mycom J Series User manual

2205B0JE-DA-J-N_2014.05.
3–14–15 Botan Koto-ku, Tokyo 135-8482, Japan
Screw Compressor
J-Series Instruction Manual
170JS-V/170JM-V/170JL-V
220JS-V/220JM-V/220JL-V
280JS-V/280JM-V/280JL-V
CAUTION
Before operating, maintaining, or inspecting this product, read the manual thoroughly and fully
understand the contents.
Keep the operation manual in a safe, designated place for future reference whenever the need
arises.
Specifications of this product are subject to change without prior notice.

2205B0JE-DA-J-N_2014.05.
Preface
Screw Compressor J-series
i
Preface
Thank you for purchasing this J-series/screw compressor (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.
170JS, 170JM, 170JL, 220JS, 220JM, 220JL, 280JS, 280JM, 280JL
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
Instruction manual name Document No. First edition issue date
J-Series Instruction manual 2205B0JE-DA-J-N_2014.05. 2009.10.01
Revision
No. Issuance Date Contents of revisions Created/ approved by:
17J0001 2010.03.15 Corrected editing error of Vi Position Sensor. Kobayashi
17J0002 2012.01.31 Addition of 220J/280J-series Kobayashi / Muta
03 2014.03.27 Revision by lubricating method change, other Muta/ Hirao
04 2014.04.25 Replaced Figure 2-1, changed the unit of motor
rotation speed to SI-unit Ikehara / Muta
05 2014.05.21 Corrected the description shortage of oil
filter requirements at Section 3.2.5.3 Ikehara/ Kubota

2205B0JE-DA-J-N_2014.05.
Warranty and Disclaimer
Screw Compressor J-series
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Warranty and Disclaimer
Warranty Clauses
If malfunctions or damages occur under proper usage and conditions following documents such as
specifications or instruction manual of this product, or, if MAYEKAWA judges that malfunctions or
damages are related to design or manufacture of the product, and if the malfunctions or damages are
within the warranty period, we will repair or replace the product without any charges.
The warranty period is “12 months from factory shipment of this product”. If use of this product is
governed by any other contracts, they will be given priority.
Disclaimer Clauses (Exclusion of Warranty Clauses)
Please note that we disclaim any responsibility for damage or malfunction to this product, as described
in the following items.
Malfunction or damage of this product caused by natural disaster, or other accidental forces
(such as windstorm, intense rainfall, flood, tidal wave, earthquake, land subsidence,
thunderbolt, fire, etc.).
Malfunction, damage, or defect to this product due to abnormal or improper use (such as
storing this product outdoors or in locations subject to high temperatures and high humidity,
unexpected inspections, tests, operations, and excessive repetition of start-up/stoppage of the
product.).
Malfunction or damage caused by devices or equipment not provided by MAYEKAWA including
operation control methods of those devices.
Malfunction or damage caused by refrigerants, gases, or lubricants 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 MAYEKAWA genuine.
Malfunction or damage caused by remodeling the product without the approval of MAYEKAWA.
Direct or indirect production warranty or all other related warranties that arose due to
malfunction or damage of this product.

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Important Information
Screw Compressor J-series
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 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.
There are guidelines that must be observed for operating this product. However, the warnings in this
manual and safety labels on the product are not all inclusive. 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 the product 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 hazards involved
and measures to avoid danger.
Do not allow any person other than those educated on 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 the parts with the 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 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.

