Manual Sabroe SMC_104-106-108_EN.pdf

Christian X´s Vej 201, P.O. Box 1810, DK-8270 Højbjerg, DenmarkPhone +45 86 27 12 66 . Fax +45 86 27 44 08

Instruction ManualSMC 104-106-108/TSMC 108 Mk 3

Reciprocating Compressor

0178-915-EN Rev. 00.02

00.01

0178-910-EN 1

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The SMC/TSMC-type piston compressor canbe fitted with a range of equipment, depend-ing on the function and requirements it is ex-pected to meet.

Some of these variants are discussed in this

instruction manual, even if they are not fea-tured on your particular unit.

The variants featured on the unit are markedwith an ’x’ in the following diagram, with theserial number stated below.

UNISAB II Control- and regulating system

Analogue Control System

Thermopump

Water cooled top and side covers

Air cooled top and side covers

Oil cooling (water-cooled side covers)

Oil cooling OSSI/HE8S

Coupling

V-belts

Pinion drive

Chain drive

Control

Compressor

Oil pump drive

Refrigerant

Serial number

Compressor type

cooling

Drive type

Equipment for parallel operation

SABROE OVUR-type oil separator

Explosion-proof electrical design

Designation

R717 ❑ R22 ❏ R134a ❏ R404A ❏ R507 ❏ _____ ❏

0171

-500

-EN

96.0

6

2 0171-702-EN

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The aim of this instruction manual is toprovide the operators with a thoroughknowledge of the compressor and the unit, atthe same time providing information about:

� the function and maintenance of theindividual components;

� service schedules;

� procedure for dismantling andreassembling of the compressor.

The instruction manual also draws attentionto typical sources of errors which may occurduring operations. It states their cause andexplains what should be done to rectify them.

It is imperative that the operators familiarizethemselves thoroughly with the contents of

this instruction manual to ensure reliable andefficient operation of the plant as SABROE isunable to provide a guarantee againstdamage occurring during the warranty periodwhere this is attributable to incorrectoperation.

To prevent accidents during dismantling andassembly of compressors and components,these should only be carried out byauthorized personnel.

The contents of this instruction manual mustnot be copied or passed on to anyunauthorized person without Sabroe’spermission.

In the space below you can enter the name and address of your local SABROEREPRESENTATIVE :

SABROE REFRIGERATION A/S

P.O. Box 1810, DK–8270 Højbjerg

Chr. X’s Vej 201, Århus, Denmark

Phone: Telefax: +45 86 27 44 74

+45 86 27 12 66

0178-910-EN 3

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Specifications for SMC 104-106-108 Mk3 and TSMC 108 Mk3, S-L-E 1. . . . . . . . . . . . . . .

Preface 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

List of Contents 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

First Aid for accidents with Ammonia 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

First Aid for accidents with HFC/HCFC 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Protecting the environment 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Description of compressor 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Handling of the compressor, areas of application, safety equipment etc. 16. . . . . . . . . . . . .

Sound data for reciprocating and screw sompressor units - all types of compressors. 17.

Vibration data for compressors - all types 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Compressor data for reciprocating compressor 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating limits 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R717 - Operating limits single stage compressors CMO, SMC 100 S-L, SMC 180 23. . R717 - Operating limits single stage compressors SMC 100 E 24. . . . . . . . . . . . . . . . . . . R717 - Operating limits two-stage compressors TCMO, TSMC 100 S-L-E, TSMC 180 25. R22- Operating limits single stage compressors CMO, SMC 100 S-L, SMC 180 26. . . . R22 - Operating limits two-stage compressors TCMO, TSMC 100 S-L, TSMC 180 27. R134a - Operating limits single stage compressors CMO, SMC 100 S-L 28. . . . . . . . . . R134a - Operating limits two-stage compressors TCMO, TSMC 100 S-L 29. . . . . . . . . . R404A - Operating limits single stage compressors CMO, SMC 100 S-L 30. . . . . . . . . . R404A - Operating limits two-stage compressors, TCMO, TSMC 100 S-L 31. . . . . . . . . R507 - Operating limits single stage compressors CMO, SMC 100 S-L 32. . . . . . . . . . . R507 - Operating limits two-stage compressors TCMO, TSMC 100 S-L 33. . . . . . . . . . . R407 - Operating limits one-stage compressors CMO & SMC 34. . . . . . . . . . . . . . . . . . .

General operating instructions for CMO/TCMO, SMC/TSMC piston compressors 35. . . . . Starting up compressor and plant 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stopping and starting-up compressor during a short period of standstill 36. . . . . . . . . . . Stopping plant for brief periods (until 2-3 days) 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stopping plant for lengthy periods (more than 2-3 days) 37. . . . . . . . . . . . . . . . . . . . . . . . Automatic plants 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure testing refrigeration plant 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pumping down refrigeration plant 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating log 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Servicing the piston compressor 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure drop test: 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing refrigerant from compressor 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubricating oil 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricating oil requirements 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General rules for use of lubricating oil in refrigeration compressors 46. . . . . . . . . . . . . . . Instructions for choosing lubricating oil for refrigeration compressors 46. . . . . . . . . . . . . Charging refrigeration compressor with lubricating oil 46. . . . . . . . . . . . . . . . . . . . . . . . . . . Changing oil in refrigeration compressor 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Charging the compressor with oil 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 0178-910-EN

Assessing the oil 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Visual assessment 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Analytical evaluation 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The analysis 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Expected discharge gas temperatures 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Servicing the refrigeration plant 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance of reciprocating compressor 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. If the compressor is operational 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. If the compressor is inoperative 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Top covers 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mounting top and water covers 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Discharge valve 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tightness testing of discharge valve 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder lining with suction valve 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting rod 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shaft seal 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main bearings 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compressor lubricating system 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil pump 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chain-driven oil pump with inverse direction of rotation 72. . . . . . . . . . . . . . . . . . . . . . . . . Oil pressure valve 74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . By-pass valve pos. 24 75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil filter 76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Suction filters 78. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stop valves 79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Unloaded start and capacity regulation on SMC and TSMC 100 and 180 compressors 81Description of unloader mechanism and capacity regulation 81. . . . . . . . . . . . . . . . . . . . . Pilot solenoid valves 83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Schematic outlines 84. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard unloaded start and capacity regulation 85. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Schematic drawings 1 85. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Totally unloaded start and capacity regulation 86. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Schematic drawings 2 86. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Relief cylinders 87. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Heating rods for heating the oil in reciprocating and screw compressors 88. . . . . . . . . . . . .

