLC-*B*-51
4032LLLC-*B*-51
4032LLMC-*B*-51
4032LLSC-*B*-51
4032XLLLC-*B*-61
4032LLLLC-*B*-61
4032LLLC-*B*-61
4032LLMC-*B*-61
4032LLSC-*B*-61
4032LLC-*B*-51
4032LLC-*B*-61
4032LMC-*B*-51
4032LMC-*B*-61
4032LSC-*B*-51
4032LSC-*B*-61
4032MLC-*B*-51
4032MLC-*B*-61
4032MMC-*B*-51
4032MMC-*B*-61
4032MSC-*B*-51
4032MSC-*B*-61
4032SLC-*B*-51
4032SLC-*B*-61
4032SMC-*B*-51
4032SMC-*B*-61
4032SSC-*B*-51
4032SSC-*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
4032**C Instruction Manual
2201Q4JE-MY-C9-N_2018.01.
Apr. 30, 2015
Revision
No.
Issue date
Major Contents of revisions
Created/approved by:
00
Apr. 30, 2015
Newly issued as a electronic edition manual.
Ikehara / Muta
01
Jan. 31, 2018
Corrected errors. Deleted Contact Information.
Takenouchi・Ito/Kato

2201Q4JE-MY-C9-N_2018.01.
Warranty and Disclaimer
Compound 2-stage Screw Compressor 4032**C ii
Warranty and Disclaimer
Warranty
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". However, if any separate
agreement has been concluded, such an agreement will have the priority 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.

2201Q4JE-MY-C9-N_2018.01.
Important Information
Compound 2-stage Screw Compressor 4032**C iii
Important Information
Intended Use of This Product
This product is a general-purpose screw compressor for refrigeration, cold storage and various gases
compression. 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 Section 2.3 "Compressor
Specifications" in this manual Chapter 2.
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. 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.

2201Q4JE-MY-C9-N_2018.01.
Important Information
Compound 2-stage Screw Compressor 4032**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 package 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. For each sight of MAYEKAWA, refer to following URL.
http://www.mayekawa.com/about/network/
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. Compressor Specifications and
Structure
Describes the main components of this product, functional
information, specification, and operating limits.
3. Installation
Describes the installation procedure of this product.
4. Compressor and Package Unit
Operation
Describes the precautions for operating this product.
5. Maintenance and Inspection
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 Exploded views and parts list.

2201Q4JE-MY-C9-N_2018.01.
Table of Contents
Compound 2-stage Screw Compressor 4032**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 of This Manual..............................................................................................ⅳ
Table of Contents................................................................................................... ⅴ
Chapter 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 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 of Motor Main Power and Control Power
(with Lockout/Tagout Mechanism) ......................................................................1-6
1.4.3 Compressor Protective Devices.......................................................................... 1-7
Chapter 2 Compressor Specifications and Structure
2.1 Overview of 4032**C..................................................................2-1
2.2 Model Designation of the Compressor ...................................................2-1
2.3 Compressor Specifications ........................................................................2-2
2.3.1 Specifications.......................................................................................................2-2
2.3.2 Operation Limits................................................................................................... 2-3
2.3.3 Outer Dimensions................................................................................................ 2-4
2.4 Compressor Structure.................................................................................2-8

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Compound 2-stage Screw Compressor 4032**C vi
2.5 Mechanisms .................................................................................................2-9
2.5.1 Basics of the Screw Compressor ........................................................................2-9
2.5.2 Suction Process...................................................................................................2-9
2.5.3 Compression Process........................................................................................2-10
2.5.4 Discharge Process............................................................................................. 2-10
2.5.5 About Volume Ratio (Vi).................................................................................... 2-10
2.5.6 Capacity Control Mechanism.............................................................................2-12
2.5.7 Bearing and Balance Piston ..............................................................................2-12
2.5.8 Shaft Seal .......................................................................................................... 2-12
2.6 Gas and Oil Flow........................................................................................2-13
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 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 the 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
Chapter 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 Change of Lubricating Oil Brand ......................................................................... 4-1
4.1.3 Precautions for Handling lubricating Oil.............................................................. 4-2
4.1.3.1 Precautions for Handling Polyalkylene Glycol (PAG).................................. 4-2
4.1.3.2 Precautions for Handling Polyolester (POE) Oil.......................................... 4-2
4.1.4 Lubricating Oil Management Criteria................................................................... 4-3
4.1.5 Lubricating Oil Replacement Timing.................................................................... 4-4
4.1.5.1 After Starting the Initial Operation ...............................................................4-4
4.1.5.2 During Normal Operation.............................................................................4-4
4.2 Precautions for Operation...........................................................................4-5
4.2.1 Prevention of Liquid Flow-back Operation........................................................... 4-5
4.2.2 Purging of Non-Condensable Gases...................................................................4-5
4.3 When Stopping the Compressor for a Long Time ....................................4-6