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Important Information
Screw Compressor J-series
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 equipments 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, cold storage, and air conditioning 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 your
sales offices or service centers.
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 place a purchase order to your local sales office
or service center for a new manual. Using the product without the manual may result in safety
issues.
If you resell the product, never fail to attach this manual to the product.
Construction of This Manual
Title of section and
chapter Description details
Preface Describes the outline of this manual and how to read the manual.
Warranty and Disclaimer Describes clauses and coverage of warranty.
Exemption of warranty clauses is described 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 work safety required
for handling the product.
2. Structure and Specifications
of the Compressor Describes the main components of this product, functional information, specifications, and operating limits.
3. Installation Describes installation procedure of this product.
4. Compressor and Package
Operation Describes precautions for operating this product.
5. Maintenance and Inspection Describes sections and period for inspecting, disassembly and
assembly of the product.
6. Troubleshooting Describes troubleshooting methods for the product in case
problems occur during operation of the product.
7. Related Documents Describes documents such as illustrated parts breakdown and
parts list.
Appendix Describes tips for design, manufacturing, and installation of the
compressor package.
Contact Information Describes contact information for our local sales offices or service
centers, which are for ordering genuine parts.

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Table of Contents
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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 Observation/Prevention ..............................................................................1-1
1.1.1 Observance (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 .................................. 1-2
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 Situation.................................................. 1-2
1.1.1.7 Do's about Waste Oil, Fluid, and Materials .................................................1-2
1.1.1.8 Other Do's.................................................................................................... 1-3
1.1.2 Prohibition (Don'ts)...........................................................................................1-3
1.2 Warnings.......................................................................................................1-4
1.2.1 Types and Meanings of Warnings.................................................................... 1-4
1.2.2 Safety labels..................................................................................................... 1-4
1.3 Residual Risks .............................................................................................1-7
1.4 Safety Devices............................................................................................1-10
1.4.1 Emergency Stop Button..................................................................................1-10
1.4.2 Breakers of Main Motor Power and Control Power
(Use of Lockout/Tagout Devices)...................................................................1-10
1.4.3 Compressor Protection Devices.....................................................................1-11
2 Structure and Specifications of the Compressor
2.1 Features of the J-Series Screw Compressor.............................................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................................................................................................2-5
2.3.3 Outer Dimensions............................................................................................. 2-7
2.4 Structure of the Compressor....................................................................2-14
2.4.1 Sectional View................................................................................................ 2-15

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2.5 Mechanisms ...............................................................................................2-24
2.5.1 Basics of the Screw Compressor ...................................................................2-24
2.5.2 Suction Process.............................................................................................. 2-25
2.5.3 Compression Process ....................................................................................2-25
2.5.4 Discharge Process..........................................................................................2-25
2.6 Oil Flow.......................................................................................................2-26
2.7 Capacity Control Characteristics .............................................................2-27
2.8 Variable Vi Control.....................................................................................2-28
2.8.1 Vi (Internal Volume Ratio) ..............................................................................2-28
2.8.2 Reasons for Adjusting Vi According to Operating Conditions........................2-29
2.8.3 Details of Variable Vi Mechanism................................................................... 2-29
2.8.3.1 Automatic Variable Vi Mode ......................................................................2-29
2.8.3.2 Fixed Vi Mode............................................................................................2-30
2.8.4 Vi Position Sensor .......................................................................................... 2-30
2.9 Solenoid Valve ...........................................................................................2-31
2.9.1 170J/220J-series ............................................................................................ 2-31
2.9.2 Explosion Proof for 170j/220J-series, Also 280J-series.................................2-33
3 Installation
3.1 Precautions for Installation.........................................................................3-1
3.2 Installation Work..........................................................................................3-2
3.2.1 Unpacking.........................................................................................................3-2
3.2.2 Storage.............................................................................................................3-2
3.2.3 Transfer ............................................................................................................3-2
3.2.4 Preparation for Installation................................................................................ 3-3
3.2.5 Installation......................................................................................................... 3-4
3.2.5.1 Installation....................................................................................................3-4
3.2.5.2 Piping...........................................................................................................3-5
3.2.5.3 Equipment and Devices for Protection of the Compressor......................... 3-6
3.2.6 Pressure Test (Leak Test)................................................................................ 3-7
3.2.7 Lubricant(Refrigerant Oil) Charge ....................................................................3-7
3.2.7.1 Initial Charge of Lubricant............................................................................3-7
3.2.7.2 Additional Charge of Lubricant Procedure ..................................................3-8
3.2.8 Charging of Refrigerant.................................................................................... 3-8
3.2.9 Check after Installation.....................................................................................3-8
3.3 Documents Related to Installation.............................................................3-9
4 Compressor and Package Operation
4.1 Adjustment before Test Operation.............................................................4-1
4.1.1 Adjustment of Unloader Slide Valve and Variable Vi Slide Valve.................... 4-1
4.2 Lubricant (Refrigerant Oil) ..........................................................................4-2
4.2.1 Precautions for Selecting the Lubricant............................................................ 4-2
4.2.2 Recommended Lubricant .................................................................................4-2
4.2.3 Change of Lubricant Brand...............................................................................4-4
4.2.4 Precautions for Handling Lubricant .................................................................. 4-4
4.2.4.1 Precautions for Handling Polyalkylene Glycol (PAG)..................................4-4