Stop valves pos. 23 and 42 89. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Monitoring cylinder lining insertion 90. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. Checking clearance volume 90. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment is made as follows: 90. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. Checking lifting reserve 91. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Check lifting reserve: 91. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure gauges 93. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Undersize Bearing Diameters for Crankshaft 95. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sundry clearances and check dimensions 96. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0178-910-EN 5

Torque moments for screws and bolts 97. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Refrigeration Plant Maintenance 99. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operational reliability 99. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pumping down the refrigeration plant 99. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dismantling plant 99. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tightness testing and pump-down of refrigeration plant 100. . . . . . . . . . . . . . . . . . . . . . . . .

Trouble-shooting on the Reciprocating Compressor Plant 101. . . . . . . . . . . . . . . . . . . . . . . . . . Remedying malfunctions 110. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Selecting lubricating oil for SABROE compressors 113. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Data sheet for listed Sabroe oils 119. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . List of major oil companies 141. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Alignment of unit, AMR coupling 143. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fitting and alignment of AMR-type coupling 146. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boring of motor flange for AMR coupling 149. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

V-belt drive for piston compressor types (T)CMO and (T)SMC 150. . . . . . . . . . . . . . . . . . . . . .

Oil Separator OVUR for SMC/TSMC 100 HPC - SMC/TSMC 180 152. . . . . . . . . . . . . . . . . . .

Connections on SMC 104-106-108 Mk3, HPC 104S-106S-108S 156. . . . . . . . . . . . . . . . . . . . Connections on TSMC 108 Mk3 157. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil return in parallel operation for reciprocating compressors 158. . . . . . . . . . . . . . . . . . . . . . .

Reciprocating compressors used for air conditioning 161. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Water-cooling of reciprocating compressors 162. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure loss in water cooling on SMC/TSMC/HPC compressors 165. . . . . . . . . . . . . . . .

Thermo pump cooling of R717 reciprocating compressors 166. . . . . . . . . . . . . . . . . . . . . . . . . Principle drawings 167. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil cooling with an OSSI or HE8S oil cooler 175. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HFC and HCFC compressors: 175. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cooling of the intermediate gas on TCMO and TSMC 100 and 180 176. . . . . . . . . . . . . . . . .

Ordering Spare Parts 181. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spare parts sets for compressors and units 182. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compressor block 182. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spare part set for Basic Unit 182. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

List of parts for SMC/TSMC 0661-680. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tools for compressor SMC/TSMC 0661-684. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spare Parts drawing 0661-521/0661-522. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spare Parts drawings (in detail) 0661-520. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Piping diagram order specific. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring diagram order specific. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dimension sketch order specific. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cooling water diagram order specific. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Foundation order specific. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Positioning of vibration dampers order specific. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 0178-910-EN

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(Chemical formula: NH3 - refrigerant no.: R717)

General

Ammonia is not a cumulative poison. It has adistinctive, pungent odour that even at verylow, harmless concentrations is detectable bymost persons. Since ammonia is self-alarm-ing, it serves at its own warning agent, sothat no person will voluntarily remain in con-centrations which are hazardous. Since am-monia is lighter than air, adequate ventilationis the best means of preventing an accu-mulation.

Experience has shown that ammonia is ex-tremely hard to ignite and under normalconditions is a very stable compound. Underextremely high, though limited concentra-tions, ammonia can form ignitable mixtureswith air and oxygen, and should be treatedwith respect.

Basic rules for first aid

1. Call a doctor immediately.

2. Be prepared: Keep an irrigation bottleavailable, containing a sterile isotonic(0.9%) NaCl-solution (salt water).

3. A shower bath or water tank should beavailable near all bulk installations withammonia.

4. When applying first aid, the persons as-sisting should be duly protected to avoidfurther injury.

Inhalation

1. Move affected personnel into fresh air im-mediately, and loosen clothing restrictingbreathing.

2. Call a doctor/ambulance with oxygenequipment immediately

3. Keep the patient still and warmly wrappedin blankets.

4. If mouth and throat are burnt (freeze oracid burn), let the conscious patient drinkwater, taking small mouthfuls.

5. If conscious and the mouth is not burnt,give hot, sweet tea or coffee (never feedan unconscious person).

6. Oxygen may be administered, but onlywhen authorized by a doctor.

7. If breathing fails, apply artificial respira-tion.

Eye injuries from liquid splashes orconcentrated vapour

1. Force the eyelids open and rinse eyes im-mediately for at least 30 minutes with thesalt water solution just mentioned


0170

-008

-EN

96.0

1

0178-910-EN 7

Skin burns from liquid splashes orconcentrated vapour

1. Wash immediately with large quantities ofwater and continue for at least 15 minutes,removing contaminated clothing carefullywhile washing.


3. After washing, apply wet compresses(wetted with a sterile isotonic (0.9%)NaCl-solution (salt water)) to affectedareas until medical advice is available.

No plant can ever be said to be too safe.Safety is a way of life.

8 0178-910-EN

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Refrigerant no.: R134a – R404A - R410A - R505A - R507 - R22, etc

General

HFC/HCFC form colourless and invisiblegasses which are heavier than air and smellfaintly of chloroform at high concentrationsonly. They are non-toxic, non-inflammable,non-explosive and non-corrosive under nor-mal operating conditions. When heated toabove approx. 300°C they break down intotoxic, acid gas components, which arestrongly irritating and aggessive to nose,eyes and skin and generally corrosive. Be-sides the obvious risk of unnoticeable, heavygases displacing the atmospheric oxygen,inhalation of larger concentrations may havean accumulating, anaesthetic effect whichmay not be immediately apparent. 24 hoursmedical observation is, therefore, recom-mended.

Basic rules for first aid

1. When moving affected persons from low-lying or poorly ventilated rooms wherehigh gas concentrations are suspected,the rescuer must be wearing a lifeline, andbe under continuous observation from anassistant outside the room.

