MYCOM MAYEKAWA 4WBHE (01) PDF MANUAL


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PDF Content Summary: Reciprocating Compressor WBHE Series Operation Manual 4WBHE/6WBHE/8WBHE/8WBHEH 6WBHEU/8WBHEU/8WBHEHU 42WBHE/62WBHE CAUTION Before installing, operating, inspecting, or servicing the compressor, read this manual thoroughly to fully understand the contents. Keep this operation manual in a safe, designated place for future reference whenever the manual is needed. Descriptions in this manual and specification of this compressor are subject to change without notice. 3–14–15 Botan Koto-ku, Tokyo 135-8482, Japan RBT011-00_2008.10. First edition: 2008/10/01 RBT011-00_2008.10. Preface Preface Thank you for having purchased our WBHE series reciprocating compressor (hereinafter indicated as "this compressor"). This operation manual (hereinafter indicated as "this manual") describes safety information, and operational and maintenance procedures in detail for safe and effective use of this compressor. Before installing or using this compressor, make sure to read this manual. Keep this manual in a safe place near the compressor for quick reference. WBHE series is a modified compressor of WBH series. This document describes also about WBH series as a matter of convenience. The production of WBH series is discontinued. The compressor configuration of the applicable WBH series are described below. 4WBH/6WBH/8WBH/8WBHH 6WBHU/8WBHU/8WBHHU 42WBH/62WBH Reciprocating Compressor WBHE Series i RBT011-00_2008.10. Warranty and Disclaimer Warranty and Disclaimer Warranty Clauses If malfunctions occur related to design or manufacture of the product under a normal limitations of use condition following documents such as operation manual of this product, and if it is within the warranty period, we will repair or replace the product. The warranty period is "12 months from factory shipment of this product". If there is an article of agreement, the description written on the agreement takes precedence in principle. Disclaimer Clauses (Exclusion of Warranty Clauses) Please note that we assume no product liability for the following disclaimer clauses for this product. ● Malfunction or damage which has been caused by accidental forces such as natural disasters (windstorm, intense rainfall, flood, tidal wave, earthquake, land sinkage, thunderbolt, fire disaster, etc.) ● Malfunction, damage, or defect of this product which has been subjected to abnormal use, improper use (such as keeping this product outside the building or in locations subject to high temperatures and high humidity, excessive liquid back operation, and repeating start-up/stoppage of the product excessively.) ● Malfunction or damage which has been caused by devices or equipment that is not delivered by us or by operation control method of those devices. ● Malfunction or damage which has been caused by using refrigerant (or gases), lubricant, and use condition (design condition) that are not approved for this product. ● Malfunction or damage which has been caused by performing maintenance and inspection that is not recommended by us. ● Malfunction or damage which has been caused by redesigning this product that has not instructed by Mayekawa/Mycom. ● Malfunction or damage which has been caused by remodeling this product that are not instructed by us. ● Production warranty or any other related warranty of this product. ● Warranty of all human disasters related to the disclaimer clauses above. Reciprocating Compressor WBHE Series ii RBT011-00_2008.10. Important Information Important Information Intended Use of Compressor The WBHE series compressor is a reciprocating compressor for refrigerating, cold storage, and air conditioning systems by using refrigerant. Do not use the compressor for any other purposes that are not intended or departing from the specifications. For the specification of this compressor, refer to "2.2 Specification of Compressor". When performing maintenance described we ask that you use qualified refrigeration personal. Important Information for Safe Use of Compressor MAYEKAWA cannot anticipate all possible hazards including any potential hazards caused by human errors, and hazards due to the environmental conditions where the compressor is used. There are plenty of guidelines that must be observed for operating the compressor the warnings in this manual and safety labels on the compressor are, not all inclusive. When operating this compressor, use extreme caution on required personal safety as well as on the items described in this manual. Listed below are the important rules for safety work with the compressor that apply to all workers including managers and supervisors. Before using this compressor, carefully read and fully understand the contents written in this manual and reliably follow the safety procedures. ● Operation, maintenance, and inspection of this compressor should only be performed by qualified personal educated about the fundamentals of the compressor and trained about the hazards involved and the measures to avoid danger. ● Do not allow any person other than those who are educated about fundamental expertise of the compressor and trained about the hazards involved and the measures to avoid dangers to approach the compressor while it is operating or while performing maintenance. ● Observe all related federal/national and local codes and regulations and instructions of our sales offices, service centers or agencies. ● This compressor may be modified without any prior notice. Therefore, the appearance of actual compressor may slightly differ from the descriptions in this manual. If you have any questions contact your sales offices or service centers. ● To prevent an accident, do not attempt to carry out any operation or maintenance other than those described in this manual, or use the compressor for any unapproved purpose.

● Replace the parts with the genuine parts.

● Every worker including managers and supervisors should actively participate in activities to insure health and safety in the workplace. Observe the following precautions when performing maintenance work on electrical control. ● Electrical maintenance of the compressor must be performed by certified/qualified personal and only those educated about the electrical control of the compressor. ● Before servicing or inspecting the electrical equipment or devices, turn "OFF" the motor main power and control power, and perform lockout/tagout to prevent them from being turned on during the work. Even when the motor main power and control power are turned "OFF", the compressor may be alive if the power is supplied from outside of the refrigeration system, cold storage, and air conditioning systems. In such cases, be sure to shut off the power supply on the power source side, and perform lockout/tagout to prevent the compressor from being turned on during the work. Reciprocating Compressor WBHE Series iii RBT011-00_2008.10. Important Information About This Manual ● This manual is 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. The drawings and technical references including this manual shall not, in whole or part, be copied, photocopied, or reproduced to any electronic medium or machine-readable form without any prior permission from MAYEKAWA. ● The photos or drawings included in this manual may slightly differ from the appearance of actual compressor. ● If this manual is lost or damaged, immediately place a purchase order to your local sales offices or service centers for a new manual. Using the compressor without the manual may result in safety issues. ● If you resell the compressor, never fail to attach this manual to the compressor. ● If there is an article of agreement regarding descriptions in this manual and specification of this compressor, the description written on that agreement takes precedence in principle. ● Descriptions in this manual and specification of this compressor is subject to change without notice. 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 clauses and coverage of warranty. Exclusion of warranty clauses is described as disclaimer. Important Information Describes important information related to the compressor and this manual. 1. Safety Reciprocating Compressor WBHE Series iv Describes safety information for the worker, safety rules for this compressor, and management details regarding the work safety that is required for handling the compressor. 2. Specification and Configuration of Compressor Describes the main components of the compressor, functional information, specification, and operation limits. 3. Installation Describes the installation procedure of the compressor. 4. Operation of the Compressor Describes the precautions for operating the compressor. 5. Maintenance Describes sections and period for inspecting, and disassembly and assembly of this product. 6. Troubleshooting Describes the methods of the compressor in case of problem occurring during operation of the compressor. 7. Related Document Describes supplemental documents such as illustrated parts breakdown and parts list. How to Order Genuine Parts Confirm the applicable parts in "7.1 Development View and Configuration Table of the Parts" of "Chapter 7, Related Document". Then, inform the product name, part number, part name, and required quantity to our sales offices or service centers. RBT011-00_2008.10. Important Information Inquiry If you need further information or have any questions, please contact your local sales offices or service centers. Description Location Telephone and facsimile No. MAYEKAWA MFG. CO., LTD (HEAD OFFICE) Reciprocating Compressor WBHE Series v 3–14–15 BOTAN KOTO-KU, TOKYO 135-8482, JAPAN TEL: (81) 3-3642-8181 FAX: (81) 3–3643-7094 MAYEKAWA MFG. CO., LTD (MORIYA PLANT) 2000, TAYSUZAWA MORIYA–SHI, IBARAKI–PREF., 302–0118, JAPAN TEL: (81) 297–48–1361 FAX: (81) 297–48–5269 NORTH AMERICA MYCOM CANADA LTD. (VANCOUVER OFFICE) UNIT 110, 6620 McMillan WAY, RICHMOND, B.C., V6W 1J7, CANADA TEL: (1) 604-270-1544 FAX: (1) 604-270-9870 MYCOM CANADA LTD. (TORONTO OFFICE) 1745 BONHILL ROAD, UNIT 6 MISSISSAUGA, ON L5T 1C1 TEL: (1) 905-564-0664 FAX: (1) 905-564-7614 MAYEKAWA U.S.A. INC. (HEAD OFFICE) 8750 WEST BRYN MAWR AVENUE, SUITE 190 CHICAGO, IL 60631, U.S.A. TEL: (1) 773-516-5070 FAX: (1) 773-516-5071 MAYEKAWA U.S.A. INC. INDUSTRIAL REFRIGERATION DIVISION (LA OFFICE, PLANT) 19475 GRAMERCY PLACE, TORRANCE, CA 90501, U.S.A. TEL: (1) 310-328-1362 FAX: (1) 310-782-6759 MAYEKAWA U.S.A. INC. INDUSTRIAL REFRIGERATION DIVISION (SEATTLE OFFICE) 19730 64TH AVENUE WEST #302, LYNNWOOD, WA 98036, U.S.A. TEL: (1) 425-977-4285 FAX: (1) 425-944-4359 MAYEKAWA U.S.A. INC. INDUSTRIAL REFRIGERATION DIVISION (MODESTO OFFICE) 4718 Green Leaf Court, Suite 5 Modesto, CA 95356, U.S.A. TEL: (1) 209-545-9752 FAX: (1) 209-545-3654 MAYEKAWA U.S.A. INC. INDUSTRIAL REFRIGERATION DIVISION (NY OFFICE) #210 SUMMIT AVENUE, SUITE C-12 MONTVALE, NEW JERSEY, 07645, U.S.A TEL: (1) 201-307-9189 FAX: (1) 201-307-1566 MAYEKAWA U.S.A. INC. INDUSTRIAL REFRIGERATION DIVISION (MIAMI OFFICE) 1845 NW 112TH AVE., SUITE #206, MIAMI, FL 33172, U.S.A. TEL: (1) 305-477-5741 FAX: (1) 305-477-5681 MAYEKAWA U.S.A. INC. INDUSTRIAL REFRIGERATION DIVISION (CHARLOTTE OFFICE) 15905 BROOKWAY DRIVE UNIT 4208 HUNTERSVILLE, NC 28078, U.S.A. TEL: (1) 704-896-3632 FAX: (1) 704-896-3697 MAYEKAWA U.S.A. INC. INDUSTRIAL REFRIGERATION DIVISION (HUSTON OFFICE) 3222 PASADENA FREEWAY PASADENA, TX 77503, U.S.A TEL: (1) 281-447-2599 FAX: (1) 281-447-6623 MAYEKAWA U.S.A.INC. MANUFACTURING DIVISION 16825 IH 35 NORTH SELMA, TX 78154, U.S.A. TEL: (1) 210-599-4518 FAX: (1) 210-599-1788 MAYEKAWA U.S.A. INC. CHEMICAL PROCESS DIVISION 19475 GRAMERCY PLACE, TORRANCE, CA 90501, U.S.A TEL: (1) 310-328-6279 FAX: (1) 310-328-8487 RBT011-00_2008.10. Important Information Description Location Telephone and facsimile No. EUROPE N.V.MAYEKAWA EUROPE S.A. LEUVENSESTEENWEG 605 1930 ZAVENTEM, BELGIUM Reciprocating Compressor WBHE Series vi TEL: (32) 2-757-9075 FAX: (32) 2-757-9023 N.V. MAYEKAWA EUROPE S.A. ZWEIGNIEDERLASSUNG DEUTSCHLAND NUERNBERGER STRASSE 118, 97076 WUERZBURG, DEUTSCHLAND TEL: (49) 931-359388-0 FAX: (49) 931-359388-20 MAYEKAWA. S.L. CALLE MONTEVIDEO 5,NAVE 13 POL.INDUSTRIAL CAMPORROSO 28806 ALCALA DE HENARES, MADRID, SPAIN TEL: (34) 91-830-0392 FAX: (34) 91-830-0397 MAYEKAWA EUROPE S.A. SUCCURSALE FRANCAISE 9,RUE MICHAEL FARADAY, 78180 MONTIGNY-LE-BRETONNEUX, FRANCE TEL: (33) 1-30-58-26-00 FAX: (33) 1-30-58-19-37 MAYEKAWA MFG. CO., LTD. MOSCOW LIAISON OFFICE 119049, MOSCOW, MYTNAYA ST. HOUSE 3, FLAT 54, RUSSIA TEL: (7) 495-230-01-76 FAX: (7) 495-230-21-12 N.V. MAYEKAWA EUROPE S.A. SWITZERLAND ZUG REPRESENTATIVE OFFICE ZUGERBERGSTRASSE 37, 6300 ZUG, SWITZERLAND TEL: (41) 41-712-1855 FAX: (41) 41-712-1853 ASIA MAYEKAWA AUSTRALIA PTY. LTD. UNIT 2, 44 McCauley Street MATRAVILLE NSW 2036, AUSTRALIA TEL: (61) 2-9695-7000 FAX: (61) 2-9695-7001 P.T.MYCOM INDONESIA GRAHA PRATAMA Building, 9TH Floor JI.M.T.HARYONO Kav.15 Jakarta 12810-INDONESIA TEL: (62) 21-8370-9484 FAX: (62) 21-8370-9483 MAYEKAWA SINGAPORE PTE.LTD. 6 TAGORE LANE SINGAPORE 787470 TEL: (65) 6451-1565 FAX: (65) 6451-4932 MYCOM INDUSTRY CO., LTD. NO.2, SHIN JANN ROAD, CHIEN CHEN DIST., KAOHSIUNG, TAIWAN, 806, REP.OF CHINA TEL: (886) 7-821-0886 FAX: (886) 7-821-4688 MYCOM INDUSTRY CO., LTD. CHEMICAL DEPARTMENT NO.2, SHIN JANN ROAD, CHIEN CHEN DIST., KAOHSIUNG, TAIWAN, 806, REP.OF CHINA TEL: (886) 7-821-7709 FAX: (886) 7-821-9019 MAYEKAWA CHINA INDUSTRIES CO., LTD. ROOM 705, WISE LOGIC INTERNATIONAL NO.66 NORTH SHANXI RD., 200041 SHANGHAI, CHINA TEL: (86) 21-5116-8958 FAX:(86) 21-5116-8928 MAYEKAWA CHINA INDUSTRIES CO., LTD. QINGDAO OFFICE ROOM 503, FULIN BUILDING NO.87 SOUTH FUZHOU ROAD, SOUTH DISTRICT QINGDAO CITY, CHINA 266071 TEL: (86) 532-8602-6169 FAX: (86) 532-8602-6269 MAYEKAWA MFG.CO., LTD SHANGHAI LIAISON OFFICE ROOM 604 DONGHAI PLAZA #3 BUILDING NO.1486 NANJING RD(W). 