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4032MSC
mycom 4032MSC
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2201Q4JE-
MY
-
C9
-N_2018.01.
Chapter 7 Related Documents
Compound 2-stage Screw Compressor 4032
**C
Ex
pl
od
ed
V
ie
ws
7-1
Chapter 7
Related Document
s
7.1
Exploded
Views, Assembly
Sectional Views
Figure 7-
1
4032
**
C
Expl
oded Vie
w
(Lo
w
-st
age)
111
113
Table of Contents
Main Page
Default Chapter
6
Table of Contents
6
Chapter 1 Safety
11
Strict Requirements and Prohibitions
11
Strict Requirements (Do's)
11
Do's on Lockout/Tagout after Shutting off the Power
11
Do's on Maintenance
11
Do's on Operation
11
Do's about Handling Emergency Situations
12
Do's about Handling of Hazardous and Toxic Substances
12
Do's about Personal Protective Gear
12
Do's about Waste Oil, Fluid, and Materials
12
Other Do's
12
Prohibitions (Don'ts)
13
Warnings
13
Residual Risks
14
Safety Devices
16
Emergency Stop Button
16
Breakers of Motor Main Power and Control Power (with Lockout/Tagout Mechanism)
16
Compressor Protective Devices
17
Chapter 2 Compressor Specifications and Structure
19
Overview of 4032**C
19
Model Designation of the Compressor
19
Compressor Specifications
20
Specifications
20
Operation Limits
21
Outer Dimensions
22
Compressor Structure
26
Mechanisms
27
Basics of the Screw Compressor
27
Suction Process
27
About Volume Ratio (VI)
28
Compression Process
28
Discharge Process
28
Bearing and Balance Piston
30
Capacity Control Mechanism
30
Shaft Seal
30
Gas and Oil Flow
31
Chapter 3 Installation
33
General Precautions for Installation
33
Installation Works
33
Unpacking
33
Storage
33
Transportation
33
Preparation for Installation
36
Installation
37
Shaft Alignment between the Compressor and Driving Machine
37
Equipment and Devices for Protection of the Compressor
38
Piping Connection
38
Additional Charge of Lubricating Oil
39
Airtightness Test
39
Charge of Refrigerant
39
Check after Installation
39
Initial Charge of Lubricating Oil
39
Lubricating Oil Charge
39
Chapter 4 Compressor and Package Unit Operation
40
Lubricating Oil (Refrigerant Oil)
40
Precautions for Selecting the Lubricating Oil
40
Change of Lubricating Oil Brand
40
Precautions for Handling Lubricating Oil
41
Precautions for Handling Polyalkylene Glycol (PAG)
41
Precautions for Handling Polyolester (POE) Oil
41
Lubricating Oil Management Criteria
42
After Starting the Initial Operation
43
During Normal Operation
43
Lubricating Oil Replacement Timing
43
Precautions for Operation
44
Prevention of Liquid Flow-Back Operation
44
Purging of Non-Condensable Gases
44
When Stopping the Compressor for a Long Time
45
Chapter 5 Maintenance and Inspection
46
Precautions for Maintenance and Inspection
46
Maintenance and Inspection List
48
Daily Management
48
Periodic Inspection
50
Guidelines for the Timing of Compressor Overhaul
51
Compressor Disassembly Preparation
52
Disassembly Tools and Workplace
52
Replacement Parts
52
Refrigerant Gas Recovery
55
Removal of Connections to the Package Unit
56
Removal and Lifting the Compressor
57
Disassembly and Inspection
58
Unloader Indicator
59
Disassembly
60
Inspection
60
Disassembly
61
Unloader Cover
61
Inspection
62
Disassembly
63
Unloader Piston and Unloader Cylinder
63
Inspection
64
Disassembly
65
Inspection
65
Shaft Seal Block
65
Bearing Cover
66
Disassembly
66
Disassembly
67
Gear Coupling
67
Inspection
67
Separating High-Stage and Low-Stage Blocks
67
Balance Piston
68
Disassembly
68
Inspection
68
Disassembly
69
Low-Stage Suction Cover and Side Bearings
69
Inspection
70
Disassembly
71
High-Stage Suction Cover and Side Bearings
71
Inspection
71
Disassembly of the High-Stage Thrust Bearing Block
72
Thrust Bearing Block
72
Disassembly of the Low-Stage Thrust Bearing Block
73
Inspection
73
Disassembly
75
Inspection
75
Rotors and Main Rotor Casing (Low-Stage/High-Stage)
75
Disassembly
76
High-Stage Bearing Head and Main Bearings
76
Inspection
76
Disassembly
77
Inspection
77
Low-Stage Bearing Head and Main Bearings
77
Reassembly
78
Unloader Slide Valve
80
Bearing Head and Main Bearings
81
Bearing Head and Rotor Casing
82
Installing the Rotors
84
Suction Cover and Side Bearings
85
Installing the Suction Cover
86
Balance Piston and Balance Piston Sleeve
87
Thrust Bearing Block
88
High-Stage Block
89
Low-Stage Block
90
End Clearance Measurement
91
End Clearance Adjustment Procedure
92
Tightening after Finishing the End Clearance Adjustment
92
Balance Piston Cover and High-Stage Unloader Cylinder
93
Bearing Cover
94
Shaft Seal Block
94
Low-Stage Unloader Cylinder
95
Unloader Cover
96
Coupling the High-Stage and Low-Stage Blocks
97
Potentiometer
98
Unloader Indicator
98
Micro-Switches and Micro-Switch Cam
99
Reassembly
99
Chapter 6 Troubleshooting
101
01: Compressor Does Not Start up
101
02: Compressor Stops Immediately after Startup
101
03: Unusually Low Pressure (Decrease of Suction Pressure)
102
04: Low Oil Pressure (Low Lubricating Oil Supply Pressure)
102
05: Intermediate Pressure Is Unusually High
103
06: Unusually High Pressure (Abnormal Discharge Pressure)
104
07: Discharge Temperature Is Abnormally High
105
08: Leak from Mechanical Seal
106
09: Squeaking of Mechanical Seal
107
10: Capacity Control Position Is Indicated Incorrectly
107
11: Capacity Control Malfunction
108
12: Compressor Generates Abnormal Vibration And/Or Sound
109
Chapter 7 Related Documents
112
Exploded Views, Assembly Sectional Views
112
Parts Configuration Table
117
Tightening Torques for Bolts and Nuts
124
About the O-Rings Used
126
List of O-Rings Used
126
O-Ring Materials Used for Screw Compressor
126
Tools for Disassembly
127
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