2. Adrenalin or similar heart stimuli must notbe used.

Inhalation

1. Move affected person into fresh air im-mediately. Keep the patient still and warmand loosen clothing restricting breathing.

2. If unconscious, call a doctor/ambulancewith oxygen equipment immediately.

3. Give artificial respiration until a doctor au-thorizes other treatment.

Eye injuries

1. Force eyelids open and rinse with a sterileisotonic (0.9%) NaCl-solution (salt water)or pure running water continuously for 30minutes.

2. Contact a doctor, or get the patient to ahospital immediately for medical advice.

Skin injuries – Freeze burns

1. Wash immediately with large quantities ofluke warm water to reheat the skin. Continue for at least 15 minutes, removingcontaminated clothing carefully whilewashing.

2. Treat exactly like heat burns and seekmedical advice.

3. Avoid direct contact with contaminated oil/refrigerant mixtures from electrically burnt-out hermetic compressors.

No plant can ever be said to be too safe.Safety is a way of life.

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��

Increasing industrialisation threatens our en-vironment. It is therefore absolutely impera-tive that we protect nature against pollution.

To this end, many countries have passed le-gislation in an effort to reduce pollution andpreserve the environment. These laws applyto all fields of industry, including refrigeration,and must be complied with.

Be especially careful with the following sub-stances:

� refrigerants

� cooling media (brines etc)

� lubricating oils.

Refrigerants usually have a natural boilingpoint which lies a good deal below 0°C. Thismeans that liquid refrigerants can be extre-mely harmful if they come into contact withskin or eyes.

High concentrations of refrigerant vapoursare suffocating when they displace air; if high

concentrations of refrigerant vapours are in-haled they attack the human nerve system.

When halogenated gasses come into contactwith open flame or hot surfaces (over approx.300°C) they decompose to produce poiso-nous chemicals, which have a very pungentodour, warning you of their presence.

In high concentrations, R717 causes respira-tory problems, and when ammonia vapourand air mix 15 to 28 vol. %, the combinationis explosive and can be ignited by an electricspark or open flame.

Oil vapour in the ammonia vapour increasesthis risk significantly as the point of ignitionfalls below that of the mixture ratio stated.

Usually the strong smell of ammonia will give ample warning of its presence beforeconcentrations become dangerous.

The following table shows the values for refri-gerant content in air, measured in volume %.Certain countries may, however, have an offi-cial limit which differs from those stated.

R717

vol.% 0,1 0,005

vol.% 0,2 0,002

R134a R404A R507 R22

0,10,10,1

R407C

0,1

HCFCHFC

R410A

0,1

Halogenated refrigerants Ammonia

Unit

Time weighted ave-

rage during a week

Warning smell

TWA

10 0178-910-EN

Further comments on refrigerants:� If released to the atmosphere, haloge-

nated refrigerants of the type HCFC (e.g. R22) may cause a depletion of theozone layer in the stratosphere. Theozone layer protects the earth from theultraviolet rays of the sun. Refrigerants ofthe types HFC and HCFC are greenhousegases with contribute to an intensificationof the greenhouse effect. They must,therefore, never be released to the atmo-sphere. Use a separate compressor todraw the refrigerant into the plant con-denser/receiver or into separate refriger-ant cylinders.

� Most halogenated refrigerants are mis-cible with oil. Oil drained from a refrigera-tion plant will often contain significantamounts of refrigerant. Therefore, reducethe pressure in the vessel or compressoras much as possible before draining theoil.

� Ammonia is easily absorbed by water:At 15°C, 1 litre of water can absorb approx. 0,5 kg liquid ammonia (or approx. 700 litres ammonia vapour).

� Even small amounts of ammonia in water(2-5 mg per litre) are enough to wreakhavoc with marine life if allowed to pollutewaterways and lakes.

� As ammonia is alkaline it will damageplant life if released to the atmosphere inlarge quantities.

Refrigerant evacuated from a refrigerantplant shall be charged into refrigerant cylin-ders intended for this specific refrigerant.

If the refrigerant is not to be reused, return itto the supplier or to an authorized incinerat-ing plant.

Halogenated refrigerants must never bemixed. Nor must R717 ever be mixed withhalogenated refrigerants.

Purging a refrigeration plant

If it is necessary to purge air from a refrige-ration plant, make sure you observe the follo-wing:

� Refrigerants must not be released to theatmosphere.

� When purging an R717 plant, use an ap-proved air purger. The purged air mustpass through an open container of waterso that any R717 refrigerant remainingcan be absorbed. The water mixture mustbe sent to an authorized incinerating plant.

� Halogenated refrigerants can not be ab-sorbed by water. An approved air purgermust be fitted to the plant. This must bechecked regularly using a leak detector.

Cooling media

Salt solutions (brines) of calcium chloride(CaCl2) or sodium chloride (NaCl) are oftenused.

In recent years alcohol, glycol and halogena-ted compounds have been used in the brineproduction.

In general, all brines must be considered asharmful to nature and must be used withcaution. Be very careful when charging orpurging a refrigeration plant.

Never empty brines down a sewer or intothe environment.

The brine must be collected in suitable con-tainers, clearly marked with the contents, andsent to an approved incinerating plant.

0178-910-EN 11

Lubricating oils

Refrigeration compressors are lubricated byone of the following oil types, depending onthe refrigerant, plant type and operating con-ditions.

– mineral oil

– semi-synthetic oil

– alkyl benzene-based synthetic oil

– polyalphaolefine-based synthetic oil

– glycol-based synthetic oil.

When you change the oil in the compressoror drain oil from the refrigeration plant’s ves-sels, always collect the used oil in containersmarked “waste oil” and send them to an ap-proved incinerating plant.

Note

This instruction provides only general information. The owner of the refrigeration plant is responsible for ensuring that all by-laws are complied with.

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��

� ��

The SMC 100 and TSMC 100 compressorshave 100 mm diameter pistons, as indicatedby the first digit in the type designation. Thenumber of cylinders in the compressor blockis indicated by the following two digits,where, for example, SMC 108 is an 8-cylin-der compressor. SMC 100 is a one-stagecompressor which compresses the gas in asingle stage.