200040 SHANGHAI, CHINA TEL: (86) 21-6247-2388 FAX: (86) 21-6247-4064 MAYEKAWA (THAILAND) CO., LTD. 2/3 MOO 14,9TH FLOOR BANGNA TOWER BLDG., TOWER A, BANGNA-TRAD RD, K.M.6.5, BANGKAEW BANGPLEE, SAMUTPRAKARN 10540 THAILAND TEL: (66) 2-751-9610 FAX: (66) 2-751-9565 RBT011-00_2008.10. Important Information Description Location Telephone and facsimile No. MAYEKAWA HOLDING 2/3 MOO 14,9TH FLOOR (THAILAND) CO., LTD. BANGNA TOWER BLDG., TOWER A, BANGNA-TRAD RD, K.M.6.5, BANGKAEW BANGPLEE, SAMUTPRAKARN 10540 THAILAND Reciprocating Compressor WBHE Series vii TEL: (66) 2-751-9610 FAX: (66) 2-751-9565 MAYEKAWA MFG.CO., LTD. HO CHI MINH CITY REPRESENTATIVE OFFICE 4FL,OSIC BUILDING No.8, NGUYEN HUE BLVD.DISTRICT 1, HO CHI MINH CITY-VIETNAM TEL: (84) 8-8256917 FAX: (84) 8-8256919 MYCOM KOREA CO., LTD. HEAD OFFICE BUILDING 10F, 40-17 3GA HANGANGRO, YONGSAN-KU SEOUL, 140-880 REP.OF, KOREA TEL: (82) 2-796-1766 FAX: (82) 2-798-7715 MYCOM KOREA CO.,LTD. CHANGWON FACTORY PALYONG DONG 24-20, CHANGWON KYUNGSANGNAM-DO 641847 REP.OF KOREA TEL: (82)55-294-8678 FAX: (82)55-299-7678 MYCOM KOREA CO., LTD. PUSAN BRANCH TONG YOUNG SU SAN 6F, 763-20 KAMCHEON-DONG, SAHA-KU, PUSAN 604-071 REP.OF KOREA TEL: (82) 51-242-3737 FAX: (82) 51-243-8542 MYCOM REFRIGERATION INDIA PVT.LTD. 1ST FLOOR, BALAJI HOUSE, NR. MAHALAXMI HEIGHTS, MUMBAI-PUNE ROAD, PIMPRI, PUNE -411 018 MAHARASHTRA, INDIA TEL: (91) 20-2746-4537 FAX: (91) 20-2746-4539 LATIN AMERICA MYCOM PERU S.A.C. CALLE LUIS PASTEUR 1490, LINCE, LIMA, PERU TEL: (51) 1-441-8552 FAX: (51) 1-222-1543 MAYEKAWA CHILE S.A.C.el. (SANTIAGO OFFICE) CORDILLERA No.331, MODULO D14,FLEX CENTER, PUERTO VESPUCIO, QUILICURA, SANTIAGO, CHILE TEL: (56) 2-739-0202 FAX: (56) 2-739-2700 MAYEKAWA DO BRASIL LTDA. (SAO PAULO) RUA LICATEM 250, JARDIM FAZENDA RINCAO POLO INDUSTRIAL DE ARUJA-SP, BRASIL CEP:07400-000 TEL: (55) 11-4654-8000 FAX: (55) 11-4654-8002 MAYEKAWA DO BRASIL LTDA. (RIO DE JANEIRO BRANCH) AV.LUIS CARLOS PRESTES NO.350, SALA 310 EDIFICIO BARRA TRADE 2, CEP: 22775-050 RIO DE JANEIRO, BRASIL TEL: (55) 21-2430-8882 FAX: (55) 21-2430-8882 MAYEKAWA DO BRASIL LTDA. (MACAE) AV.PAPA JOAO XXIII No.54,VILA TEL: (55) 22-2772-6069 CAOLINA FAX: (55) 22-2759-3112 CASA 22-IMBETIBA CEP: 27913-200 MACAE-RJ, BRASIL MYCOM CENTROAMERICA S.A 350 METROS OESTE DEL SERVICENTRO SHEYZA, SAN ANTONIO DE BELEN, HEREDIA- COSTA RICA TEL: (506) 2293-7656 FAX: (506) 2293-5991 RBT011-00_2008.10. Important Information Description Location Telephone and facsimile No. MYCOM VENEZUELA SALES & SERVICES,C.A. (CARACAS OFFICE) Reciprocating Compressor WBHE Series viii CALLE LOS MANGOS, EDIFICIO SELEMAR PISO 8, SABANA GRANDE CARACAS, VENEZUELA TEL: (58) 212-216-6026 FAX: (58) 212-216-0608 MYCOM VENEZUELA SALES & SERVICE, C.A. (MARACAY OFFICE) AV.INTERCOMUNAL TURMERO, EDF.TECHOMAT METROPOLITANO, PISO 1,OFICINA 3,MARACAY, EDO.ARAGUA, VENEZUELA TEL: (58) 243-269-4913 FAX: (58) 243-269-3952 MAYEKAWA DE MEXICO, S.A.DE C.V. (CUERNAVACA OFFICE) AV.DE LOS 50 MTS.NO.381, CIVAC. JIUTEPEC MORELOS, C.P.62578, MEXICO TEL: (52) 77-73-19-0925 FAX: (52) 77-73-19-0947 MAYEKAWA DE MEXICO, S.A.DE C.V. (MEXICO CITY OFFICE) AV.COYOACAN #945 COL.DEL VALLE DEL.BENITO JUAREZ C.P.03100, MEXICO, D.F. MEXICO TEL: (52) 55-5062-0870 FAX: (52) 55-5062-0898 RBT011-00_2008.10. Revision Description Revision Description Operation manual name Reciprocating Compressor WBHE Series ix WBHE Series Operation Manual Document No. RBT011-00_2008.10. First issue edition date 2008/10/1 Revision No. Issuance Date Contents of revisions (modified clause, page, and details) Created/approved by: RBT011-00_2008.10. Table of Contents Table of Contents Chapter 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 .................................. 1-1 1.1.1.4 Do's about Personal Protective Devices ..................................................... 1-2 1.1.1.5 Strict Do's about Handling of Hazardous and Toxic Substances ................ 1-2 1.1.1.6 Strict Do's about Handling Emergency Situation......................................... 1-2 1.1.1.7 Strict Do's about Waste Oil, Fluid, and Materials ........................................ 1-2 1.1.1.8 Other Strict Do's........................................................................................... 1-2 1.1.2 Prohibition (Don'ts) .............................................................................................. 1-2 1.2 Warnings.......................................................................................................1-3 1.2.1 Types and Meanings of Warnings ....................................................................... 1-3 1.3 Remaining Hazard........................................................................................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 Mechanisms).................................................................. 1-6 1.4.3 Safety Cover (Driving Section) ............................................................................ 1-7 1.4.4 Safety Valve......................................................................................................... 1-8 1.4.5 Automatic Control and Protection Equipment of WBHE Compressor................. 1-9 1.4.6 Water Failure Alarm........................................................................................... 1-11 1.4.7 Oil Heater and Thermometer Switch ................................................................. 1-12 1.5 Example of Material Safety Data Sheet (MSDS) ......................................1-13 Chapter 2 Specification and Configuration of Compressor 2.1 Specification of Compressor ......................................................................2-1 2.1.1 Identification......................................................................................................... 2-1 2.1.1.1 Compressor Configuration........................................................................... 2-1 2.1.1.2 Name Plate.................................................................................................. 2-1 2.1.1.3 Code Designation of WBHE Series............................................................. 2-2 2.1.1.4 Refrigerant and its Cooling Method............................................................. 2-2 2.1.2 Specification ........................................................................................................ 2-3 2.1.2.1 Specification ................................................................................................ 2-3 2.1.2.2 Design Pressure .......................................................................................... 2-4 2.1.3 Operating Limit .................................................................................................... 2-5 2.1.4 External Dimensions............................................................................................ 2-6 2.2 Configuration of Compressor.....................................................................2-8 2.2.1 Updated Contents of Configuration ..................................................................... 2-8 2.2.1.1 Crankcase ................................................................................................... 2-8 2.2.1.2 Shaft Seal .................................................................................................... 2-9 2.2.1.3 Thrust Load Bearing .................................................................................. 2-10 2.2.1.4 Oil Infusing Route of Oil Pump .................................................................. 2-11 2.2.1.5 Piston Rings and Piston ............................................................................ 2-12 Reciprocating Compressor WBHE Series x RBT011-00_2008.10. Table of Contents 2.2.1.6 Discharge Valve Cage and Valve Plate..................................................... 2-13 2.2.1.7 Crankshaft of Single-stage Eight-cylinder Compressor ............................ 2-14 2.2.1.8 Application for 0% Load Operation (Optional Specification) ..................... 2-14 2.2.2 Development View and Parts List...................................................................... 2-15 2.2.3 Modified Parts.................................................................................................... 2-21 2.2.3.1 Modified Parts............................................................................................ 2-21 2.2.3.2 Deleted Parts............................................................................................. 2-21 2.2.4 Cross-Sectional View of Assembly.................................................................... 2-22 2.2.5 Oil Supply Mechanism ....................................................................................... 2-25 2.2.6 Unloader Mechanism......................................................................................... 2-26 2.3 V-Belt and Direct Coupling........................................................................2-27 Chapter 3 Installation 3.1 Safety Precautions for Installation.............................................................3-1 3.2 Installation Works ........................................................................................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................................................................................... 3-4 3.2.5 Installation............................................................................................................ 3-6 3.2.5.1 Installation.................................................................................................... 3-6 3.2.5.2 Position of the Oil Returning Point in the Oil Separator / Procedure of Oil Returning.......................................................................... 3-6 3.2.5.3 Protection Switch......................................................................................... 3-6 3.2.5.4 Centering of the Compressor/Driving Machine and Attachment of the V-belt ....................................................................... 3-7 3.2.5.5 Piping......................................................................................................... 3-10 3.2.5.6 Changing Rotational Direction of Compressor.......................................... 3-13 3.2.5.7 Charging of Lubricating Oils ...................................................................... 3-13 3.2.6 Check after Installation ...................................................................................... 3-13 Chapter 4 Operation of the Compressor 4.1 Lubricating Oils............................................................................................4-1 4.1.1 Precautions for Selecting the Lubricating Oils..................................................... 4-1 4.1.2 Initial Oil Charging Method .................................................................................. 4-2 4.1.3 Replenishment of the Lubricating Oils................................................................. 4-2 4.1.4 Set Oil Pressure................................................................................................... 4-2 4.1.5 Oil Quantity .......................................................................................................... 4-3 4.2 Initial Operation............................................................................................4-4 4.2.1 Initial Operation Method....................................................................................... 4-5 4.3 Capacity Control Order ...............................................................................4-6 4.4 Operation Notices ........................................................................................4-7 4.4.1 Start/Stop Limitation ............................................................................................ 4-7 4.4.2 Settings ................................................................................................................ 4-7 4.4.3 Action for Stopping the Compressor for Long Period of Time............................. 4-8 4.4.4 Operation after the Compressor has been Stopped for Long Period of Time..... 4-9 Reciprocating Compressor WBHE Series xi RBT011-00_2008.10. Table of Contents 4.4.5 Lubricating the Mechanical Seal before Starting Operation................................ 4-9 4.4.5.1 Initial Oil Supply to the Mechanical Seal Sliding Section ............................ 4-9 4.4.5.2 Initial Oil Supply to the Oil Passages in the Compressor (Rotating the Crankshaft) ............................................................................ 4-9 4.4.6 Oil Pressure Regulating Valve........................................................................... 4-10 4.4.7 Starter ................................................................................................................ 4-11 4.4.8 Operation after Replacing Oil Pump.................................................................. 4-11 Chapter 5 Maintenance 5.1 Safety Precautions for Maintenance ..........................................................5-1 5.2 Periodic Inspection......................................................................................5-2 5.2.1 Daily Inspection ................................................................................................... 5-2 5.2.2 Monthly Inspection............................................................................................... 5-3 5.2.3 Biannual Inspection ............................................................................................. 5-3 5.3 Maintenance (Overhaul) ..............................................................................5-4 5.3.1 Maintenance Period and Operation Conditions................................................... 5-4 5.3.2 First Maintenance ................................................................................................ 5-5 5.3.3 Second Maintenance ........................................................................................... 5-5 5.3.4 Third Maintenance ............................................................................................... 5-6 5.4 Lubricating Oils Control Standard .............................................................5-7 5.5 Disassembly.................................................................................................5-8 5.5.1 Requirements for Disassembly............................................................................ 5-9 5.5.1.1 Interruption of All the Power Circuits ........................................................... 5-9 5.5.1.2 Disposal of Refrigerant and Oil from This System ...................................... 5-9 5.5.1.3 Draining of Cooling Water ........................................................................... 5-9 5.5.1.4 Removal of V-belt or Coupling..................................................................... 5-9 5.5.1.5 Ensuring of Proper Tools and Work Space................................................ 5-10 5.5.2 Flow of Work...................................................................................................... 5-11 5.5.2.1 Removal of Cooling Water Piping.............................................................. 5-12 5.5.2.2 Removal of the Head Cover ...................................................................... 5-12 5.5.2.3 Removal of Safety Head Spring ................................................................ 5-13 5.5.2.4 Removal of Discharge Valve ASSY........................................................... 5-14 5.5.2.5 Unloader Device ........................................................................................ 5-16 5.5.2.6 Oil Cooler and Hand Hole Cover............................................................... 5-17 5.5.2.7 Disassembly of the Cylinder ASSY ........................................................... 5-18 5.5.2.8 Cylinder Sleeve ......................................................................................... 5-20 5.5.2.9 Pistons and Connecting Rod..................................................................... 5-20 5.5.2.10 Piston Ring ................................................................................................ 