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Table of Contents
Compound 2-stage Screw Compressor 4032**C vii
Chapter 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 Workplace ..................................................................... 5-7
5.3.2 Replacement Parts..............................................................................................5-7
5.3.3 Refrigerant Gas Recovery................................................................................. 5-10
5.3.4 Removal of Connections to the Package Unit................................................... 5-11
5.3.5 Removal and Lifting the Compressor................................................................5-12
5.4 Disassembly and Inspection.....................................................................5-13
5.4.1 Unloader Indicator ............................................................................................. 5-14
5.4.1.1 Disassembly..............................................................................................5-15
5.4.1.2 Inspection..................................................................................................5-15
5.4.2 Unloader Cover.................................................................................................. 5-16
5.4.2.1 Disassembly..............................................................................................5-16
5.4.2.2 Inspection..................................................................................................5-17
5.4.3 Unloader Piston and Unloader Cylinder............................................................5-18
5.4.3.1 Disassembly..............................................................................................5-18
5.4.3.2 Inspection..................................................................................................5-19
5.4.4 Shaft Seal Block ................................................................................................5-20
5.4.4.1 Disassembly..............................................................................................5-20
5.4.4.2 Inspection..................................................................................................5-20
5.4.5 Bearing Cover....................................................................................................5-21
5.4.5.1 Disassembly..............................................................................................5-21
5.4.6 Separating High-stage and Low-stage Blocks...................................................5-22
5.4.6.1 Disassembly..............................................................................................5-22
5.4.7 Gear Coupling....................................................................................................5-22
5.4.7.1 Disassembly..............................................................................................5-22
5.4.7.2 Inspection..................................................................................................5-22
5.4.8 Balance Piston...................................................................................................5-23
5.4.8.1 Disassembly..............................................................................................5-23
5.4.8.2 Inspection..................................................................................................5-23
5.4.9 Low-stage Suction Cover and Side Bearings.................................................... 5-24
5.4.9.1 Disassembly..............................................................................................5-24
5.4.9.2 Inspection..................................................................................................5-25
5.4.10 High-stage Suction Cover and Side Bearings...................................................5-26
5.4.10.1 Disassembly..............................................................................................5-26
5.4.10.2 Inspection.................................................................................................. 5-26
5.4.11 Thrust Bearing Block .........................................................................................5-27
5.4.11.1 Disassembly of the High-stage Thrust Bearing Block...............................5-27
5.4.11.2 Disassembly of the Low-stage Thrust Bearing Block................................5-28
5.4.11.3 Inspection..................................................................................................5-28

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Compound 2-stage Screw Compressor 4032**C viii
5.4.12 Rotors and Main Rotor Casing (Low-stage/High-stage)....................................5-30
5.4.12.1 Disassembly..............................................................................................5-30
5.4.12.2 Inspection.................................................................................................. 5-30
5.4.13 High-stage Bearing Head and Main Bearings...................................................5-31
5.4.13.1 Disassembly..............................................................................................5-31
5.4.13.2 Inspection.................................................................................................. 5-31
5.4.14 Low-stage Bearing Head and Main Bearings....................................................5-32
5.4.14.1 Disassembly..............................................................................................5-32
5.4.14.2 Inspection.................................................................................................. 5-32
5.5 Reassembly................................................................................................5-33
5.5.1 Unloader Slide Valve......................................................................................... 5-35
5.5.2 Bearing Head and Main Bearings......................................................................5-36
5.5.3 Bearing Head and Rotor Casing........................................................................5-37
5.5.4 Installing the Rotors........................................................................................... 5-39
5.5.5 Suction Cover and Side Bearings......................................................................5-40
5.5.6 Installing the Suction Cover............................................................................... 5-41
5.5.7 Balance Piston and Balance Piston Sleeve.......................................................5-42
5.5.8 Thrust Bearing Block .........................................................................................5-43
5.5.8.1 High-stage Block .......................................................................................5-44
5.5.8.2 Low-stage Block........................................................................................ 5-45
5.5.8.3 End Clearance Measurement....................................................................5-46
5.5.8.4 End Clearance Adjustment Procedure......................................................5-47
5.5.8.5 Tightening after Finishing the End Clearance Adjustment ........................5-47
5.5.9 Balance Piston Cover and High-stage Unloader Cylinder.................................5-48
5.5.10 Bearing Cover....................................................................................................5-49
5.5.11 Shaft Seal Block ................................................................................................5-49
5.5.12 Low-stage Unloader Cylinder............................................................................5-50
5.5.13 Unloader Cover.................................................................................................. 5-51
5.5.14 Coupling the High-stage and Low-stage Blocks................................................ 5-52
5.5.15 Unloader Indicator ............................................................................................. 5-53
5.5.15.1 Potentiometer............................................................................................5-53
5.5.15.2 Micro-switches and Micro-switch Cam......................................................5-54
5.5.15.3 Reassembly...............................................................................................5-54

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Table of Contents
Compound 2-stage Screw Compressor 4032**C ix
Chapter 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
Chapter 7 Related Documents
7.1 Exploded Views, Assembly Sectional Views ............................................7-1
7.2 Parts Configuration Table...........................................................................7-6
7.3 Tightening Torques for Bolts and Nuts...................................................7-13
7.4 About the O-rings Used.............................................................................7-15
7.4.1 List of O-rings Used........................................................................................... 7-15
7.4.2 O-ring Materials Used for Screw Compressor................................................... 7-15
7.5 Tools for Disassembly...............................................................................7-16
Contact Information
Sales 0ffices/Service Centers ..................................................................... Contact-1
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