mycom i125S User manual

2200M4JE-HO-iS2-N_2014.04.
i-Series Screw Compressor
Instruction Manual i125S / i125L
i160S / i160M / i160L
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 is subject to change without prior notice.
This manual is applied to each compressor after the serial number
shown below.
i125S: 8750303 i125L: 8770301
i160S: 8710055 i160M: 8720018 i160L: 8730030

2200M4JE-DA-iS2-N_2014.04.
Preface
Screw Compressor i-series i
Preface
Thank you for purchasing our i-series screw compressor (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.
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
i-Series Screw Compressor
Instruction manual 2200M4JE-DA-iS2-N_2014.04. April 28, 2014
Revision
No. Issue Date Contents of revisions (modified clause, page, and details) Created/ approved by:
00 April 28, 2014 Newly issued as applicable to the product after May
2014, due to modification of the i-series specifications. Kawamoto
/ Ikeda, Hirao

2200M4JE-DA-iS2-N_2014.04.
Warranty and Disclaimer
Screw Compressor i-series 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)
Please note that we disclaim any responsibility for damage or malfunction to this product, as described
in the following items.
Any failure or damage caused by an act of God including, but not limited to, windstorm, heavy
rain, flood, high tide, earthquake, subsidence of ground, lightning strike, fire, etc.
Malfunctions, damage, or degradation due to misuse or unacceptable use of the product
(including improperly storing the product outdoors or under too hot/humid conditions,
excessively frequent liquid flow-back operation, extremely frequent start-stop cycles, etc.).
Any failure or damage caused by other systems or devices not supplied by MAYEKAWA
including operation control methods of them.
Any failure or damage caused by the use of any refrigerant (or gas) or lubricant not applicable
to this product.
Any failure or damage caused by the performance of maintenance or inspection procedures
not recommended by MAYEKAWA.
Any failure or damage caused by the use of any other than the genuine parts of MAYEKAWA.
Any failure or damage caused by any conversion or modification of the product other than as
instructed by MAYEKAWA.
Direct or indirect production warranty or all other related warranties that arose due to a failure
or damage of this product.

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Important Information
Screw Compressor i-series 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 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 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.

2200M4JE-DA-iS2-N_2014.04.
Important Information
Screw Compressor i-series iv
[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.
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.
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 to one of our local sales offices or
service centers for a new manual. Using this product without the manual may result in safety
issues.
When you resell this product, be sure to transfer this manual to the next owner.


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Important Information
Screw Compressor i-series v
Structure of This Manual
Chapter/Section Title Description
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 Mechanisms Describes the main components of this product, functional information, specification, operating limits, drawings, and parts list.
3. Installation Describes the installation procedure of this product.
4. Operation of Compressor
and the Package 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 List of disassembly tools for i-series compressor, and other information
Appendix : Packaging Points Describes basic points for the design and manufacture of compressor
package unit.
Contact Information Describes contact information for our local sales offices or service
centers, which are for ordering genuine parts.

2200M4JE-DA-iS2-N_2014.04.
Table of Contents
Screw Compressor i-series vi
Table of Contents
Preface ････････････････････････････････････････････････････････ⅰ
Revision History ･･････････････････････････････････････････････････････････････ⅰ
Warranty and Disclaimer･･･････････････････････････････････････ⅱ
Warranty Clauses................................................................................................... ⅱ
Disclaimer Clauses (Exclusion of Warranty Clauses) ........................................ 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................................................................................. ⅴ
Table of Contents･･･････････････････････････････････････････････ⅵ
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 Specification of Compressor
2.1 Features of i-Series Compressor.........................................2-1
2.2 Model Designation of the Compressor......................................................2-1

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Screw Compressor i-series vii
2.3 Compressor Specifications ........................................................................2-2
2.3.1 Specifications.......................................................................................................2-2
2.3.2 Operation Limits................................................................................................... 2-3
2.3.3 Alarm Set Values................................................................................................. 2-4
2.3.4 Outer Dimensions................................................................................................ 2-5
2.4 Configuration of Compressor...................................................................2-10
2.4.1 Sectional View...................................................................................................2-10
2.4.2 Development View of Parts ............................................................................... 2-16
2.4.3 Parts Configuration Table.................................................................................. 2-18
2.5 Mechanisms ...............................................................................................2-24
2.5.1 Basics of the Screw Compressor ......................................................................2-24
2.5.2 Suction Process.................................................................................................2-24
2.5.3 Compression Process........................................................................................2-25
2.5.4 Discharge Process............................................................................................. 2-25
2.5.5 About Volume Ratio (Vi)....................................................................................2-25
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...................................................................................3-3
3.2.5 Installation............................................................................................................3-3
3.2.5.1 Piping Connection .......................................................................................3-3
3.2.5.2 Equipment and Devices for Protection of the Compressor.........................3-3
3.2.6 Airtightness Test..................................................................................................3-4
3.2.7 Lubricant Charge................................................................................................. 3-4
3.2.7.1 Initial Charge of Lubricant............................................................................3-4
3.2.7.2 Additional Charge of Lubricant....................................................................3-5
3.2.8 Charge of Refrigerant.......................................................................................... 3-5
3.2.9 Check after Installation........................................................................................3-5
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...................................................................................4-2
4.1.2.1 Recommended Lubricants forAmmonia Refrigerant .................................. 4-2
4.1.2.2 Oils for Systems Using HFC Refrigerants...................................................4-3
4.1.3 Change of Lubricant Brand..................................................................................4-3
4.1.4 Precautions for Handling Lubricant .....................................................................4-3
4.2 Precautions for Operation...........................................................................4-4
4.2.1 Prevention of Liquid Flow-back ...........................................................................4-4