5-21 5.5.2.11 Cover Plate................................................................................................ 5-22 5.5.2.12 Shaft Seal .................................................................................................. 5-23 5.5.2.13 Oil Pump.................................................................................................... 5-24 5.5.2.14 Drag Crank ................................................................................................ 5-24 5.5.2.15 Main Bearing Head.................................................................................... 5-25 5.5.2.16 Main Bearing ............................................................................................. 5-25 5.5.2.17 Crankshaft ................................................................................................. 5-26 5.5.2.18 Thrust Bearing ........................................................................................... 5-27 5.5.2.19 Removal of Strainers ................................................................................. 5-27 Reciprocating Compressor WBHE Series xii RBT011-00_2008.10. Table of Contents 5.6 Assembly....................................................................................................5-31 5.6.1 List of Tightening Bolts ...................................................................................... 5-32 5.6.2 Work Flow.......................................................................................................... 5-33 5.6.2.1 Thrust Bearing ........................................................................................... 5-34 5.6.2.2 Crankshaft ................................................................................................. 5-35 5.6.2.3 Main Bearing and Main Bearing Head ...................................................... 5-36 5.6.2.4 Drag Crank and Oil Pump ......................................................................... 5-37 5.6.2.5 Shaft Seal and Cover Plate ....................................................................... 5-38 5.6.2.6 Assembly of the Cylinder ASSY (Three Ring Specification)...................... 5-41 5.6.2.7 Assembly of the Cylinder ASSY(WBH Series) .......................................... 5-46 5.6.2.8 Mounting of the Cylinder ASSY in Crankcase........................................... 5-50 5.6.2.9 Adjustment of the Unloader Device........................................................... 5-54 5.6.2.10 Valve Plate................................................................................................. 5-55 5.6.2.11 Attachment of Strainers and Hand Hole Covers, Idling............................. 5-57 5.6.2.12 Idling Check............................................................................................... 5-57 5.6.2.13 Head Cover ............................................................................................... 5-59 5.6.2.14 Cooling Water Piping................................................................................. 5-62 5.6.2.15 Final Inspection ......................................................................................... 5-63 Chapter 6 Troubleshooting 6.1 Troubleshooting Table ................................................................................6-1 Chapter 7 Related Document 7.1 Development View and Parts List...............................................................7-1 7.1.1 Compressor Assembly Development View ......................................................... 7-1 7.1.2 Development View of the Cylinder ...................................................................... 7-2 7.1.3 Development View of the Thrust Bearing............................................................ 7-3 7.1.4 Development View of the Main Bearing .............................................................. 7-3 7.1.5 Parts List.............................................................................................................. 7-4 7.2 Specification of Discharge Elbow and Scale Trap....................................7-9 7.3 Specification of Oil Pump .........................................................................7-10 7.4 Specification List of Suction Valve and Discharge Valve ......................7-11 7.4.1 Specification List of Suction Valve..................................................................... 7-11 7.4.2 Specification List of Discharge Valve ................................................................ 7-11 7.5 List of Tightening Torques for Bolts and Nuts........................................7-12 7.6 Part Replacement Standards ....................................................................7-13 7.7 Standard Thrust Gap .................................................................................7-21 Reciprocating Compressor WBHE Series xiii RBT011-00_2008.10. Table of Contents Reciprocating Compressor WBHE Series xiv RBT011-00_2008.10. 1 Safety 1 Safety 1.1 Observation/Prevention 1.1.1 Observance (Do's) 1.1.1.1 Do's on Operation ● Attach safety and protection devices into compressors operation sequence. ● Regularly inspect the safety and protective devices function properly. ● If safety and protective devices do not work properly or the compressor continues to run even during test of these devices, stop the operation! Inform your supervisor of it immediately. ● If the compressor stops for unknown reasons, immediately inform your supervisor of it and obtain his/her approval before restarting the compressor. ● Some refrigerants in use generate bad smell or toxic gases. Make sure to ventilate the air during work. ● The properties of refrigerant and lubricating oils can be corrosiveness, decomposability, and toxicity, insure to obtain the Material Safety Data Sheet (MSDS) and follow its instructions. ● When stopping the operation of this compressor, turn "OFF" the motor (main power), heater power, and control power. Close the suction and discharge side shut-off valves. Follow proper compressor evacuation procedures. 1.1.1.2 Do's on Maintenance ● Before performing the work together with at least one other person, thoroughly confirm each other's work details and acknowledge other worker's movement. ● Always turn OFF and lock out/tag out the motor (main power), control power, and other devices before troubleshooting during operation, and before setup, cleaning, or maintenance and inspection of the compressor. Also, make sure that those powers are NOT turned on accidentally during the works. ● Always confirm that no pressure is applied to the inside of compressor, and refrigerating, cold storage, air conditioning systems before troubleshooting during operation, and before setup, cleaning, or maintenance and inspection of the compressor. ● Some refrigerants in use generate bad smell or toxic gases. Make sure to ventilate the air during work. ● The properties of refrigerant and lubricating oils can be corrosiveness, decomposability, and toxicity, insure to obtain the Material Safety Data Sheet (MSDS) and follow its instructions. ● Return tools to their proper place after use. 1.1.1.3 Do's on Lockout/Tagout after Shutting off the Power ● Install lockout/tagout mechanisms on the main breakers of motor main power and control power. Performing lockout/tagout after shutting off the power is very effective for preventing the compressor being turned on accidentally and causing injury while two or more workers are working on compressor. ● If there are any possibilities of danger during works (especially during cleaning, maintenance and inspection, and troubleshooting), turn "OFF" the motor main power and control power, and perform lockout/tagout. ● It is assumed that workers neglect to shut off the power and perform lockout/tagout in the following situations. Clearly notify the workers of the works which require lockout/tagout and their necessity. It is assumed that workers do not perform lockout/tagout before starting works, because it is troublesome for them to turn "OFF" the motor main power and control power and perform lockout/tagout. It is assumed that workers judge lockout/tagout are not required for safety, and neglect them after turning "OFF" the motor main power and control power. Reciprocating Compressor WBHE Series 1.1 Observation/Prevention 1-1 RBT011-00_2008.10. 1 Safety 1.1.1.4 Do's about Personal Protective Devices ● Prepare and use protective devices complying with the safety standards of the regulations. ● Check the function of each protective device before using. ● Wear designated clothes such as work outfits. ● Do not wear any neckties or jewelry as there is a possibility of being entangled by a movable part or rotating part. Put on a helmet as your hair may get entangled. ● Do not have anything in your pocket to prevent objects from falling into the compressor and refrigerating, cold storage, air conditioning systems. 1.1.1.5 Strict Do's about Handling of Hazardous and Toxic Substances ● Obtain Material Safety Data Sheet (MSDS) from manufacturers of hazardous and toxic substances. ● Check the MSDS and follow the handling instructions recommended by the manufacturers to handle and store those substances. ● An example of Material Safety Data Sheet (MSDS) is provided as a reference at the end of this chapter. 1.1.1.6 Strict Do's about Handling Emergency Situation ● Formulate an emergency action plan complying with the regulations. Post it on a place so that the workers can always see the emergency action plan. 1.1.1.7 Strict Do's about Waste Oil, Fluid, and Materials ● Disposing of refrigerant and oil used for the compressor and refrigerating, cold storage, air conditioning systems. are subject to a number of regulations for the environmental protection purposes. Follow the local, state, federal acts and regulations and your company's rules when disposing of such waste oil, fluid and materials. 1.1.1.8 Other Strict Do's ● Keep the floor clean around the refrigerating, cold storage, and air conditioning systems, and provide a safety aisle. ● During a work, use only the safety aisle to move around the equipment. Keep the safety aisle free from any tools and cleaning fluid. ● If water or oil is spilled on the compressor or the floor, immediately wipe it off to prevent workers from injury caused by slipping. 1.1.2 Prohibition (Don'ts) ● Do not remove or relocate any safety device, including electrical interfaces. ● Do not disable any safety device by short-circuiting or bypassing without any permission. ● Do not leave the compressor unsafe and unattended, by removing a safety cover or some other measures. ● Do not touch, clean, or lubricate any moving part of the compressor. ● Do not touch, clean, or lubricate the compressor during its operation. ● Do not touch relays or electric systems such as terminal block with bare hands when turning on the power. Reciprocating Compressor WBHE Series 1.1 Observation/Prevention 1-2 RBT011-00_2008.10. 1 Safety 1.2 Warnings To alert workers to danger, the following two measures are always provided with the compressor. ● Warnings described in this manual ● Safety labels affixed on the compressor 1.2.1 Types and Meanings of Warnings This manual includes the following four types of warnings to be used for expected hazards during operation and maintenance of the compressor. Neglecting such warnings may cause accidents, resulting in personal injury or even death. Also, the compressor or its auxiliary equipment may be heavily damaged. Therefore, be sure to always observe the instructions of the warnings. Reciprocating Compressor WBHE Series 1.2 Warnings 1-3 Indicates an imminently hazardous situation which, if not avoided, will result in serous injury or death. Indicates a potential hazardous situation which, if not avoided, could result in serous injury or death. Indicates a potential hazardous situation which, if not avoided, may result in minor or moderate injury. Indicates a potentially hazardous situation which, if not avoided, may result in property damage. Emphasizes important items and indicates profitable information. RBT011-00_2008.10. 1 Safety 1.3 Remaining Hazard The following information is provided on the assumption that this compressor is operated, inspected, and maintained while being used in general refrigerating, cold storage, and air conditioning systems. Note that all hazardous sources cannot be predicted for the refrigerating, cold storage, and air conditioning systems you actually use. Devise appropriate countermeasures for hazardous sources in your systems. Table 1-1 Hazardous Sources Hazardous Parts Predicted Hazard Countermeasures in Operation Reciprocating Compressor WBHE Series 1.3 Remaining Hazard 1-4 Countermeasures in Cleaning, Inspection, and Parts Exchange A Driving section • Contact and entanglement in rotational part • Drop-off of moving part • Recovery after interruption of energy supply • Installation of guard and cover • Lockout/tagout of motor main power and control power B Head cover • Damage caused by contacting hot part • Installation of guard • Wearing protective devices • Wearing protective devices • Operation with a temperature of 40 °C or less C Discharge piping • Damage caused by contacting hot part • Installation of guard • Wearing protective devices • Wearing protective devices • Operation with a temperature of 40 °C or less D Unloader solenoid valve • Electric Shock • Installation of guard • Wearing protective devices • Lockout/tagout of control power E Heater • Electric Shock • Burns • Installation of guard and cover • Wearing protective devices • Lockout/tagout of the heater power • Wearing protective devices • Operation with a temperature of 40 °C or less F Suction (side) shut-off valve • Contact with and inhale of toxic substances • Low temperature burns • Wearing protective devices • Sufficient ventilation • Installation of guard • Wearing protective devices • Sufficient ventilation G Discharge (side) shut-off valve • Contact with and inhale of toxic substances • Burns • Wearing protective devices • Sufficient ventilation • Installation of guard • Wearing protective devices • Sufficient ventilation • Operation with a temperature of 40 °C or less H Gas purge valve • Contact with and inhale of toxic substances • Wearing protective devices • Sufficient ventilation • Wearing protective devices • Sufficient ventilation RBT011-00_2008.10. 1 Safety Hazardous Parts Predicted Hazard Countermeasures Operation Reciprocating Compressor WBHE Series 1.3 Remaining Hazard 1-5 in Countermeasures in Cleaning, Inspection, and Parts Exchange I Oil drain • Burns • Contact with toxic substances • Do not contact with it during operation • Wearing protective devices • Operation with a temperature of 40 °C or less J Noise and vibration • Damage caused by noise • Wearing protective devices — Fig. 1-1 Hazardous Sources RBT011-00_2008.10. 