In the TSMC 100 two-stage compressors, thegas is compressed in two stages at a ratio of1:3 between the number of high- and low-pressure cylinders. Thus, a TSMC 108 has 2high-pressure cylinders and 6 low-pressurecylinders. The SMC 100 and TSMC 100 areavailable in three versions: an S-type with 80mm stroke, an L-type with 100 mm stroke,and an E-type with 120 mm stroke. The compressor works on the refrigerantsmentioned in the following chapter.

The type can be determined by the name-plate, located on the end face of the com-pressor, facing away from the coupling/beltdrive. The following illustration shows a SABROE nameplate.

SABROE

Shop noMax. speed

Test pressureWorking pressureSwept volume

Type Refrigerant

barbar

r.p.m.

T0177093_2

AARHUS DENMARK

m3/h

Year

Similarly, the name-plate indicates the com-pressor’s serial number, which is also stamp-ed into the compressor housing near the suc-tion chambers.

Whenever contacting SABROE about thecompressor, its serial number should bestated.

In the compressors the pistons operate incylinder linings, inserted in the compressorblock with two cylinders under each top cov-er. The suction valves, of the ring-plate type,are mounted at the top of the cylinder linings.The pressure valves form the top of the cylin-

0178-910-EN 13

der linings and are kept in position by a pow-erful safety spring. The safety spring allowsthe discharge valve unit to rise, providing agreater throughflow aperture in the event ofliquid strokes in the cylinder. This preventsany overloading of the connecting rod bear-ings.

The crankshaft is supported in slide bearingsable to assimilate both radial and axialforces. The oil pressure for the bearings andthe capacity regulating system is suppliedfrom the gearwheel oil pump incorporated inthe compressor.

At the axle end, the crankshaft is fitted with abalanced slide-ringtype seal consisting of acast iron ring with an O-ring which rotateswith the crankshaft, and a stationaryspring-loaded carbon ring.

All compressors can be capacity-regulatedby connecting or disconnecting the cylindersin pairs. The following diagram shows thecapacity stages at which the compressorscan operate.

Capacity regulation is controlled by means ofsolenoid valves mounted on the compressor.

SMC 104 x x

SMC 106 x x x

SMC 108 x x x x

TSMC 108 x x x

25% 33% 50% 67% 75% 100%

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Direction of rotation

In order to reduce the noise level from theelectric motors these are often executed withspecially shaped fan wings, thus determininga particular direction of rotation.

In case you yourself order a motor youshould take into consideration whether themotor is intended for direct coupling or forbelt drive of the compressor.

The direction of rotation of the compressorfor compressors CMO-TCMO and SMC-TSMC is indicated by an arrow cast into thecompressor cover, near the shaft seal.

On the BFO compressors the direction ofrotation is not indicated by an arrow but isstandard as illustrated by the followingsketch:

Seen towards shaft end

Handling of compressor and unit

For lifting of the compressor the large modelsare equipped with a threaded hole for mount-ing of the lifting eye. As to the weight of thecompressor, see table on compressor data.

Note:

The compressor block alone may be liftedin the lifting eye. The same applies to themotor.

The unit is lifted by catching the lifting eyeswelded onto the unit frame. These have been

clearly marked with red paint. The weight ofthe unit is stated on the package as well as inthe shipping documents.

During transportation and handling careshould be taken not to damage any of thecomponents, pipe or wiring connections.

Areas of application of the recipro-cating compressorsCompressor types: BFO 3-4-5CMO-TCMO, SMC 100-TSMC 100 Mk3, S, L, ESMC 180-TSMC 180, HPO-HPC

In view of preventing an unintended applica-tion of the compressor, which could causeinjuries to the operating staff or lead to tech-nical damage, the compressors may only beapplied for the following purposes:

The compressor may ONLY be used:

� As a refrigeration compressor with a num-ber of revolutions and with operating limitsas indicated in this manual or according toa written agreement with SABROE.

� With the following refrigerants:R717 – R221 – R134a1 – R404A1 –R410A1 – R5071 – R6001 – R600A1 –R2901 – LPG1 1) Exempted are the following compres-sors:SMC-TSMC 100 E (only R717)HPO and HPC (only R717 and R410A))

All other types of gas may only be used following a written approval from SABROE.

� As a heat pump:

0178-910-EN 15

– BFO 3-4-5

CMO - TCMO and SMC - TSMC maybe used with a max. discharge pressureof 25 bar.

– HPO – HPC may be used with a max.discharge pressure of 40 bar.

� In an explosion-prone environment, pro-vided the compressor is fitted with ap-proved explosion-proof equipment.

The compressor must NOT be used:

� For evacuating the refrigeration plant of airand moisture,

� For putting the refrigeration plant under airpressure in view of a pressure testing,

� As an air compressor.

Emergency device

The compressor control system must beequipped with an emergency device.

In case the compressor is delivered with aSABROE-control system this emergency de-vice is found as an integrated part of the con-trol.

The emergency device must be executed ina way to make it stay in its stopped position,following a stop instruction, until it is deliber-ately set back again. It must not be possibleto block the emergency stop without a stopinstruction being released.

It should only be possible to set back theemergency device by a deliberate act, andthis set back must not cause the compressorto start operating. It should only make it pos-sible to restart it.

Other demands to the emergency device:

� It must be possible to operate it by meansof an easily recognizable and visible

manual handle, to which there is free ac-cess.

� It must be able to stop any dangerous si-tuation, which may occur, as quickly aspossible without this leading to any furtherdanger.

Combustion motors

If combustion motors are installed in roomscontaining refrigeration machinery or roomswhere there are pipes and components con-taining refrigerant, you must make sure thatthe combustion air for the motor is derivedfrom an area in which there is no refrigerantgas, in case of leakage.

Failure to do so will involve a risk of the lubri-cating oil from the combustion motor mixingwith the refrigerant; at worst, this may giverise to corrosion and damage the motor.

Explosion-proof electrical execution

If the compressor is delivered in an explo-sion-proof electrical execution, this is statedin the table on page 1 of this instructionmanual.

Likewise, the compressor will, besides theSABROE name plate, be equipped with anEx-name plate like the one illustrated below.