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4.2.4.2 Precautions for Handling Polyolester (POE) Oil.......................................... 4-5
4.3 Precautions for Operation...........................................................................4-6
4.3.1 Prevention of Liquid Return (Liquid Backflow) Operation.................................4-6
4.3.2 Purging of Non-condensable Gases.................................................................4-6
4.4 Action for Stopping the Compressor for Long Period of Time ...............4-7
5 Maintenance and Inspection
5.1 Precautions for Maintenance and Inspection............................................5-1
5.2 Maintenance List..........................................................................................5-2
5.2.1 Daily Management............................................................................................5-2
5.2.2 Periodical Inspection......................................................................................... 5-5
5.2.3 Guidelines for Compressor Overhaul Frequency.............................................5-6
5.2.4 Replacement Parts of the Compressor in Overhauling.................................... 5-7
5.3 Management of Lubricant .........................................................................5-18
5.3.1 Lubricant Management Standard...................................................................5-18
5.3.2 Replacement Interval for Lubricant.................................................................5-19
5.3.2.1 First system startup...................................................................................5-19
5.3.2.2 During normal operation............................................................................ 5-19
5.4 Disassembly and Assembly of the Compressor.....................................5-20
5.4.1 Tools for Disassembly and Work Place..........................................................5-20
5.4.2 Replacement Parts.........................................................................................5-20
5.4.3 Recovering the Refrigerant.............................................................................5-20
5.4.4 Removing the Compressor.............................................................................5-21
5.4.5 Removing Oil from Inside the Compressor ....................................................5-22
5.4.6 Common Work Items...................................................................................... 5-23
5.4.7 Vi Position Sensor .......................................................................................... 5-25
5.4.7.1 Common Precautions for Removal/Installation.........................................5-26
5.4.7.2 Precautions for Removal...........................................................................5-26
5.4.7.3 Precautions for Installation........................................................................ 5-26
5.4.8 Seal Cover......................................................................................................5-27
5.4.8.1 Common Precautions for Removal/Installation.........................................5-29
5.4.8.2 Precautions for Removal...........................................................................5-29
5.4.8.3 Precautions for Installation........................................................................ 5-30
5.4.9 Bearing Cover................................................................................................. 5-31
5.4.9.1 Common Precautions for Removal/Installation.........................................5-32
5.4.9.2 Precautions for Removal...........................................................................5-32
5.4.9.3 Precautions for Installation........................................................................ 5-33
5.4.10 Unloader Indicator/Capacity Control Solenoid Valve ..................................... 5-34
5.4.10.1 Precautions for Removal...........................................................................5-35
5.4.10.2 Precautions for Installation........................................................................5-35
5.4.11 Unloader Cover...............................................................................................5-36
5.4.11.1 Common Precautions for Removal/Installation.........................................5-38
5.4.11.2 Precautions for Removal........................................................................... 5-38
5.4.11.3 Precautions for Installation........................................................................5-39
5.4.12 Unloader Cylinder...........................................................................................5-42
5.4.12.1 Common Precautions for Removal/Installation.........................................5-43
5.4.12.2 Precautions for Removal...........................................................................5-43