1 Safety 1.4 Safety Devices For safe use and protection of the compressor, make sure to attach safety devices to your compressor, complying with the regulations and the following descriptions. To keep safety devices continuously normal, proper and periodical maintenance and inspections are indispensable. They must be performed as an important part of the maintenance/inspection schedule. Provide users of your compressor with necessary information on types, attachment positions, functions, and related devices of the safety devices. ● Check the safety devices after turning on the power and before operation of the compressor. If they do not operate normally, immediately take countermeasures against it. 1.4.1 Emergency Stop Button ∎ Overview/Function/Purpose Used to stop to the compressor immediately if an emergency occurs in the driving section of the compressor. ∎ Installation Positions In the control board on the compressor and in the operation control room ∎ Stop/Restoration Methods Formulate the stop/restoration methods of emergency stop button, and make sure to provide users of this compressor with them. ∎ Inspection Method/Cycle The emergency stop button requires operational test before test operation of compressor and periodically after that. Formulate the inspection method and cycle of emergency stop button, and make sure to provide users of this compressor with necessary information. 1.4.2 Breakers of Motor Main Power and Control Power (with Lockout/Tagout Mechanisms) ∎ Overview/Function/Purpose When a work which may cause hazards (especially during cleaning, maintenance, inspection, and troubleshooting) while the motor main power and control power are turned "OFF", those powers may be turned ON accidentally and cause injury to workers. To prevent this, lockout/tagout mechanisms must be installed on the breakers of motor main power and control power. ∎ Installation Positions Breakers of motor main power and control power ∎ Methods of Performing and Releasing Lockout/Tagout Make sure to formulate methods of performing and releasing lockout/tagout referring to the regulations created by Occupational Safety & Health Administration (OSHA) and other facilities, and provide users of this compressor with necessary information. ∎ Inspection Method/Cycle Make sure to formulate the inspection method and cycle of lockout/tagout mechanisms, and provide users of this compressor with necessary information. Reciprocating Compressor WBHE Series 1.4 Safety Devices 1-6 RBT011-00_2008.10. 1 Safety 1.4.3 Safety Cover (Driving Section) ∎ Overview/Function/Purpose Prevents from contact and entanglement in the driving section of this compressor. ∎ Installation Positions Driving section Reciprocating Compressor WBHE Series 1.4 Safety Devices 1-7 Fig. 1-2 Attachment of Driving Section Safety Cover No. Description No. Description 1 Driving section safety cover (for belt) 2 Driving section safety cover (for coupling) ∎ Inspection Method/Cycle Make sure to formulate the inspection method and cycle of safety cover, and provide users of this compressor with necessary information. RBT011-00_2008.10. 1 Safety 1.4.4 Safety Valve ∎ Overview/Function/Purpose A safety valve is used to prevent the compressor from bursting when its internal pressure rises abnormally. ∎ Installation Positions Install a safety valve on discharge outlet between the shut-off valve (service valve) and the compressor. Set the safety valve so that it operates even when the shut-off valve is closed during operation. Reciprocating Compressor WBHE Series 1.4 Safety Devices 1-8 Fig. 1-3 Attachment Example of Safety Valve No. Description 1 Safety valve ∎ Settings Set the pressure of safety valve to the design pressure of compressor or lower. Make sure to formulate the setting of safety valve, and provide users of this compressor with necessary information. ∎ Inspection Method/Cycle The safety valve requires operational test before test operation of compressor and periodically after that. Formulate the inspection method and cycle of safety valve, and make sure to provide users of this compressor with necessary information. ● Properly process the discharge outlet of safety valve according to the type of refrigerant, following the local, state, federal acts and regulations. If ammonia is discharged into the atmosphere, it highly possibly causes health damage such as intoxication and bad smell. And if it is discharged into enclosed space such as inside of the machine room, it may cause serious accident such as deficiency of oxygen. ● The size of the safety valve required differs as the local, state, federal acts and regulations differ according to the country and regions where the compressor is used. If there are any questions about installing the safety valves, please contact your local sales offices or service centers. RBT011-00_2008.10. 1 Safety 1.4.5 Automatic Control and Protection Equipment of WBHE Compressor ∎ Overview/Function/Purpose ● Oil pressure decrease protection equipment (OP) When the oil pressure in compressor (the deduction of the pressure in crank case from the value on oil pressure gauge (apparent pressure) ) is lowered by deficiency of lubricating oils, clogging of filter, and interfusion of refrigerant, automatically shuts off the motor circuit and stops the operation of compressor. Prevents the sliding section from abnormal friction, and the unloader mechanism from inoperative. ● Abnormal high pressure protection equipment (HP) When the discharge pressure on compressor becomes abnormally high because the compressor is operated incorrectly or the water supply for condenser is cut, shuts off the motor circuit automatically to stop the operation of compressor. Prevents bursting of the devices from occurring. ● Control of the compressor capacity: Low pressure control equipment (LP) The number of capacity control step in the compressor is determined by the number of cylinder. Generally two cylinders are considered as one bank. Therefore, capacity control of four steps is available for eight cylinders, three steps for six cylinders, and two steps for four cylinders. Capacity control is performed by detecting suction pressure. For this detection, the low pressure control switch is used. It automatically controls opening/closing of the solenoid valve connected to the unloader piston in the capacity control mechanism of compressor. ● Automatic control and protection equipment (such as oil temperature or discharge temperature) required for the refrigerating, cold storage, and air conditioning systems you actually use. Reciprocating Compressor WBHE Series 1.4 Safety Devices 1-9 RBT011-00_2008.10. 1 Safety ∎ Connecting Positions Reciprocating Compressor WBHE Series 1.4 Safety Devices 1-10 Fig. 1-4 Connections of Oil Pressure Decrease Protection Equipment (OP)/Abnormal High Pressure Protection Equipment (HP)/Low Pressure Control Equipment (LP) No. Description No. Description

1 Low pressure gauge connection 3/8" × φ 6 (LP/OP) 3 Oil pressure gauge connection 1/4" × φ 6 (OP) 2 High pressure gauge connection 3/8" × φ 6 (HP)

RBT011-00_2008.10. 1 Safety ∎ Settings Referring to the table below, formulate the settings of oil pressure decrease protection equipment (OP)/abnormal high pressure protection equipment (HP)/low pressure control equipment (LP), and make sure to provide users of this compressor with necessary information. Refer to "4.4.2 Settings" for details on setting specification. Table 1-2 Setting Examples Enabled (ON) Disabled (OFF) Timer Recovery Oil pressure decrease Low pressure + Low pressure + protection (OP) 0.10 Mpa 0.12 Mpa Reciprocating Compressor WBHE Series 1.4 Safety Devices 1-11 30 seconds Manual recovery Abnormal high pressure protection (HP) 2.6 MPaG or lower ― None Manual recovery Low pressure control (LP) Depends on refrigerant and system in use Automatic recovery ● For Abnormal high pressure protection (HP), set lower value than the initial discharge pressure of safety valve. Also, according to the refrigerant and system in use, set the value which enables protection equipment to detect an error immediately. To measure pressure electrically and generate an alarm by a control circuit (such as sequencer), it is one of the effective methods to generate a pre-alarm when the pressure is approaching the abnormal value. ∎ Inspection Method/Cycle Each compressor protection equipment requires operational test and check of scale markings for set value before test operation of compressor and periodically after that. Formulate the inspection method and cycle of each compressor protection equipment, and make sure to provide users of this compressor with necessary information. ● If oil pressure decrease protection (OP) or abnormal high pressure protection (HP) operates, make sure to eliminate the cause of it before recovering the compressor. 1.4.6 Water Failure Alarm ∎ Overview/Function/Purpose Prevents the head cover and lubricating oils from becoming hot by stopping the functions of water cooling head cover and water cooled type oil cooler. ∎ Installation Positions Cooling water system ● If operation test of abnormal high pressure protection equipment (HP) is performed at the setting value, it may cause bursting of devices. Make sure to perform the test at the normal operation pressure or below. ● For operational test, use devices such as pressurize tester to check that alarms and switches operate normally. Do not operate the compressor with all the valves closed, or in any other dangerous conditions.

RBT011-00_2008.10. 1 Safety ∎ Settings Formulate the setting of water failure alarm, and make sure to provide users of this compressor with necessary information. ∎ Inspection Method/Cycle The water failure alarm requires operational test before test operation of compressor and periodically after that. Formulate the inspection method and cycle of water failure alarm, and make sure to provide users of this compressor with necessary information. 1.4.7 Oil Heater and Thermometer Switch ● If the heater is energized without it and the thermoswitch soaked in oil, the heater becomes overheated, resulting in burnout (dry-burning). When energizing the heater, always pay attention to the oil level. ∎ Overview/Function/Purpose The oil heater is a cartridge type sheathed heater. It is pressure-proof sealed type with heating wires wrapped with insulator and externally sealed with stainless tube. It is designed for maximum heat release dimensions possible. The oil heater is used to prevent refrigerant from dissolving in oil more than required during operation stop of compressor, and from condensing in the crankcase. Therefore, it is used during operation stop of compressor, not during operation. ∎ Installation Positions The thermoswitch which controls temperature of heater is attached inside the heater. ∎ Settings Formulate the setting of thermoswitch, and make sure to provide users of this compressor with necessary information. ∎ Inspection Method/Cycle The thermoswitch requires operational test before test operation of compressor and periodically after that. Formulate the inspection method and cycle of thermoswitch, and make sure to provide users of this compressor with necessary information. Reciprocating Compressor WBHE Series 1.4 Safety Devices 1-12 RBT011-00_2008.10. 1 Safety 1.5 Example of Material Safety Data Sheet (MSDS) Reciprocating Compressor WBHE Series 1.5 Example of Material Safety Data Sheet (MSDS) 1-13 RBT011-00_2008.10. 1 Safety Reciprocating Compressor WBHE Series 1.5 Example of Material Safety Data Sheet (MSDS) 1-14 RBT011-00_2008.10. 2 Specification and Configuration of Compressor 2 Specification and Configuration of Compressor 2.1 Specification of Compressor 2.1.1 Identification 2.1.1.1 Compressor Configuration The configuration of WBHE series is as follows. Table 2-1 Compressor Configuration Model Model Specification Single-stage compressor 4WBHE/6WBHE/8WBHE/8WBHEH 100% unload specification 6WBHEU/8WBHEU/8WBHEHU Reciprocating Compressor WBHE Series 2.1 Specification of Compressor 2-1 Standard specification B.B specification Booster specification Single two-stage compressor 42WBHE/62WBHE Standard specification The B.B specification cannot be operated with suction pressure lower than atmospheric pressure. 2.1.1.2 Name Plate ● The name plate differs depending on the region, country, and regulation. (The above name plate is an example.) RBT011-00_2008.10. 2 Specification and Configuration of Compressor 2.1.1.3 Code Designation of WBHE Series Reciprocating Compressor WBHE Series 2.1 Specification of Compressor 2-2 ● Refer to the specification document for details of the specification. ● The code for WBHE series is engraved in "MODEL" on a name plate. ● WBH series does not have "Piston Specification". 2.1.1.4 Refrigerant and its Cooling Method The cooling specification for head cover and oil cooler is roughly classified as below depending on the type of refrigerant. Table 2-2 Refrigerant. and Cooling Method Refrigerant Cooling Specification NH3 Water-cooling head cover + Water-cooling oil cooler HFCs, R22, propane Water-cooling head cover + Water-cooling oil cooler Water-cooling head cover + Direct expansive oil cooler Air-cooling head cover + Water-cooling oil cooler Air-cooling head cover + Direct expansive oil cooler Item Designation Code Details N NH3 (1) Refrigerant type F HFCs, R22 P Propane 4 Single-stage, four cylinders 6 Single-stage, six cylinders 8 Single-stage, eight cylinders (2) Number of cylinders 42 Single two-stage, four cylinders (low stage)/two cylinders (high stage) 62 Single two-stage, six cylinders (low stage)/two cylinders (high stage) Not required Standard (3) Discharge pressure H High operation pressure (For single-stage with eight cylinders only) (4) Capacity control mechanism Not required Standard U 100% unload specification Not required Standard and booster (5) Suction pressure BB High suction pressure (Rolling bearing) Not required Standard (6) Piston specification S Four piston rings RBT011-00_2008.10. 2 Specification and Configuration of Compressor 2.1.2 Specification 2.1.2.1 Specification Table 2-3 Specification Item Unit 4WBHE 6WBHEU 6WBHE/ Reciprocating Compressor WBHE Series 2.1 Specification of Compressor 2-3 8WBHE 8WBHEH/ 8WBHEU 8WBHEHU 42WBHE 62WBHE Refrigerant - NH3, HFCs (R404A, R507A, R134a, R407C, R23), R22, propane1) Number of Cylinders - 4 6 8 4+2 6+2 Bore mm 130 Stroke mm 100 Minimum rotation rpm 800 Maximum rotation rpm 1200 Displacement (when the maximum rotation is 1200 rpm) m3/h 382 573 765 382 573 Rotational direction2) - Clockwise (when seen from shaft end) Capacity control range % 100-50 (-0) 100-66-33-0 100-66-33/ 100-75-50-25/ 100-75-50-25- 0 100-50 100-66-33 Oil filling amount (excluding the oil cooler) l 20 24 26 25 26 GD2 (excluding the flywheel) kg·m2 1.650 1.790 1.903 1.790 1.903 Product weight3) (Excluding the flywheel and other optional parts) kg 1020 1200 1450 1260 1510 Product weight3) including the flywheel4) (excluding other optional parts) kg 1100 1300 1570 1340 1610 Cooling water - Sweet water ethylene glycol (less than 50% concentration) propylene glycol (less than 50% concentration) 1) When R23 is used, the special specification should be applied. Contact us for details. 2) This rotational direction is the positive rotation and the standard direction. This can be changed to the negative rotation to order or by adjustment. 