T2516273_0

16 0178-910-EN

The temperature of tangible surfaces

When a compressor is working, the surfacesthat are in contact with the warm dischargegas also get warm. However, the temperatu-re depends on which refrigerants and underwhich operating conditions the compressor is working. Often, it exceeds 70°C which formetal surfaces may cause your skin to beburnt even at a light touch.

Consequently, the compressors will be equip-ped with yellow warning signs informingyou that pipes, vessels and machine parts

close to the warning signs during operationare so hot that your skin may be burnt from 1second’s touch or longer.

0170

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0178-910-EN 17

��

��

In the following tables the noise data of thecompressors is stated in:

– A-weighted sound power level LW (Sound Power Level)

– A-weighted sound pressure level LP(Sound Pressure level)

The values for LW constitute an average of alarge number of measurings on various units.The measurings have been carried out in ac-cordance with ISO 9614-2.

The values are further stated as averagesound pressure in a free field above a re-flecting plane at a distance of 1 meter froma fictional frame around the unit. See fig. 1.

Normally, the immediate sound pressurelies between the LW and LP values and canbe calculated provided that the acoustic dataof the machine room is known.

For screw compressors the average valuesare indicated in the tables for the followingcomponents.

� SAB 81-83-85-87-89, SAB 128, Mk3,SAB 163 Mk3, SAB 202, SAB 330, SVand FV:Compressor block + IP23 special motor +oil separator.

� SAB 128 HR and SAB 163 HR:Compressor block at max. number of revolutions + IP23 special motor + oil separator

� SAB 110:Compressor block + IP23 standard motor+ oil separator

Dimensional tolerances are:

±3 dB for SAB, SV and FV screw com-pressors±5 dB for VMY screw compressors

As to the reciprocating compressors thevalues are stated for the compressor blockonly.

The dimensional values are stated for 100%capacity.

Fictional frame

Reflecting plane

Fig. 1

1 meter

Dimensional plane

1 meter

18 0178-910-EN

Note the following, however:

� at part load or if the compressor workswith a wrongly set Vi the sound level cansometimes be a little higher than the oneindicated in the tables.

� additional equipment such as heat ex-changers, pipes, valves etc. as well as thechoice of a different motor type can in-crease the noise level in the machineroom.

� as already mentioned, the stated soundpressures are only average values abovea fictional frame around the noise source.Thus, it is sometimes possible to measurehigher values in local areas than the onesstated – for inst. near the compressor andmotor.

� the acoustics is another factor that canchange the sound level in a room. Pleasenote that the sound conditions of the sitehave not been included in the stateddimensional values.

� by contacting SABROE you can havesound data calculated for other operatingconditions.

The tables have been divided into reciprocat-ing and screw compressors, respectively.The reciprocating compressors are furtherdivided into one- and two-stage compressorsas well as in a heat pump. In each table theoperating conditions of the compressor dur-ing noise measuring have been stated, justas the refrigerant used has been mentioned.

0178-910-EN 19

RECIPROCATING COMPRESSORSOne-stageEvaporating temperature = –15°CCondensing temperature =+35°CRefrigerant = R22/R717Number of revolutions =1450 rpm.

Compressor block LW LP

CMO 24 84 69

CMO 26 86 71

CMO 28 87 72

SMC 104 S 95 79

SMC 106 S 96 80

SMC 108 S 97 81

SMC 112 S 99 82

SMC 116 S 100 83

SMC 104 L 96 80

SMC 106 L 97 81

SMC 108 L 98 82

SMC 112 L 100 83

SMC 116 L 101 84

SMC 104 E 96 80

SMC 106 E 97 81

SMC 108 E 98 82

SMC 112 E 100 83

SMC 116 E 101 84

Evaporating temperature = –15°CCondensing temperature = +35°CRefrigerant = R22/R717Number of revolutions = 900 rpm.


SMC 186 101 83

SMC 188 102 84

Two-stageEvaporating temperature = –35°CCondensing temperature = +35°CRefrigerant = R22/R717Number of revolutions =1450 rpm.

TCMO 28 81 66

TSMC 108 S 95 79

TSMC 116 S 97 81

TSMC 108 L 96 80

TSMC 116 L 98 82

TSMC 108 E 96 80

TSMC 116 E 98 82

LW LPCompressor block

Evaporating temperature = –35°CCondensing temperature = +35°CRefrigerant = R22/R717Number of revolutions = 900 rpm.


TSMC 188 100 82

Heat pumpEvaporating temperature = +20°CCondensing temperature = +70°CRefrigerant = R22/R717Number of revolutions =1450 rpm.

HPO 24 91 76

HPO 26 93 78

HPO 28 94 79

HPC 104 97 81

HPC 106 98 82

HPC 108 99 84


20 0178-910-EN

SCREW COMPRESSORSEvaporating temperature = –15°CCondensing temperature = +35°CRefrigerant = R22/R717Number of revolutions = 2950 rpm.*Number of revolutions = 6000 rpm.

SAB 110 SM 98 81SAB 110 SF 98 81SAB 110 LM 98 81SAB 110 LF 98 81

SAB 128 HM Mk2 102 84SAB 128 HF Mk2 106 88SAB 128 HM Mk3 101 84SAB 128 HF Mk3 104 86SAB 128 HR* 102 84

SAB 163 HM Mk2 105 86SAB 163 HF Mk2 109 90SAB 163 HM Mk3 103 86SAB 163 HF Mk3 106 87SAB 163 HR* 103 85

SAB 202 SM 104 85SAB 202 SF 105 86SAB 202 LM 104 85SAB 202 LF 105 86

SAB 330 S 106 87SAB 330 L 106 87SAB 330 E 106 87

SV 17 100 83SV 19 101 84

FV 19* 101 86

SV 24 103 85

FV 24* 104 86

SV 26 103 85

FV 26* 107 85

SAB 81 101 86SAB 83 102 85SAB 85 103 86SAB 87 105 86SAB 89 108 85


Min liquid pressure for liquid injection, suctionpressure bar (a) x 2+2 bar

Evaporating temperature = –35°CCondensing temperature = –5°CRefrigerant = R22/R717

Number of revolutions = 2950 rpm.