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5.4.12.3 Precautions for Installation........................................................................5-44
5.4.13 Vi Cylinder ......................................................................................................5-45
5.4.13.1 Common Precautions for Removal/Installation.........................................5-47
5.4.13.2 Precautions for Removal...........................................................................5-47
5.4.13.3 Precautions for Installation........................................................................5-47
5.4.14 Balance Piston Cover.....................................................................................5-48
5.4.14.1 Common Precautions for Removal/Installation.........................................5-49
5.4.14.2 Precautions for Removal...........................................................................5-49
5.4.14.3 Precautions for Installation........................................................................5-49
5.4.15 Suction Cover.................................................................................................5-50
5.4.15.1 Common Precautions for Removal/Installation.........................................5-52
5.4.15.2 Preparation for Suction Adapter Removal.................................................5-52
5.4.15.3 Precautions for Removal...........................................................................5-52
5.4.15.4 Precautions for Installation........................................................................5-53
5.4.16 Thrust Bearings ..............................................................................................5-54
5.4.16.1 Precautions for Removal...........................................................................5-56
5.4.16.2 Precautions for Installation........................................................................5-56
5.4.17 Separation of Suction Cover and Main Rotor Casing.....................................5-58
5.4.17.1 Common Precautions for Removal/Installation.........................................5-59
5.4.17.2 Precautions for Removal...........................................................................5-59
5.4.17.3 Precautions for Installation........................................................................5-59
5.4.18 Suction Cover.................................................................................................5-60
5.4.18.1 Common Precautions for Removal/Installation.........................................5-60
5.4.18.2 Precautions for Removal...........................................................................5-61
5.4.18.3 Precautions for Installation........................................................................5-61
5.4.19 Rotors.............................................................................................................5-62
5.4.19.1 Common Precautions for Removal/Installation.........................................5-63
5.4.19.2 Precautions for Removal...........................................................................5-63
5.4.19.3 Precautions for Installation........................................................................5-64
5.4.20 Separation of Bearing Head and Main Rotor Casing.....................................5-65
5.4.20.1 Precautions for Removal...........................................................................5-66
5.4.20.2 Lifting of Bearing Head.............................................................................. 5-66
5.4.20.3 Lifting of Main Rotor Casing......................................................................5-66
5.4.20.4 Precautions for Installation........................................................................5-65
5.4.21 Bearing Head..................................................................................................5-67
5.4.21.1 Common Precautions for Removal/Installation.........................................5-67
5.4.21.2 Precautions for Removal...........................................................................5-68
5.4.21.3 Precautions for Installation........................................................................5-68
5.4.22 Suction Adapter (except for 280J)..................................................................5-69
5.4.22.1 Common Precautions for Removal/Installation.........................................5-70
5.4.22.2 Precautions for Removal...........................................................................5-71
5.4.22.3 Precautions for Installation........................................................................5-71
5.4.23 Unloader Slide Valve Guide ...........................................................................5-72
5.4.24 Adjustment of End Clearance......................................................................... 5-73
5.4.25 Inspection for Runout Male Rotor Shaft .........................................................5-75
5.4.26 Inspection for Runout of Seal Cover Mount Face (Bearing Cover)................ 5-75
6 Troubleshooting
Table 6.1 Troubleshooting .............................................................................................. 6-1

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7 Related Documents
7.1 Development View and Configuration Table of the Parts........................7-1
7.2 List of Tightening Torques for Bolts and Nuts........................................7-22
7.3 List of Tools for Disassembly...................................................................7-27
7.4 Design Modification Notification (follow-up)...........................................7-28
Appendix 1 Tips for Design, Manufacturing, and Installation of
the Compressor Package
Appendix 1.1 Precautions for Design of
the Compressor Package........................................... Appendix 1-1
Appendix 1.2 Tips for Compressor Package Manufacturing.......... Appendix 1-6
Appendix 1.3 Tips for Compressor Package Installation ............... Appendix 1-6
Contact Information