3) This weight includes the water-cooling head cover, water-cooling oil cooler, and stop valve manufactured by Mayekawa. 4) For direct driving, install the flywheel. ● This product is designed to be used indoor and on land. Outdoor or shipboard application is possible by option. Contact us for outdoor or shipboard application. ● The standard head cover and oil cooler are for use with sweet water. Seawater specification is also available if requested. Contact us for request. (The oil cooler for use with seawater is direct expansive type.) ● Our direct coupling (genuine part) has a flywheel function. If a coupling without flywheel function is used, vibration may be increased. Use our direct coupling. (Refer to "2.3 V-Belt and Direct Coupling".) RBT011-00_2008.10. 2 Specification and Configuration of Compressor 2.1.2.2 Design Pressure Table 2-4 Design Pressure Item Unit High Pressure Section Low Pressure Section Design pressure MPaG 2.6 1.46 Reciprocating Compressor WBHE Series 2.1 Specification of Compressor 2-4 ● The design pressure differs depending on the regulation of each district or country. "Design pressure" in "High Pressure Section" in this table indicates the maximum value acquired by the compressor. Therefore, the actual design pressure at high pressure section should be this value or less according to the regulation. Check the actual pressure referring to the name plate and the specification document. ● For the low pressure section, pressure may be required to exceed the value in this table. Contact us in such case. RBT011-00_2008.10. 2 Specification and Configuration of Compressor 2.1.3 Operating Limit The following is the operating limit of WBHE series reciprocating compressor. Table 2-5 Operating Limit Item Applicable Model Limit Value Remarks Single-stage Maximum discharge pressure compressor 2.36 [MPaG] Single two-stage compressor 1.96 Reciprocating Compressor WBHE Series 2.1 Specification of Compressor 2-5 8WBHE/8WBHEU ≤ 1.96 Booster specification < 0.6 Minimum discharge pressure [MPaG] All models 0.6 Except the booster specification Single-stage Maximum suction pressure compressor 0.588 2) 3) [MPaG] Single two-stage compressor 0.35 Standard specification ≤ 0.35 Booster specification ≤ 0.05 Maximum intermediate pressure [MPaG] Single two-stage 1 compressor 000 rpm: 0.822 1 100 rpm: 0.656 HFCs, R22 1 200 rpm: 0.538 Minimum suction pressure [MPaG] All models -0.0733 B.B specification > 0 Single-stage Maximum differential pressure compressor 2.00 [MPa] Single two-stage compressor 1.52 = Pd – Ps 1) 8WBHE/8WBHEU ≤ 1.47 Maximum [-] compression ratio All models NH3: ≤ 9 HFCs: ≤ 10 Discharge temperature limit Minimum compression ratio [-] All models ≥ 1.5 Minimum oil supply pressure [MPaG] All models Ps +0.15 Maximum oil supply pressure [MPaG] All models Ps +0.4 Maximum cooling water pressure [MPaG] All models 0.5 Minimum cooling water pressure [MPaG] All models 0.2 Maximum discharge temperature [deg.C] All models NH3: 140 HFCs, R22, propane: 120 Minimum [deg.C] suction temperature All models -60 Maximum oil supply temperature [deg.C] All models 50 Oil cooler outlet Minimum oil supply temperature [deg.C] All models 30 This should be higher than ambient temperature. Suction superheat [K] All models > 0, ≤ 20 Discharge superheat [K] All models ≥ 15 Maximum cooling water temperature [deg.C] All models 50 Temperature at the jacket outlet Use limit of the cooling water hose Minimum cooling water temperature [deg.C] All models 15 Temperature at the jacket inlet Maximum/minimum speed (rpm) rotation All models 1200 / 800 The rotation speed can be controlled. Maximum shaft power of belt-drive [kW] All models 114 Differs depending on the belt type. 1) Ps: Suction pressure, Pd: Discharge pressure 2) Standstill is included. Standstill of booster specification is the same as the one of standard specification. 3) If this value exceeds 0.35 MPa, B.B specification should be applied. RBT011-00_2008.10. 2 Specification and Configuration of Compressor ● Contact us if you have any questions about operation limit. 2.1.4 External Dimensions Reciprocating Compressor WBHE Series 2.1 Specification of Compressor 2-6 ● There is no change in the external dimensions for WBHE and WBH series. Fig. 2-3 External Dimensions of N6WBHEU Fig. 2-1 External Dimensions of N4WBHE Fig. 2-2 External Dimensions of N6WBHE RBT011-00_2008.10. 2 Specification and Configuration of Compressor Reciprocating Compressor WBHE Series 2.1 Specification of Compressor 2-7 ● The external dimensions of N8WBHEH, N8WBHEU, and N8WBHEHU are the same as of N8WBHE. Fig. 2-5 External Dimensions of N42WBHE Fig. 2-6 External Dimensions of N62WBHE Fig. 2-4 External Dimensions of N8WBHE RBT011-00_2008.10. 2 Specification and Configuration of Compressor 2.2 Configuration of Compressor This compressor ( WBHE series reciprocating compressor) is designed for improving WBH series. WBHE and WBH series are substantially improved in their configuration from conventional WB series, and the updated contents are also described. 2.2.1 Updated Contents of Configuration The following is the updated contents of this compressor from WB series. 2.2.1.1 Crankcase The crankcase of this compressor has bearing head function; therefore, the bearing head equipped in WB series has been eliminated. (Refer to Fig. 2-7) Due to this change, the mechanism of equalizing the pressures in the crank chamber and the suction chamber is changed. (Refer to Fig. 2-8) The cooling jacket of casing is also eliminated. Reciprocating Compressor WBHE Series 2.2 Configuration of Compressor 2-8 Fig. 2-7 Cross-sectional View of WBHE Symbol Description Remarks A Oil infusing route of oil pump Refer to Fig. 2-11. B Piston ring Refer to Fig. 2-12. C Bearing head function section D Gas pressure equalization route Refer to Fig. 2-8. E Shaft Seal Refer to Fig. 2-9. F Thrust load holding mechanism Refer to Fig. 2-10. ● Assembly and removal of crankshaft can be performed from the oil pump side only. RBT011-00_2008.10. 2 Specification and Configuration of Compressor Reciprocating Compressor WBHE Series 2.2 Configuration of Compressor 2-9 Fig. 2-8 Gas Pressure Equalization Mechanism at Low Pressure Section Symbol Description No. Description A Suction chamber 1 Crankcase B Crank chamber 26 Cover plate C Gas flow 2.2.1.2 Shaft Seal Due to the improvement of shaft seal performance, new-model shaft seal that has been used in K series is adopted. Fig. 2-9 Shaft Seal No. Description No. Description 34 Seal ring 39 "O" ring (JIS W 1516 G19) 35 Drive collar assembly 41 Floating seat 37 "O" ring (JIS B 2401 P110) 42 "O" ring (JIS W 1516 G27) RBT011-00_2008.10. 2 Specification and Configuration of Compressor 2.2.1.3 Thrust Load Bearing If the suction pressure is negative, the crankshaft moves to the oil pump side (to the left in the figure below). If the suction pressure is positive, the crankshaft moves to the opposite side of the oil pump (to the right in the figure below). Due to this, thrust load is generated as indicated by the arrows in the figure below. In this compressor configuration, this thrust load is held at two positions; at the thrust bearing and the main bearing. Due to this change, the lock nut used in WB series to retain the shaft seal collar (and position the crankshaft) is eliminated. Reciprocating Compressor WBHE Series 2.2 Configuration of Compressor 2-10 Fig. 2-10 Thrust Load Holding Mechanism Symbol Description No. Description A Thrust load 2 Crankshaft 12 Main bearing B Load holding surface when the suction pressure is less than 0 MPaG (negative pressure) 29 Thrust bearing 56 Oil pump C Load holding surface when the suction pressure is more than 0 MPaG (positive pressure) RBT011-00_2008.10. 2 Specification and Configuration of Compressor 2.2.1.4 Oil Infusing Route of Oil Pump The oil infusing route of oil pump is changed. The part indicated with rightward sloped lines is the crankcase, and the part indicated with leftward sloped lines is the main bearing head in the figure below. The connection part of crankcase and main bearing head in the oil infusing route is changed to the flange, and a gasket is interposed for connection to improve the sealing performance in the route. Reciprocating Compressor WBHE Series 2.2 Configuration of Compressor 2-11 Fig. 2-11 Oil Infusing Route of Oil pump Symbol Description No. Description A Oil 1 Crankcase B Oil flow 8 Main bearing head 9 Main bearing head gasket 56 Oil pump 119 Oil strainer RBT011-00_2008.10. 2 Specification and Configuration of Compressor 2.2.1.5 Piston Rings and Piston The specification of piston rings and the piston are changed. The piston rings are reduced from four to three and changed in thickness to reduce friction. Due to this, the piston is also changed to the one for three rings. Reciprocating Compressor WBHE Series 2.2 Configuration of Compressor 2-12 Fig. 2-12 Piston Rings and Piston No. Description No. Description 85 Piston 90 Piston ring 2nd 89 Piston ring 1st 100 Oil ring 3rd (with coil) ● This change is applied to the WBHE three-ring specification only. ● Refrigerant R23 and the shipboard compressor that can be shifted between two-stage and single-stage (NH3) are four-ring specification (the code of (6) Piston specification in "2.1.1.3 Code Designation of WBHE Series" is "S"). RBT011-00_2008.10. 2 Specification and Configuration of Compressor 2.2.1.6 Discharge Valve Cage and Valve Plate The discharge valve cage and valve plate in the single-stage compressor and the high stage of single two-stage compressor are changed. Reciprocating Compressor WBHE Series 2.2 Configuration of Compressor 2-13 Fig. 2-13 Discharge Valve Cage and Valve Plate No. Description No. Description 1 Discharge valve cage 2 Valve plate The models of discharge valve cage and valve plate are set for WBHE as shown in the table below. Fig. 2-6 Models of Discharge Valve Cage and Valve Plate WBHE Remarks Discharge valve cage assembly model WCN-II WCRH for refrigerant HFCs (except R23) Valve plate model WN-II — ● The conventional discharge valve cage is used for refrigerant HFCs (except R23). (Model: WCRH) ● The model of discharge valve cage in the low stage of single two-stage compressor that uses propane as refrigerant is WCN-II. ● The models of discharge valve cage and valve plate in use are engraved on themselves. ● WBH series is not applicable to the above description. ● For the model details of valve plate and discharge valve cage, refer to "7.4 Specification List of Suction Valve and Discharge Valve". RBT011-00_2008.10. 2 Specification and Configuration of Compressor 2.2.1.7 Crankshaft of Single-stage Eight-cylinder Compressor The material of crankshaft in single-stage eight-cylinder compressor has two types depending on the operation conditions. For the specification of high operation pressure, material whose strength is higher than before is used. Table 2-7 Compressor Configuration Specification Model High operation pressure 8WBHEH The operable pressure range is the same as that of WB series. 8WBHE 2.2.1.8 Application for 0% Load Operation (Optional Specification) 0% load operation can be performed with 6WBHE and 8WBHE/8WBHEH as optional specification. However, for 6WBHE with optional function, the position of discharge piping differs from WB series (6WB) due to the restriction of mechanism. For 6WBHE without optional function, the position of discharge piping is common to that of WB series (6WB). The position of discharge piping of 8WBHE is common regardless of optional function, and common to that of WB series (8WB). "U" is added to the model. (Example: 8WBHEU) 0% load operation can be performed with 4WBHE, 42WBHE, and 62WBHE the same as with WB series (however, only in the low stage for single two-stage compressor). Reciprocating Compressor WBHE Series 2.2 Configuration of Compressor 2-14 ● This function is provided for a special purpose. This does not allow a long-time operation under 0% load status. In 0% load operation, gas is not exhausted from the compressor, resulting in a rapid rise of the gas temperature in the case. Due to this, the reference operation time is approx. two to three minutes. (The operation time differs depending on the refrigerant. Contact us for details.) RBT011-00_2008.10. 2 Specification and Configuration of Compressor 2.2.2 Development View and Parts List ∎ Compressor Assembly Development View Reciprocating Compressor WBHE Series 2.2 Configuration of Compressor 2-15 Fig. 2-14 Compressor Assembly Development View RBT011-00_2008.10. 2 Specification and Configuration of Compressor ∎ Development View of the Cylinder Reciprocating Compressor WBHE Series 2.2 Configuration of Compressor 2-16 Fig. 2-15 Development View of the Cylinder RBT011-00_2008.10. 2 Specification and Configuration of Compressor ∎ Development View of the Thrust Bearing Fig. 2-16 Development View of the Thrust Bearing ∎ Development View of the Main Bearing Reciprocating Compressor WBHE Series 2.2 Configuration of Compressor 2-17 Fig. 2-17 Development View of the Main Bearing RBT011-00_2008.10. 2 Specification and Configuration of Compressor ∎ Parts List Part Number Part Name Remarks 1 Crankcase 2 Crankshaft 3 Drag crank 4 Shaft key 5 Flat washer 6 Lock washer 7 Flywheel set bolt 8 Main bearing head 9 Main bearing head gasket 10 Main bearing head hexagon head bolt (short) 11 Main bearing head hexagon head bolt (long) 12 Main bearing 225 Main bearing "O" ring (for single two-stage compressor) 13 Main bearing screw 14 CUNO filter assembly 15 CUNO filter cover gasket 16 CUNO filter cover hexagon head bolt 22 Oil pressure regulating valve assembly 26 Cover plate 27 Cover plate gasket 27-1 Cover plate "O" ring 28 Cover plate hexagon head bolt 29 Thrust bearing 29-1 Thrust bearing (B.B type) 226 Thrust bearing "O" ring (for single two-stage compressor) 30 Thrust bearing hexagon head bolt washer 31 Thrust bearing hexagon head bolt 32 Shaft seal assembly 34 Seal ring 37 Seal ring "O" ring 35 Drive collar assembly 39 Drive collar "O" ring 41 Floating seat 42 Floating seat "O" ring 45 Hand hole cover (with window) 46 Hand hole cover (without window) 47 Hand hole cover gasket 48 Hand hole cover screw 49 Head cover (air cooled) 50 Head cover (water cooled) 51 Head cover gasket 52 Head cover screw 53 Head jacket cover 55 Head jacket cover gasket 54 Head jacket cover screw 56 Oil pump assembly 58 Oil pump "O" ring 59 Oil pump gasket 60 Oil pump hexagon head screw 61 Cylinder sleeve 62 Cam ring (leftward sloped) 63 Cam ring (rightward sloped) 65 Retaining ring Reciprocating Compressor WBHE Series 2.2 Configuration of Compressor 2-18 RBT011-00_2008.10. 