Compressor unit LW LP

SAB 163 BM 106 88

SAB 163 BF 110 92

Evaporating temperature = –15°CCondensing temperature =+35°CRefrigerant = R22/R717



VMY 347 H 97 82

VMY 447 H 100 85

VMY 536 H 104 88

Evaporating temperature = 0°CCondensing temperature =+35°CRefrigerant = R22/R717



VMY 347 M 99 84

VMY 447 M 101 86

VMY 536 M 105 89

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0178-910-EN 21

��

Vibration data for SABROE screw compres-sors comply with the following norm:

ISO 2372 group C

Depending on the laying of the foundationand the size of the motor a screw compres-

sor unit can - under normal circumstances -be classified in Class III or IV according tothe following table from ISO 2372. Recip.compressor units can be classified in classIV, likewise under normal conditions.

Vibration severity ranges and examples of their application to small machines (Class I) medium size ma-chines (Class II), large machines (Class III) and turbo machines (Class IV)

Ranges of vibration severityExamples of quality judgement

for separate classes of machines

Range ms-velocity V (in mm/s) Class I Class II Class III Class IVat the range limits

0.280.450.71

1.121.82.84.5

7.1

11.2

1828

45

71

0.280.450.71

1.121.82.84.5

7.111.2

18

28

45

A

B

C

D

A

B

C

D

A

B

C

D

A

B

C

D

SABROE screw compressor unit: Group C, class III or IVSABROE recip. compressor unit:Group C, class IV.

Pay attention to the following, however:

� On placing the unit on the vibrationdampers delivered by SABROE(additional) the vibrations against thefoundation are reduced by:

– 85-95% for screw compressor units

– 80 % for recip. compressor units

� However, a higher vibration level may oc-cur if:

– Motor and compressor have not beenaligned as described in the InstructionManual.

– For screw compressors, if the compres-sor runs at a wrong Vi ratio.

– The pipe connections have beenexecuted in a way that makes them forcepull or push powers on the compressorunit or they may transfer vibrations to theunit, caused by natural vibrations or con-nected machinery.

– The vibrations dampers have not beenfitted or loaded correctly as indicated onthe foundation drawing deliveredtogether with the order.

Jesper Jensen

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CMO 4, CMO 24-28, TCMO 28, SMC 104-116,TSMC 108-116, SMC 186-188, TSMC 188

Operating limitsSABROE prescribes operating limits within which the compressor and any additional equipmentmust operate. These limits for R717, R22, R134a, R404A, R507 and R407C are shown in thefollowing tables, together with the main data for the compressor.

Compressortype

Number ofcylinders

Bore

mm

Stroke

mm

Max/minSpeed

RPM

Swept volume

max RPM*m3/h

Weight(max.)

compr. blockkg

CMO 4 4 65 65 1800/900 93,2 200CMO 24 4 70 70 1800/900 116 340CMO 26 6 70 70 1800/900 175 380CMO 28 8 70 70 1800/900 233 410TCMO 28 2+6 70 70 1800/900 175 410SMC 104S 4 100 80 1500/700 226 580SMC 106S 6 100 80 1500/700 339 675SMC 108S 8 100 80 1500/700 452 740SMC 112S 12 100 80 1500/700 679 1250SMC 116S 16 100 80 1500/700 905 1350TSMC 108S 2+6 ♦ 100 80 1500/700 339 775TSMC 116S 4+12 ♦ 100 80 1500/700 679 1400SMC 104L 4 100 100 1500/700 283 580SMC 106L 6 100 100 1500/700 424 675SMC 108L 8 100 100 1500/700 565 740SMC 112L 12 100 100 1500/700 848 1250SMC 116L 16 100 100 1500/700 1131 1350TSMC 108L 2+6♦ 100 100 1500/700 424 775TSMC 116L 4+12♦ 100 100 1500/700 757 1400SMC 104E 4 100 120 1500/700 339 600SMC 106E 6 100 120 1500/700 509 700SMC 108E 8 100 120 1500/700 679 770SMC 112E 12 100 120 1500/700 1018 1300SMC 116E 16 100 120 1500/700 1357 1400TSMC 108E 2+6♦ 100 120 1500/700 509 800TSMC 116E 4+12♦ 100 120 1500/700 1018 1450SMC 186 6 180 140 1000/450 1283 2560SMC 188 8 180 140 1000/450 1710 2840TSMC 188 2+6♦ 180 140 1000/450 1283 2900

✶ The maximum speed permitted can be lower than stated here depending on operating conditions and refrigerant; please see the following diagrams.

♦ Two - stage compressors (High Stage cylinders and Low Stage cylinders)

TE

TC°C

–30

–20

–10

–60 –50 –40 –30 –20 –10 0 10 20 30 40

0

10

20

30

40

50

60

70

T24

5400

_0/2

Co

nd

ensi

ng

tem

per

atu

re

Evaporating temperature

�

�

�

�

°C–70–40

–76 –58 –40 –22 –4 14 32 50 68 86 104 °F–94

°F

–22

–4

14

32

50

68

86

104

122

140

158

–40

0178-910-EN 23

R717Operating limits

single stagecompressors

CMOSMC 100 S-L

SMC 180

Type Area rpm Cooling

max min Booster Single and HP-stage compr.

1–2 Air-cooled top- and side covers # - or water-cooledCMO 20

3-41800 900

Water-cooled Thermopump or water-cooled

1-2 Air-cooled top- and side covers # - or water-cooled

SMC 100 S-L 31500

700

4 1200Water-cooled Thermopump or water-cooled

1 750

SMC 180 2-3 1000 450 Water-cooled

4 900

# Including refrigerant-cooled oil cooler

Thermopump:Top- and side covers are cooledby refrigerant injection.Oil cooling included in the system

Water-cooled:Top- and side covers.Oil cooling included in the system.

NB: At part load the discharge gas temp. must not exceed 150°C/302°F

T24

5400

_0/2

�

�

�

TE

TC°C

–30

–20

–10

–60 –50 –40 –30 –20 –10 0 10 20 30 40

0

10

20

30

40

50

60

70

Co

nd

ensi

ng

tem

per

atu

re


°C–70–40

–76 –58 –40 –22 –4 14 32 50 68 86 104 °F–94

°F

–22

–4

14

32

50

68

86

104

122

140

158

–40

24 0178-910-EN



SMC 100 E

Type Area rpm Cooling

max min Booster Single and HP-stage compr.