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Screw Compressor i-series viii
4.2.2 Purging of Non-Condensable Gases...................................................................4-4
4.2.3 Action for Stopping the Compressor for Long Period of Time.............................4-5
Chapter 5 Maintenance and Inspection
5.1 Precautions for Maintenance and Inspection............................................5-1
5.2 Maintenance and Inspection 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................................................5-5
5.3 Management of Lubricant ...........................................................................5-6
5.3.1 Lubricant Management Criteria ........................................................................... 5-6
5.3.2 Lubricant Replacement Frequency......................................................................5-6
5.4 Compressor Disassembly Preparation......................................................5-7
5.4.1 Tools for Disassembly .........................................................................................5-7
5.4.2 Replacement Parts..............................................................................................5-8
5.4.3 Refrigerant Gas Treatment.................................................................................. 5-8
5.4.3.1 Valves Used.................................................................................................5-8
5.4.3.2 Refrigerant Gas Recovery...........................................................................5-8
5.4.4 Removing Parts Connected to the Unit............................................................... 5-9
5.4.5 Removing and Lifting the Compressor.............................................................. 5-10
5.4.6 Removing Oil from Compressor........................................................................5-10
5.5 Disassembly and Inspection.....................................................................5-11
5.5.1 Mechanical seal................................................................................................. 5-11
5.5.1.1 Disassembly...............................................................................................5-11
5.5.1.2 Inspection .................................................................................................. 5-12
5.5.2 Bearing Cover....................................................................................................5-13
5.5.2.1 Disassembly..............................................................................................5-13
5.5.2.2 Inspection...................................................................................................5-13
5.5.3 Balance Piston...................................................................................................5-14
5.5.3.1 Disassembly..............................................................................................5-14
5.5.3.2 Inspection .................................................................................................. 5-14
5.5.4 End Cover..........................................................................................................5-14
5.5.5 Thrust Bearings .................................................................................................5-14
5.5.5.1 Disassembly..............................................................................................5-15
5.5.5.2 Inspection .................................................................................................. 5-15
5.5.6 Bearing Head.....................................................................................................5-16
5.5.6.1 Disassembly..............................................................................................5-16
5.5.6.2 Inspection .................................................................................................. 5-16
5.5.7 Rotors ................................................................................................................5-16
5.5.7.1 Disassembly..............................................................................................5-16
5.5.7.2 Inspection .................................................................................................. 5-16
5.5.8 Radial Bearing...................................................................................................5-17
5.5.8.1 Disassembly..............................................................................................5-17
5.5.8.2 Inspection .................................................................................................. 5-17
5.5.9 Suction Strainer and Check Valve.....................................................................5-17

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Screw Compressor i-series ix
5.5.9.1a Disassembly (i125)....................................................................................5-17
5.5.9.1b Disassembly (i160).................................................................................... 5-17
5.5.9.2 Inspection .................................................................................................. 5-18
5.5.10 Unloader ............................................................................................................ 5-18
5.5.10.1 Disassembly..............................................................................................5-18
5.5.10.2 Inspection .................................................................................................. 5-18
5.6 Reassembly................................................................................................5-19
5.6.1 Unloader ............................................................................................................5-20
5.6.2 Rotor and Inner Ring of Radial Bearing............................................................. 5-20
5.6.3 Bearing Head.....................................................................................................5-21
5.6.4 Outer Ring of Radial Bearing.............................................................................5-21
5.6.5 Suction Strainer and Check Valve.....................................................................5-22
5.6.5.1 i125 Series.................................................................................................5-22
5.6.5.2 i160 Series.................................................................................................5-22
5.6.6 Adjustment of Thrust Bearing and End Clearance............................................5-23
5.6.6.1 End Clearance Measurement....................................................................5-25
5.6.6.2 End Clearance Adjustment........................................................................5-26
5.6.6.3 Tightening after End Clearance Adjustment..............................................5-27
5.6.7 Balance Piston...................................................................................................5-27
5.6.8 Bearing Cover....................................................................................................5-28
5.6.9 Mechanical seal................................................................................................. 5-28
5.6.10 End Cover..........................................................................................................5-31
Chapter 6 Troubleshooting
 Table 6-1 Troubleshooting................................................................................6-1
Chapter 7 Related Documents
7.1 Tightening Angles for Lock Nuts................................................................7-1
7.2 List of Tools for Disassembly of i-Series...................................................7-2
Appendix
Basic Points for Design and Manufacturing of Compressor
Package Unit
Contact Information
HowtoOrder GenuineParts
Sales Offices/Service Centers