2 Specification and Configuration of Compressor Part Number Part Name Remarks 66 Cylinder sleeve gasket 67 Reciprocating Compressor WBHE Series 2.2 Configuration of Compressor 2-19 Cylinder sleeve "O" ring (for high stage in single two-stage compressor) 68 Lift pin 69 Lift pin spring 70 Lift pin stop ring 71 Suction valve 72 Suction valve spring 73 Valve plate 74 Discharge valve cage guide 75 Discharge valve cage guide hexagon head bolt 76 Connecting rod assembly (for high stage in single two-stage compressor) 77 Connecting rod assembly 78 Connecting rod screw 79 Connecting rod hexagon head bolt washer 80 Connecting rod tightening nut (first) 81 Connecting rod tightening nut (second) 82 Connecting rod bushing 83 Connecting rod needle bearing (for high stage in single two-stage compressor) 84U Bearing halves (top) 84L Bearing halves (bottom) 85 Piston 86 Piston pin 87 Piston pin locking spring 89 Piston ring 1st 90 Piston ring 2nd 100 Oil ring 3rd 101 Oil ring 4th Not used with three-ring specification. 109 Discharge valve cage 110 Discharge valve 111 Discharge valve seat 112 Discharge valve hexagon head bolt 113 Discharge valve tightening nut (first) 114 Discharge valve tightening nut (second) 116 Discharge valve spring 117 Safety head spring 119 Oil strainer 121 Oil strainer cover 122 Oil strainer cover gasket 123 Oil strainer cover hexagon head bolt 135 Unloader push rod 142 Unloader device spring 143 Pushrod washer 144 Pushrod hexagon head bolt 145 Unloader piston 146 Unloader piston cover 147 Unloader piston cover gasket 149 Unloader piston cover hexagon head bolt 150 Unloader piston cover hexagon socket head bolt 150-1 Hexagon socket head bolt washer 164 Oil sight glass 165 Oil sight glass "O" ring 166 Oil sight gland 167 Oil sight gland hexagon head bolt RBT011-00_2008.10. 2 Specification and Configuration of Compressor Part Number Part Name Remarks 154 Suction strainer 156 Suction filter metal mesh canvas *1 158 Suction strainer holder spring 159 Canvas holder snap ring *1 161 Suction end cover 162 Suction end cover gasket 163 Suction end cover hexagon head bolt 168 Discharge elbow 169 Discharge elbow gasket 170 Discharge elbow hexagon head bolt 172 Discharge shut-off valve mating gasket 173 Discharge shut-off valve 173-1 Discharge shut-off valve companion flange 173B Reciprocating Compressor WBHE Series 2.2 Configuration of Compressor 2-20 Discharge shut-off valve companion flange mounting bolt and nut 174 Discharge shut-off valve mounting bolt and nut 175 Scale trap 176 Scale trap mating gasket 177 Scale trap hexagon head bolt 178 Scale Trap Screen 178-1 Scale trap metal mesh canvas 179 Scale trap cover 180 Scale trap cover gasket 181 Scale trap cover hexagon head bolt 182 Suction shut-off valve 182-1 Suction shut-off valve companion flange 182B Suction shut-off valve companion flange mounting bolt and nut 183 Suction shut-off valve mounting bolt and nut 184 Suction shut-off valve mating gasket 185W Water-cooled oil cooler assembly 185R Lubricating oils cooler assembly 197 Thermometer set (discharge side) 234 Head jacket cover water flange 235 Head jacket cover water flange gasket 236 Head jacket cover water flange hexagon head bolt 205 Unloader solenoid valve JO4140 T-type half union (R3/8×Ø6×R3/8) *1 These parts are not assembled if the scale trap (175) is mounted. RBT011-00_2008.10. 2 Specification and Configuration of Compressor 2.2.3 Modified Parts 2.2.3.1 Modified Parts This is the list of parts modified from WB series of the compressor (modified parts). Table 2-8 Modified Parts List No.*1 Part Name Qty. Compati bility*2 Reciprocating Compressor WBHE Series 2.2 Configuration of Compressor 2-21 Remarks 1 Crankcase 1 No 2 Crankshaft 1 Yes Eight-cylinder has two types of material. 8 Main bearing head 1 No 9 Main bearing head gasket 1 No 10 Main bearing head hexagon head bolt (short) 14 No M16×L55 11 Main bearing head hexagon head bolt (long) 2 No M16×L110 12 Main bearing 1 No 26 Cover plate 1 No 27-1 Seal box "O" ring 1 No JIS 2401 G230 28 Cover plate hexagon head bolt 12 No M16×L55 29 Thrust bearing 1 No 29-1 Thrust bearing-BB 1 No For thrust roller bearing 32 Shaft seal 1 No 142 Unloader device spring - Yes The quantity differs depending on the model. 89 Piston ring 1st - No WBHE three-ring specification 90 Piston ring 2nd - No WBHE three-ring specification 100 Oil ring 3rd - No WBHE three-ring specification 85 Piston - No WBHE three-ring specification 73 Valve plate - Yes WBHE 109 Discharge valve cage - Yes WBHE ※ 1: For No. refer to "2.2.2 Development View and Parts List". ※ 2: "Yes" for compatibility indicates that the parts modified for this compressor can be used in the conventional compressor, WB series. Even if the compatibility is "Yes", parts of WB series cannot be used in this compressor. 2.2.3.2 Deleted Parts This is the list of WB series parts that are not used in this compressor (deleted parts). Table 2-9 Deleted Parts List Part Name Qty. Remarks Bearing head 1 Bearing head gasket 1 Bearing head hexagon head screw 4 M16×L40 (Hexagon socket head bolt) Lock nut 2 M95×P1.5 Oil ring 4th - Not used with WBHE three-ring specification. RBT011-00_2008.10. 2 Specification and Configuration of Compressor 2.2.4 Cross-Sectional View of Assembly Reciprocating Compressor WBHE Series 2.2 Configuration of Compressor 2-22

Fig. 2-18 4WBHE Front View Fig. 2-20 6WBHE Front View Fig. 2-19 4WBHE Side View Fig. 2-21 6WBHE Side View

RBT011-00_2008.10. 2 Specification and Configuration of Compressor Reciprocating Compressor WBHE Series 2.2 Configuration of Compressor 2-23

Fig. 2-24 42WBHE Front View Fig. 2-22 8WBHE Front View Fig. 2-25 42WBHE Side View Fig. 2-23 8WBHE Side View

RBT011-00_2008.10. 2 Specification and Configuration of Compressor Reciprocating Compressor WBHE Series 2.2 Configuration of Compressor 2-24

Fig. 2-26 62WBHE Front View Fig. 2-27 62WBHE Side View

RBT011-00_2008.10. 2 Specification and Configuration of Compressor 2.2.5 Oil Supply Mechanism Reciprocating Compressor WBHE Series 2.2 Configuration of Compressor 2-25 Fig. 2-28 Oil Supply Mechanism 1. Lubricating oils is retained as required in the oil pan (a) at the bottom of crankcase. 2. When the oil pump (c) is driven by the crankshaft (h), lubricating oils in the oil pan (a) is suctioned via the oil strainer (b). 3. The lubricating oils is pressurized and drained by the oil pump (c), and passes the oil filter (c). 4. The lubricating oils filtered by the CUNO filter (d) is discharged from the crankcase to outside of the compressor and passes the oil cooler (e). 5. The lubricating oils is cooled by the oil cooler (e), and divided into the cover plate and crankcase. 6. The lubricating oils enters from the cover plate into the shaft seal (f). The lubricating oils which lubricates the shaft seal (f) returns to the oil pan. 7. The lubricating oils enters into the crankcase and is divided. The one stream passes the thrust bearing (g) on the seal side to the oil supply opening on the crankshaft (h). The other stream passes the main bearing (i), and is divided into the oil supply opening on the crankshaft (h) and capacity control mechanism (unloader) (j). 1) The lubricating oils which passes the crankshaft (h) lubricates the crank pin, and passes the oil supply line in the connecting rod. Then it lubricates and cools the cylinder (inner wall of the cylinder, piston ring, piston pin (k) and bearing on the connecting rod small end). 2) When the solenoid valve is not energized (OFF), lubricating oils divided into the capacity control mechanism (unloader) (j) enters the unloader cylinder and presses the unloader piston, then the unloader mechanism becomes loaded. When the solenoid valve is energized (ON), the oil discharge route opens and the oil in the unloader cylinder is discharged. Then, the pressure decreases. The pressure which presses the unloader piston decreases, and the piston is pressed back by the force of unloader device spring. Then, the piston becomes unload. 3) The oil pressure regulating valve (l) bypasses part of lubricating oils via the oil pan so that the difference between pressure in the oil pan (suction pressure) and oil supply pressure is maintained at a constant value. RBT011-00_2008.10. 2 Specification and Configuration of Compressor 2.2.6 Unloader Mechanism Fig. 2-29 Unloader Mechanism The capacity control (unloader) mechanism controls the operation of suction valve using unloader piston. By controlling the operation of suction valve, it changes the number of cylinder which compresses gas to change the suction capacity (performance). The details of mechanism are as below. ● Seat of the suction valve are attached on the top of cylinder sleeve (flange). Gas enters into the cylinder from the passage between the external and internal seats. A lift pin which moves upward and downward is installed in the gas passage at the center of these seats. The top side of lift pin contacts the suction valve. The bottom of lift pin is on the inclined surface of cam ring for the cylinder which rotates in the outside diameter of cylinder sleeve. This cylinder cam ring is rotated by the rod which is moved by the unloader piston. This rotation moves the lift pin upward and downward. ● If the lift pin is moved downward to below the seat surface, the suction valve (suction valve) operates depending on the pressure difference. However, when the lift pin pushes up and retains the suction valve by the rotation of cam ring, the suction valve does not close even if pressure difference is generated. In this state, even though the piston moves upward and downward in the cylinder, the gas only passes in and out from the suction opening. Due to this, the pressure does not increase and the gas is not discharged. At this time, this cylinder is in unload state. As described above, this mechanism controls the capacity by changing the number of cylinder which compresses gas. ● The cam ring is moved by oil pressure and the spring. If the unloader piston is not pressurized by oil, it becomes unload by the force of spring. Therefore, the capacity can be controlled by cutting off the oil pressure during compressor operation. This is performed by energizing (turning ON) the solenoid valve to be opened. ● For a good balance between drained and supplied oil, the piping fitting on the oil supply side of unloader (with main bearing head assembled) is narrowed to φ1, and the fitting on the outlet side of solenoid valve main unit is narrowed to between φ5 and 5.5. Reciprocating Compressor WBHE Series 2.2 Configuration of Compressor 2-26 RBT011-00_2008.10. 2 Specification and Configuration of Compressor 2.3 V-Belt and Direct Coupling ∎ Flywheel Specification List Model Other than Europe and Australia Reciprocating Compressor WBHE Series 2.3 V-Belt and Direct Coupling 2-27 Europe and Australia 4WBHE 460ΦC-8 460ΦSPC-8 6WBHE 460ΦC-10 460ΦSPC-8 8WBHE 460ΦC-12 460ΦSPC-8 42WBHE 460ΦC-8 460ΦSPC-8 62WBHE 460ΦC-10 460ΦSPC-8 ∎ Direct Coupling (Selected) The model of coupling to be used differs depending on the motor capacity. Motor Capacity Coupling Model 75 kW or less BX600 Assy 90 kW or over GB03 Assy This product is equipped with a flywheel function. RBT011-00_2008.10. 2 Specification and Configuration of Compressor Reciprocating Compressor WBHE Series 2.3 V-Belt and Direct Coupling 2-28 RBT011-00_2008.10. 3 Installation 3 Installation 3.1 Safety Precautions for Installation Reciprocating Compressor WBHE Series 3.1 Safety Precautions for Installation 3-1 ● This chapter is based on the assumption that the compressor is installed for the purpose of refrigeration, cold storage, and air conditioning systems, recreational systems. If the specifications differ for your systems, refer to this chapter and consider safety, before operation. If there are any questions, please contact your local sales offices or service centers. ● Insure that installation work is performed by a qualified personnel or contracting company. Make sure that the work is performed in compliance with local laws and ordinances. ● Read this chapter and related documents, and fully understand their contents before performing installation. ● Electrical works should be performed only by those certified by local governing body. ● Do not place any part of your body under the lifted compressor. RBT011-00_2008.10. 3 Installation 3.2 Installation Works 3.2.1 Unpacking Check that there is no abnormality such as damage on the compressor. ● If there are abnormalities or deficient parts on the compressor, please contact your local sales offices or service centers immediately. ● Unnecessary packing materials should be discarded according to the laws and ordinances, or your company's rules. 3.2.2 Storage Perform the followings to store the compressor before installation. ● Store it indoors. ● Infuse nitrogen gas into the compressor and seal it. ● Nitrogen gas has been infused into the compressor at packing to prevent from rusting. 3.2.3 Transfer ● Dropping of the lifted compressor may cause death or serious injury. Do not stand under the lifted compressor. 1. For lifting the compressor within the safety limit, use lifting equipment and tools appropriate for the weight of compressor. 2. Leave sufficient space for lifting. 3. Always check wire rope before using. Thoroughly check for kink, knot, or breakage. Do not perform lifting before checking the wire rope. If there are any problems or questions, undergo an inspection by an expert. 4. For lifting the compressor individually, hook the wire rope on the lifting bolt of compressor. 5. For lifting the compressor with base and motor, hook the wire rope on the lifting bolt and the base of compressor. Do not use the lifting bolt on the motor. 6. Check path of compressor installation to make sure it is free of obstacles. 7. Check that the hook is above the center of gravity of the unit before lifting. 8. Direct all the workers to stay clear of the work site before lifting. 9. Before lifting compressor notify all workers in area of dangers during lifting process. Remove all nonessential personal from area till lift is complete. Do not perform lifting unless those signals (such as calling the name and gesturing by hand) are completely recognized. 10. Wind up the wire rope slowly until shortly before the compressor leaves from the ground. 11. Remove all tension slowly until the compressor leaves the ground, and check that the compressor is balanced. If it is tilted, lower compressor and correct the tilt. Then, wind up the wire rope again. 12. Lift the compressor slowly. If it is lifted rapidly, it may damage the lifting tools such as wire rope or a part of the compressor. 13. When the lifting is started, check that the wire rope and other lifting tools are normal by observing. Check that the compressor is not tilted. 14. When moving the lifted compressor, always use tag line/induction rope. Reciprocating Compressor WBHE Series 3.2 Installation Works 3-2 RBT011-00_2008.10. 3 Installation 15. Have other people to stay clear of the movement direction and check the safety before moving the compressor. 16. Do not lift the compressor over head of the safety aisle unless absolutely necessary. 17. Do not lower the compressor and block the safety aisle. Always clear the safety aisle to be passable. 18. Remove obstructions before lowering the compressor onto the ground. The compressor should not be tilted or unstable. 19. Before lowering the compressor, notify others. 