1-(1a) 1500SMC 100E

2 1200700 Water-cooled Thermopump or water

Thermopump:Top- and side covers are cooledby refrigerant injection.Oil cooling included in the system


NB: At part load the discharge gas temp. must not exceed 150°C/302°F

1a: In this area the compressor is not allowed to run at a capacity below 50%.

0178-910-EN 25


two-stagecompressors

TCMOTSMC 100 S-L-E

TSMC 180

Type Area rpm Cooling Note

max min top and side

TCMO 1–2 1800 900 Thermopump or water-cooled

TSMC 100 S-L-E

1-2 1500 700 Thermopump or water-cooled 1)

1 7501)TSMC 180

2 1000450 Water-cooled 1)

Oil cooling is always necessary.

Thermopump:Only the HP Stage top covers are cooledby a thermo pumpOil cooling included in the system


Part-load operation:1) Depending on the operating conditions

and the presure on the compressor a by-pass system may be required.

See section: By-pass system for two-stage compressors.

�

�

0177

128_

0 V

IEW

3,1

TE

TC°C

–30

–20

–10

–60 –50 –40 –30 –20 –10 0 10 20 30 40

0

10

20

30

40

50

60

70

Co

nd

ensi

ng

tem

per

atu

re


°C–70–40

–76 –58 –40 –22 –4 14 32 50 68 86 104 °F–94

°F

–22

–4

14

32

50

68

86

104

122

140

158

–40

�

�

�

�

TE

TC°C

–30

–20

–10

–60 –50 –40 –30 –20 –10 0 10 20 30 40

0

10

20

30

40

50

60

70

Co

nd

ensi

ng

tem

per

atu

re


°C–70–40

–76 –58 –40 –22 –4 14 32 50 68 86 104°F–94

°F

–22

–4

14

32

50

68

86

104

122

140

158

–40

0177

128_

0 V

IEW

4,1

26 0178-910-EN

R22Operating limits


CMOSMC 100 S-L

SMC 180

Type Area rpm Oil-cooling Notemax min required 1)

1 no

21500

noCMO

3900

At less than 50% capacity

41800

yes

1 1000 no

2 1200 noSMC 100 S

3 1500700

At less than 50% capacity

4 1200 yes

1 Not applicable

2 1000 noSMC 100 L

3 1200 700 At less than 50% capacity

4 1000 yes

1-2 Not applicable

SMC 180 3 At less than 50% capacity

4750 450

yes

Top covers: Air-cooled design only.1) When oil cooling is required there is a free

choice between A and B - However, forSMC 180 only A may be selected.

A: Water-cooled side coversB: Built-in refrigerant-cooled oil cooler with

thermostatic expansion valve.

��

�

�

TE

TC°C

–30

–20

–10

–60 –50 –40 –30 –20 –10 0 10 20 30 40

0

10

20

30

40

50

60

70

Co

nd

ensi

ng

tem

per

atu

re


°C–70–40

–76 –58 –40 –22 –4 14 32 50 68 86 104 °F–94

°F

–22

–4

14

32

50

68

86

104

122

140

158

–40

0177

128_

0 V

IEW

5,1

0178-910-EN 27

R22 Operating limits


TCMOTSMC 100 S-L

TSMC 180

Type Area rpm Oil-cooling Note

max min required 1)

1-2 1500TCMO

3-4 1800900 no

1 1000TSMC 2-3 1200 700 yes 2)100 S

4 1500

1 Not applicableTSMC 2 1000

2)100 L3-4 1200

700 yes 2)

1-2 Not applicableSMC 180

3-4 750 450 yes 2)





Part-load operation:2) Depending on the operating conditions

and the presure on the compressor a by-pass system may be required.

See section: By-pass system for two-stage com-pressors.

28 0178-910-EN

R134a Operating limits


CMOSMC 100 S-L


max min required 1)

1200 no1-2

1500 At less than 50% capacityCMO

1500900

no3

1800 At less than 50% capacity

1 1000 no

2 1200 noSMC 100 S

1200700

no3


1 Not applicable

2 1000 noSMC 100 L

1000 700 no3


Top covers: Air-cooled design only.1) When oil cooling is required there is a

free choice between A and B.



T01

7712

8_ V

8,1

��

�

TE

TC°C

–30

–20

–10

–60 –50 –40 –30 –20 –10 0 10 20 30 40

0

10

20

30

40

50

60

70

Co

nd

ensi

ng

tem

per

atu

re


°C–70–40

–76 –58 –40 –22 –4 14 32 50 68 86 104 °F–94

°F

–22

–4

14

32

50

68

86

104

122

140

158

–40

80 176

0178-910-EN 29

R134a Operating limits


TCMOTSMC 100 S-L


max min required 1)

1-2 15001)TCMO 28

3 1800900 1)

1 1000TSMC 2 1200 700 1) 2)100 S

3 1500

1 Not applicableTSMC 2 1000

1) 2)100 L3 1200

700 1) 2)

1) Oil cooling:Not required.Top- and side covers:Only air-cooled.

2) Part-load operation:By-pass equipment required to maintain itermediate temperature at minimum load.

T01

7712

8_0

V8,

1

�

�

�

TE

TC°C

–30

–20

–10

–60 –50 –40 –30 –20 –10 0 10 20 30 40

0

10

20

30

40

50

60

70

Co

nd

ensi

ng

tem

per

atu

re


°C–70–40

–76 –58 –40 –22 –4 14 32 50 68 86 104°F–94

°F

–22

–4

14

32

50

68

86

104

122

140

158

–40

30 0178-910-EN

R404A Operating limits


CMOSMC 100 S-L


max min required 1)

1200 no1

1500 At less than 50% capacityCMO 20

1500900

no2


1 1000 no

SMC 100 S 1200 700 no2


1 1000 noSMC 100 L

2 1200700

no





2742

63.1

Rev

. 0

�

�

TE

TC°C

–30

–20

–10

–60 –50 –40 –30 –20 –10 0 10 20 30

0

10

20

30

40

50

60

Co

nd

ensi

ng

tem

per

atu

re


°C–70

–76 –58 –40 –22 –4 14 32 50 68 86 °F–94

°F

–22

–4

14

32

50

68

86

104

122

140

0178-910-EN 31

R404A Operating limits


TCMO TSMC 100 S-L


max min required 1)