20. When lowering the compressor onto two or more blocks, align the tops of blocks so that the compressor becomes stable horizontally on them. 21. Lower the lifted compressor slowly so that it is not damaged by impact on the ground. Reciprocating Compressor WBHE Series 3.2 Installation Works 3-3 RBT011-00_2008.10. 3 Installation 3.2.4 Preparation for Installation ∎ Installation Space The figures below show the minimum necessary space for disassemble and reassemble of the compressor. Referring to these figures, secure space which allows easy operation, cleaning, maintenance, and inspection. Reciprocating Compressor WBHE Series 3.2 Installation Works 3-4 ● Installation space for 6WBHEU will be the same as 6WBHE. However, the connecting position of the suction pipe differs. ● Installation space for 8WBHEH, 8WBHEU, and 8WBHEHU will be the same as 8WBHE. Fig. 3-1 Installation Space RBT011-00_2008.10. 3 Installation Reciprocating Compressor WBHE Series 3.2 Installation Works 3-5 Fig. 3-2 Installation Space ∎ Illumination Prepare illumination devices which allow easy operation, cleaning, maintenance, and inspection. ∎ Ventilation If natural ventilation is insufficient, install ventilation fans according to the regulations. ∎ Cooling Water Referring to chapter 7, secure cooling water necessary for your system. ∎ Noise and Vibrations Perform appropriate measures. RBT011-00_2008.10. 3 Installation ∎ Piping Table 3-1 Connected Piping List 42WBH 62WBHE 4WBHE 6WBHE 8WBHE Low Stage Reciprocating Compressor WBHE Series 3.2 Installation Works 3-6 High Stage Low Stage High Stage With suction valve MYCOM 80A MYCOM 100A MYCOM 100A MYCOM 80A MYCOM 65A MYCOM 100A MYCOM Suction gas Without suction valve 65A 1) MYCOM 80A MYCOM 100A MYCOM 100A MYCOM 80A MYCOM 65A MYCOM 100A MYCOM 65A With discharge valve MYCOM 80A MYCOM 80A MYCOM 100A MYCOM 65A MYCOM 50A MYCOM 65A MYCOM Discharge gas Without discharge 50A valve 2) MYCOM 80A MYCOM 80A MYCOM 100A MYCOM 65A MYCOM 50A MYCOM 65A MYCOM 50A High pressure gauge connection port 3/8"×φ6 Low pressure gauge connection port 3/8"×φ6 Oil pressure gauge connection port 1/4"×φ6 Cooling water inlet 3/4" Cooling water outlet 3/4" Oil separator return inlet (float type) 3/8" Oil separator return inlet (not float type) 3/4" (without suction valve: 3/8") Safety valve connection port The connection port differs depends on the specification. 1) Discharge elbow is equipped (discharge elbow is not equipped on 4WBHE.) 2) Scale strap is equipped (scale strap is not equipped on 4WBHE.) 3.2.5 Installation 3.2.5.1 Installation Check that mounting surfaces of the refrigerating, cold storage, and coolant systems to compressor are horizontal. If not, the compressor may be deformed by tightening bolts, and fail to operate normally. 3.2.5.2 Position of the Oil Returning Point in the Oil Separator / Procedure of Oil Returning Float valve is recommended to be installed when returning oil from the oil separator and the system. When returning oil from the system, heat the oil so that the refrigerant do not return to the compressor. 3.2.5.3 Protection Switch To protect the compressor and prevent accidents, attach the protection equipment below. For details, refer to "1.4.5 Automatic Control and Protection Equipment of WBHE Compressor". ● Oil pressure decrease protection equipment (OP) ● Abnormal high pressure protection equipment (HP) ● Low pressure control equipment (LP) RBT011-00_2008.10. 3 Installation 3.2.5.4 Centering of the Compressor/Driving Machine and Attachment of the V-belt Specification of the Belt: V-belt (Standard & Red), Type of the Belt: C ● To replace the V-belt with a new one, purchase the same set of belt as the current one, and replace the whole set at once. Even if their nominal dimensions are the same, their actual lengths may slightly differ. In such case, operation force is applied only to the short belt. This may cause wear of the belt and abnormal vibration. Also, if old and new belts are used together, the difference of their wear amounts may cause abnormal vibration. ● V-belt should be free from compressor oil and lubrication oil. If those oils adhere to V-belt, wipe them off. ● The V-belt in belt unit is adjusted to the initial appropriate tension load before shipment. However, the tension load may become less than the minimum tension load due to initial extension of V-belt during the period before operation. Depending on the destination of shipment, region, or country, initial appropriate tension load may not be adjusted. Check and adjust the tension load to the one of new belt before operation. ∎ Centering and Attachment of V-belt If the compressor is with common base, centering is performed on the V-belt before shipment. However, check the center again after installation. 1. String on the side of pulley to check that the compressor and the motor center core are parallel. If the center core is not in the correct position, it accelerates wearing the belt due to high-speed rotation, and shortens the life span of the compressor and motor by applying force to the bearings. Reciprocating Compressor WBHE Series 3.2 Installation Works 3-7 Fig. 3-3 Centering of V-belt RBT011-00_2008.10. 3 Installation For centering by driving the belt, strain a string on the side of flywheel and motor pulley. Centering standard: L=1 mm or less Fig. 3-4 Centering Standard 2. Loosen the slide base of motor, move the compressor and the pulley closer to each other, and attach the V-belt to groove V while slacking the V-belt. Check that the V-belt fits groove V, and pull the motor with the bolt so that the belt becomes tensioned. Deflection = 0.016 × Span length (mm) (Span length ≈ Center distance) Fig. 3-5 Deflection No. Description No. Description 1 Tension meter 3 Deflection 2 Center distance 4 Span length Table 3-2 Simplified Table of Deflection Amount (mm) Center Distance (mm) 1000 1100 1200 1300 1400 1500 Deflection (mm) 16 18 19 21 22 24 Table 3-3 Simplified Table of Tension Load (kgf/belt) Tension Load of New Belt Tension Load at Re-Straining Minimum Tension Load 4.0 - 4.5 3.0 - 3.5 2.5 or more Note 1: Re-tighten the belt for the first time after 4—8 hours from the starting the operation. Note 2: Rotate the flywheel (pulley) to check the tension load of V-belt. Note 3: When the belt is under the minimum tension load, make sure that the belt does not move excessively by operation, because the load fluctuates due to the load conditions. Note 4: The tension load at re-straining after one-year operation should be 2.5 or more (kgf/belt). Reciprocating Compressor WBHE Series 3.2 Installation Works 3-8 RBT011-00_2008.10. 3 Installation ● During the first operation of compressor for 4 to 8 hours after replacing the V-belt, initial extension and friction occur to the new V-belt. Due to these and other causes such as peel-off of coating from flywheel, the tension load of V-belt decreases drastically to less than the minimum. If the V-belt is continuously used in this condition, the service life of V-belt is shortened by slipping. In addition to this, defects may occur such as excessive movement of V-belt, overturn and deviation caused by wear of belt on one side. Make sure to re-tighten the V-belt soon after operation. ● If the belt strain is insufficient, its service life is shortened. If the belt is replaced with a new one, operate the compressor with the new belt for 24—48 hours and check the tension again. ∎ Centering and Attachment of Couplings The installation positions of compressor and motor are designated according to the center distance appropriate for attachment of couplings. Also, the difference of center core heights must be within 0.1 mm by machining process of frames. Align the center cores by correcting the parallelism and deviation between left and right shafts. 1. Retain the compressor on the frame, and attach the coupling hub on the compressor side to the crankshaft. 2. Set the dial indicator on the motor axle using a magnetic stand or others, so that the probe contacts the external diameter and surface of the coupling hub on the compressor side. Reciprocating Compressor WBHE Series 3.2 Installation Works 3-9 Fig. 3-6 Measurement of Axle Core Symbol Description No. Description A Measurement of core deviation 1 Dial indicator B Measurement of angle deviation 3. Read the scale of dial while rotating the motor axle. Then operate the motor so that the core runout of outer periphery (core deviation) is 0.05 mm or less (relative deviation 0.1 mm or less), and the deflection of hub face (angle deviation) is 0.05 mm or less per radius 100 mm. 4. When the as alignment is within the specified measurements, tighten the motor on the frame. 5. Attach the coupling hub on the motor side to the axle. Do not tighten it at this point. RBT011-00_2008.10. 3 Installation Reciprocating Compressor WBHE Series 3.2 Installation Works 3-10 Fig. 3-7 Coupling No. Description No. Description 1 Flywheel 8 Over load washer (II) 2 Sub ring 9 Element 3 Sub ring fixing bolt 10 Over load washer (I) 4 Ring (II) 1) 11 Bolt 5 Spring washer 12 Key set screw (Hexagon socket set screw) 6 Spacer 13 Hub 7 Nut 1) Equipped when the motor is 90 kW or more (GB03 Assembly). 6. Attach the coupling/insert to the coupling hub on the compressor side. Insert bolts from the back of hub (on the compressor side), then attach washers, coupling/insert, washers, and nuts in the described order. The washers are processed to be curved on one side. This side should face to the coupling/insert. 7. Attach the spacers to the coupling/insert attached in step 6. The large hole on the hub face of spacer is back clearance for the tightening nuts of coupling/insert on the compressor side. 8. Retain the coupling/insert on the motor side on the spacer. 9. When attaching the hub and coupling/insert on the motor side, move the hub to the gap in which the washers fit, and adjust the interval between the coupling hubs. If the washers do not fit in easily, or there are gaps between the coupling/insert, washers, and hub face, force in the axle direction (thrust) is applied. Prevent this thrust from applying. 10. Tighten the hub on the motor side on the axle. 11. Tighten all the nuts at the specified torque again. 3.2.5.5 Piping Vibration generated from the compressor is transmitted to the building via two systems: substruction and piping. Take into consideration the piping support to prevent resonance in the building. RBT011-00_2008.10. 3 Installation ∎ Refrigerant Piping Observe the followings when connecting the refrigerant piping. ● Compressor is one of the few components with moving parts in the refrigerating, cold storage, and air conditioning systems. Moving part should be free from dust. During piping work, do not put tools such as scale into it. ● The compressor may contain nitrogen gas infused before shipment to prevent from rusting. Do not open the suction and discharge valves unless it is required. Do not open the suction and discharge valves unless it is required. ● The piping must be free from moisture. It may cause troubles after starting operation. Assemble the piping in dry condition. ● If the suction piping is assembled inappropriately, it may cause troubles such as oil in the piping not returning to the compressor, and liquid compression. ● When connecting the piping to the compressor, select a pipe whose size is the same as the connection of compressor. If the pipe size is smaller than the connection of compressor, it restricts the oil or refrigerant flow, resulting in troubles. ● Make sure to attach supports to the piping so that excessive force is not applied to the compressor. Also, when a vibration-proof base is used, install flexible tubes on the piping. ● Separate pipes on which dew may form. Reciprocating Compressor WBHE Series 3.2 Installation Works 3-11 RBT011-00_2008.10. 3 Installation ∎ Cooling Water Piping ● Do not divide the cooling water system from the oil cooler to the head jacket. This is dangerous because the difference of pressure loss (resistance) restricts the cooling water flow, resulting in failure to cool necessary sections. ● The oil on the discharge side can be deteriorative due to overheating in the compressor. Always flow cooling water during operation of compressor. The cooling water piping differs depending on the oil cooler specifications; water cooled type oil cooler or direct expansive oil cooler. ● Water cooled type oil cooler: cooling water that ran through the oil cooler is supplied to the head jacket. ● Direct expansive type oil cooler: cooling water is supplied directly to the head jacket. Reciprocating Compressor WBHE Series 3.2 Installation Works 3-12 Fig. 3-8 WBHE Series Cooling Water Schematic Diagram for Water Cooled Type Oil Cooler No. Description No. Description (1) Cooling water inlet (water cooled type oil cooler) (2) Cooling water outlet (jacket head cover) Fig. 3-9 WBHE Series Cooling Water Schematic Diagram for Direct Expansive Type Oil Cooler No. Description No. Description (1) Cooling water inlet (jacket head cover) (2) Cooling water outlet (jacket head cover) ● Cooling water piping for 6WBHEU will be the same as 6WBHE. ● Cooling water piping for 8WBHEH, 8WBHEU, 8WBHEHU will be the same as 8WBHE. ● Cooling water piping for 6WBHEU will be the same as 6WBHE. ● Cooling water piping for 8WBHEH, 8WBHEU, 8WBHEHU will be the same as 8WBHE. RBT011-00_2008.10. 3 Installation Table 3-4 Cooling Water Piping (Withstand Pressure Braided Hose) Specification Item Specification Cooling water inlet size Rc3/4 Cooling water outlet size Rc3/4 Maximum cooling water 0.5 MPaG or lower pressure Maximum cooling water 50°C or below temperature 3.2.5.6 Changing Rotational Direction of Compressor Rotational direction of the compressor can be changed. However, in that case, rotational direction of the oil pump must also be changed. For details on changing the rotational direction, refer to "5.6.2.4 Drag Crank and Oil Pump". ● If you want to change rotational direction after starting operation with another rotational direction, change the direction after performing maintenance work of the compressor. 3.2.5.7 Charging of Lubricating Oils Refer to "4.1.2 Initial Oil Supplying Method". 3.2.6 Check after Installation Referring to the items described below which should be performed after installation of compressor, formulate a list and procedure to check the refrigerating, cold storage, and air conditioning systems you use, based on their specification. ∎ Automatic Control, Connections ● Wiring between the control board and each switch ● Activation mode (auto/semi-auto) and rotational direction of motor ● Insulating resistance of motor ∎ Operation Test of Protection Equipment For details, refer to "1.4.5 Automatic Control and Protection Equipment of WBHE Compressor". ● If operation test of abnormal high pressure protection equipment (HP) is performed at the setting value, it may cause bursting of devices. Make sure to perform the test at the normal operation pressure or below. ● Oil pressure decrease protection equipment (OP) ● Abnormal high pressure protection equipment (HP) ● Low pressure control equipment (LP) and unloader solenoid valve ∎ Air Tightness Test, Refrigerant Leakage Test Perform air tightness test and refrigerant leakage test on your systems. Reciprocating Compressor WBHE Series 3.2 Installation Works 3-13 RBT011-00_2008.10. 3 Installation Reciprocating Compressor WBHE Series 3.2 Installation Works 3-14 RBT011-00_2008.10. 4 Operation of the Compressor 4 Operation of the Compressor 4.1 Lubricating Oils The lubricating oils is used for lubricating the moving parts of the compressor, preventing abnormal wear, and cooling each section. The following oil properties are required: ● There should be an appropriate viscosity under temperature and pressure conditions within the range of use. ● The oil should flow even under the low temperature conditions (within the range of operating temperature for the refrigerant system). ● The oil should be chemically–stabilized so that it does not corrode or transelement the components (such as metals or rubbers). ● Wax should not be separated from the oil even under low temperature. ● Sludge and carbon should not be generated easily even under high temperature. ● Water should not be contained in the oil. 4.1.1 Precautions for Selecting the Lubricating Oils ● Brands to be used for base oil differ depending on the types of refrigerant. For details, contact our sales office or Mayekawa representative. ● Do not use the Polyolester (POE) oil when NH3 is used for refrigerant. ● Lubricating oils of ISO–VG46—68 is recommended. ● The viscosity of the oil supplied to the sliding section must, at least, be assured. If the lubricating oils (compatible oil), to which a large amount of refrigerant is penetrated, is used, the viscosity may deteriorate significantly so that it is below the product specification under usage condition. Select the oil so that the viscosity is 20—70 mm2/s under usage condition. ● The circulation of the lubricating oils for the overall equipment must be taken into consideration. After the lubricating oils lubricates/cools each section of the compressor, it returns to the oil pan of the crankcase. However, some of the oil is discharged together with the refrigerant. Most of the oil discharged from the compressor is captured by the oil separator while some of it flows to the condenser or evaporator. As described above, there should be sufficient flow ability and stability inside each device with the different temperature zones. ● For details on using NH3 and Polyolester (POE) oil together, contact our sales office or Mayekawa representative. ∎ To change the brand of the lubricating oils: ● Changing the existing lubricating oils with other brand oil may cause an unexpected problem due to mixing of new and old oils. Take sufficient care when changing the oil. ● If the manufacturers are different, contact both of them to confirm whether changing the oil is going to cause problems. The same confirmation is required for changing the brand even if it is of the same manufacturer. ● There is no problem in changing the viscosity level within the same brand. However, the viscosity level (after change) should be appropriate for operation. [Example] SUNISO 3GS -> SUNISO 4GS Reciprocating Compressor WBHE Series 4.1 Lubricating Oils 4-1 RBT011-00_2008.10. 4 Operation of the Compressor 4.1.2 Initial Oil Charging Method When supplying the oil initially or changing the oil after overhaul, supply the oil from the cover plate (1 in the figure below) to fill the oil cooler, oil filter, mechanical seal, and oil passages with the oil. Then, after reattaching the joints and pipings removed for supplying oil, supply the oil from the initial oil supplying port (2 in the figure below). Supply the oil by vacuuming the compressor or pressurizing with the oil supply pump. Reciprocating Compressor WBHE Series 4.1 Lubricating Oils 4-2 No. Description 1 Oil supplying port on the cover plate (for replenishment) 2 Initial oil supplying port 4.1.3 Replenishment of the Lubricating Oils The lubricating oils level lowers gradually during the operation. While the oil level can be checked through the oil sight glass, replenish the oil in the following manner. ● When replenishing the oil, be careful so that the oil will not be contaminated by air or water. ● When replenishing the lubricating oils, use clean oil with no foreign materials contained. ● To prevent bubbling in the crankcase, supply the oil gradually. ● To avoid absorption of water vapor in the air, store the lubricating oils with it sealed until it is used. <Replenishment Method during Operation (Example)> 1. Close the compressor suction shut–off valve gradually until suction pressure becomes slightly vacuum (approx. –0.026 MPaG (–20 cmHg)). 2. The oil will be vacuumed gradually from the oil supply/drain valve (oil drain valve) on the compressor. 3. After the specified amount of oil is replenished, close the oil supply/drain valve completely. 4. Open the suction shut–off valve gradually, and change the equipment to the steady operation. 4.1.4 Set Oil Pressure Adjust the oil pressure to 0.12—0.20 MPa above suction pressure (maximum of 0.4 MPa) using the oil pressure regulating valve. RBT011-00_2008.10. 4 Operation of the Compressor 4.1.5 Oil Quantity Quantity of lubricating oils in the crankcase is judged by the oil level viewed through the oil sight glass. Reciprocating Compressor WBHE Series 4.1 Lubricating Oils 4-3 Symbol Oil Quantity A Lower limit B Standard C Upper limit During operation, oil level that can be viewed through the oil sight glass decreases. Check the oil quantity through the oil sight glass and replenish oil so that the oil quantity do not fall below the lower limit. (Oil must be supplied periodically, at least for the amount that exuded from the shaft seal and for the amount that carried over from the oil separator.) Table 4-1 Initial Oil Supply Quantity (For Crankcase) (L) 4WBHE 6WBHE 8WBHE 42WBHE 62WBHE Upper limit 24.9 29.8 31.2 30.7 32.1 Standard 19.9 24.0 25.6 25.4 26.2 Lower limit 15.4 19.4 20.3 19.7 20.9 With oil tank 40.0 45.0 50.0 46.0 50.0 Note) Initial oil supply quantity for oil cooler and oil separator is not included. Diameter of the yellow ring on the oil sight glass is approximately 30 mm. RBT011-00_2008.10. 4 Operation of the Compressor 4.2 Initial Operation ● Scale trap metallic mesh canvas is included in the scale trap. Remove the canvas after test operation. Otherwise, the canvas may prevent suction, resulting in performance degradation. For the compressors without scale trap, a canvas is included in the suction strainer. Remove it after test operation as well. Refer to "5.5.2 Flow of Work". The refrigerant equipment, which has been installed, should be operated while maintaining its initial functions for a long period of time. Therefore, initial operation is significantly important. When approx. 24 hours have passed after the first startup of the compressor, foreign materials such as dust, scale, rust, and sand in the piping can accumulate in the compressor because they flow with the refrigerant gas. Fine foreign materials that can not be removed by the scale trap or the suction filter will mix into the oil, resulting in failure or abnormal wear. Suction of foreign materials into the compressor will continue until all foreign material has been pulled into the compressor, the greatest amount is suctioned after the initial startup. Presence of foreign materials can be checked by inspecting the scale trap and the suction filter, and checking the contamination of oil. The oil in the crankcase can be the first sign of contamination of the refrigeration system. Therefore, if the oil stays clear for a long period of time, it can be judged that inside of the equipment is also clean. If the oil seems to be slightly blackened or turbid in brown, the oil is contaminated with foreign materials in the equipment. Replace the oil as soon as possible so as to prevent foreign materials from penetrating into the sliding section of the compressor. Take sufficient care of the following two points: ● Inspection/cleaning of the filter and replacement of the oil Cleaning of the filter may not be required when inside of the refrigerant cycle in the refrigerating, cold storage, and air conditioning systems are clean. Replace the element. ● Watch for any abnormal sound or temperature of the compressor. ● Cleaning the oil filter, scale trap, and suction filters requires processing of the refrigerant and opening of the compressor. For processing of the refrigerant and assembly/disassembly of the compressor, refer to "Chapter 5. Maintenance". Table 4-2 Reference of the Oil Replacement and Filter Inspection Elapsed Time Reciprocating Compressor WBHE Series 4.2 Initial Operation 4-4 Replacement of Oil Inspection and and Cleaning of Oil Cleaning of CUNO Strainer Filter Cleaning of Scale Trap After completion of refrigerant charging operation Cleaning of Suction Filter × × — — After completion of trial operation × × × × 100 hours after starting operation × × × × 500 hours after starting operation × × × × RBT011-00_2008.10. 4 Operation of the Compressor Replacement of Oil Inspection and Elapsed Time and Cleaning of Oil Cleaning of CUNO Strainer Filter Reciprocating Compressor WBHE Series 4.2 Initial Operation 4-5 Cleaning of Suction Cleaning of Scale Filter Trap Every 1000 hours × × × × Note If contamination of the lubricating oils or clogging of the filter is found, perform oil replacement or inspection/cleaning and replacement regardless of the above conditions. 4.2.1 Initial Operation Method ● When using a compressor stored for a long period of time (for one year or more) after purchase or a compressor that has not been operated for half year or more, always open the head cover, hand hole cover, and seal cover and inspect the inside before starting operation. At that time, apply oil and replace the O–ring of the mechanical seal. 1. Before starting operation, rotate the crankshaft (manually) for 20 turns or more, and check that the oil level viewed through the oil sight glass has decreased. If the shaft cannot be rotated manually, activate the motor instantaneously (for about one or two seconds) to check that the oil pressure gauge operates. Otherwise, service life of each part will be dramatically shortened. Never fail to rotate the shaft. 2. Operate the compressor. 3. Perform the initial operation according to "Table 4-2 Reference of the Oil Replacement and Filter Inspection". RBT011-00_2008.10. 4 Operation of the Compressor 4.3 Capacity Control Order The capacity control order is as follows: Table 4-3 Capacity Control Order Symbol Description Remarks ○ Cylinder number □ Unloader push rod number L Leftward sloped cam ring R Rightward sloped cam ring ( ) Capacity control order Order to be unloaded from 100% loaded condition * Equipped only for 100% unload specification Reciprocating Compressor WBHE Series 4.3 Capacity Control Order 4-6 The four cylinders in standard 4WBHE are equipped with unload mechanism. The purpose of this is to reduce the load during startup. The capacity control during normal operation is 100% to 50%. Fig. 4-1 Capacity Control Order RBT011-00_2008.10. 4 Operation of the Compressor 4.4 Operation Notices Notices to protect the compressor during operation are as follows. 4.4.1 Start/Stop Limitation To use the compressor normally, number of start/stop times and the stop time are specified as follows. Table 4-4 Specification for Number of Start/Stop Times and the Stop Time No. Item Qty. Remarks 1 Number of start/stop times 3 times/hour 2 Stop time At least 5 min Reciprocating Compressor WBHE Series 4.4 Operation Notices 4-7 Refer to the operation manual of electrical equipment. 3 Minimum operation time At least 15 min 4 Unloader operation interval At least 3 min To operate the compressor at 0% load, contact our sales offices or service centers. 5 Oil level Oil sight glass 10—90% 4.4.2 Settings To use the compressor normally, each items are specified as follows. Table 4-5 Settings Item Unit Alarm Trip Remarks Rotation speed Maxi rpm mum Minim um - > 1200 (no delay) - < 800 (no delay) > 2.36 (no delay) > 2.6 (no delay) Single-stage compressor Except 8WBHE/8WBHEU > 1.96 (no delay) Single two-stage Maxi compressor and mum 8WBHE/8WBHEU > 0.60 (60 sec.) > 2.6 Discharge pressure MPa (no delay) Minim um > 2.6 (no delay) Booster specification < 0.60 (30 sec.) - Except the booster specification > 0.35 (30 sec.) > 0.35 (60 sec.) Maxi > 0.588 > mum (30 sec.) 0.588 (60 sec.) B.B specification Suction pressure MPa > 0.05 (60 sec.) - Booster specification < -0.0733 Minim (30 sec.) um < 0 (30 sec.) < -0.0733 (60 sec.) < 0 (60 sec.) B.B specification > 0.822 (30 sec.) > 0.822 (60 sec.) R22 ≤ 1000 rpm HFCs ≤ 1000 rpm Intermediate pressure For single two-stage compressor Maxi > 0.656 mum (30 sec.) > 0.538 (30 sec.) > 0.656 (60 sec.) R22 ≤ 1100 rpm HFCs ≤ 1100 rpm and separate two-stage MPa > 0.538 (60 sec.) Minim um - - R22 ≤ 1200 rpm HFCs ≤ 1200 rpm RBT011-00_2008.10. 4 Operation of the Compressor Item Unit Alarm Trip Remarks > 2.0 (30 sec.) Reciprocating Compressor WBHE Series 4.4 Operation Notices 4-8 Calculated value Single-stage compressor Except 8WBHE/8WBHEU > 1.52 (30 sec.) > 2.0 (60 sec.) Differential pressure (= Discharge - Suction) Maxi mum Calculated Calculate with absolute pressure > 1.47 (30 sec.) MPa > 1.52 (60 sec.) value Single two-stage compressor > 1.47 Calculated value (60 sec.) 8WBHE/8WBHEU Minim um - - Compression ratio (= Discharge / Suction) For single two-stage compressor Low stage: > 9 Maxi (60 sec.) - Calculated value NH3 mum > 10 (60 sec.) - Calculated value HFCs, R22 (= discharge / intermediate) High stage: (= intermediate / suction) Calculate with absolute pressure - Minim um < 1.5 (60 sec.) < 1.5 (120 sec.) Calculated value Maxi mum > 0.40 (30 sec.) > 0.45 Oil supply pressure MPa Minim (30 sec.) um Calculated value < 0.12 = oil supplied - suction (30 sec.) > 145 (5 sec.) < 0.10 (30 sec.) > 150 (no delay) NH3 Maxi Discharge temperature deg.C mum > 125 > 130 HFCs, R22 (5 sec.) (no delay) Minim um - - Maxi mum > Suction temperature 60 deg.C Minim (60 sec.) - um < -58 (30 sec.) < - 60 (30 sec.) Discharge superheat Maxi K mum Minim - - um Calculated value Delay time for startup is 30 min. Maxi mum < 15 (60 sec.) < 10 (60 sec.) Calculated value Delay time for startup is 30 Suction superheat K min. Minim um > 25 (60 sec.) - ≤ 0 (30 sec.) ≤ 0 (60 sec.) Calculated value Maxi mum > 50 (60 sec.) > 55 Oil supply temperature deg.C Minim (60 sec.) um Delay time for startup is 30 < 30 < 25 min. (60 sec.) (60 sec.) 1) Maximum permissible time for the delay time is described in the parentheses. 2) The setting values are specified for the purpose to protect the compressor. 3) Pressures described are the readings on the pressure gauge. 4) If there are additional agreements, that agreement takes precedence in principle. 4.4.3 Action for Stopping the Compressor for Long Period of Time If the compressor will be stopped for a long period of time, close the suction (side)/discharge (side) shut off valves, then set the motor (main power), heater power, and control board power to "OFF".


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