11)TCMO 28

21800 900 1)

TSMC 1 12001) 2)

100 S 2 1500700 1) 2)

TSMC 1 10001) 2)

100 L 2 1200700 1) 2)



2742

63.3

Rev

. 0

�

�

TE

TC

°C

0

10

20

–60 –50 –40 –30 –20 –10 0

30

40

50

60

Co

nd

ensi

ng

tem

per

atu

re


°C–70–10

–76 –58 –40 –22 –4 14 32 °F–94

°F

32

50

68

86

104

122

140

14

32 0178-910-EN


single stagecompressors CMOSMC 100 S-L


max min required 1)

1 1200 no

2 1500 At less than 50% capacityCMO 20

2 1500900

no

3 1800 At less than 50% capacity

1 1200 no

SMC 100 S 2 1200 700 no

3 1500 At less than 50% capacity

1 1000 noSMC 100 L

2 1200700

no





7426

3.2

Rev

. 0

�

�

TE

TC°C

–30

–20

–10

–60 –50 –40 –30 –20 –10 0 10 20 30

0

10

20

30

40

50

60

Co

nd

ensi

ng

tem

per

atu

re


°C–70–40

–76 –58 –40 –22 –4 14 32 50 68 86 °F–94

°F

–22

–4

14

32

50

68

86

104

122

140

–40

0178-910-EN 33



TCMO TSMC 100 S-L

Area rpm Oil-cooling NoteType

max min required 1)

11)TCMO 28

21800 900 1)

TSMC 1 12001) 2)

100 S 2 1500700 1) 2)

TSMC 1 10001) 2)

100 L 2 1200700 1) 2)



2742

63.4

Rev

. 0

TE

TC

°C

0

10

20

–60 –50 –40 –30 –20 –10 0

30

40

50

60

Co

nd

ensi

ng

tem

per

atu

re


°C–70–10

–76 –58 –40 –22 –4 14 32 °F–94

°F

32

50

68

86

104

122

140

14

�

�

34 0178-910-EN

R407COperating Limits

one-StageCompressor type

CMO & SMC

Type Area rpm Oil-cooling Notemax min required 1)

1 1500 no

CMO 2 900 At less than 50% capacity

31800

yes

1 1200 no

SMC 100 S 2 1500 700 At less than 50% capacity

3 1200 yes

1 1000 no

SMC 100 L 2 1200 700 At less than 50% capacity

SMC 100 L 3 1000 yes

1 NOT APPLICABLE

SMC 180 2 At less than 50% capacity

3750 450

yes





Co

nd

ensi

ng

tem

per

atu

re


TE

–30

–20

–10

0

10

–60 –50 –40 –30 –20 –10 0 10 20 30

20

40

50

30

60

�

�

�

TC

–76 –58 –40 –22 –4 14 32 50 68 86 °F–94

°F

–22

–4

14

32

50

68

86

104

122

140

T245411_0 view 2

°C–70

°C

0171

-461

-EN

96.0

6

0178-910-EN 35

��

��

Starting up compressor and plant

� Before the initial start-up of the compres-sor following a lengthy stand-still period ofseveral months, the compressor must beprelubricated. Hereby, the bearings arelubricated and the oil system filled upwith oil before the compressor is set run-ning.Carry out the prelubrication by connect-ing the oil pump to the prelubricatingvalve which in the more recent SMC-TSMC-HPC compressors is connected tothe shaft seal housing pos. 6A and on theCMO-TCMO-HPO to the cover pos. 86Hor 87K. As prelubricating pump we recom-mend SABROE’s hand-operated oil pumppart no 3141-155, which is mounted asshown in fig. 1.

Fig. 1

��

��

� ��

��

��

��

For pre-lubrication use a clean new refriger-ant machine oil of the same type as theone found in the compressor, and pump asfollows:

Compressortype

Pump strokes w.SABROEs

hand-operated

Estimatedoil quantity

Liters

CMOTCMOHPO

SMC 104106-108TSMC 108HPC

SMC 112-116TSMC 116

SMC 186-188TSMC 188

appr. 25

appr. 35

appr. 45

appr. 50

2.5

3.5

4.5

5.0

oil pump

� The heating rod in the crankcase must beenergized at least 6-8 hours before start-ing up the compressor in order to boil anyrefrigerant out of the compressor oil. Atthe same time, the suction check valvemust be open.

� Check oil level in crankcase. The oil levelmust always be visible in the oil sightglass. See section: Charging the compres-sor with oil.

� Start condenser cooling, brine pumps,fans at air coolers as well as any com-pressor cooling device.

� Check correct setting of safety auto-matics on compressor.

� Open discharge stop valve at compressor.

� Set capacity regulator to minimum capa-city.

36 0178-910-EN

� In order to avoid excessive pressure re-duction in the compressor on start–up, thesuction stop valve must be opened a fewturns, as there is otherwise a risk of oilfoaming in the crankcase.

� Open all other stop valves except for themain valve in the liquid line and possibleby-pass valves serving other purposes.

� Check that the time relay 3K13 keeps thesolenoid valve in the oil return line closedfor 20-30 mins. after start-up of the com-pressor.

� Start compressor motor and check suctionand oil pressures.

� Carefully continue opening suction stopvalve to its full open position.

� Open main valve in liquid line.

� If the oil in the crankcase foams, or knock-ing noises are heard from the compressorbecause droplets of liquid are being fed inwith the suction gas, throttle suction stopvalve immediately.

� The compressor is now operating. Increase capacity stepwise, allowing thecompressor to adjust to new conditionsbefore switching to next stage. Check carefully whether oil is foaming andwhether oil pressure is correct.

� Check whether oil return from oil separa-tor is working. (Pay attention to any clog-ging of filter and nozzle.) The pipe should normally be warm.

� Do not leave plant for first 15 minutes afterstart-up and never before it has stabilized.

Stopping and starting-up com-pressor during a short period ofstandstill

Before stopping the compressor, its capacitymust be reduced to the lowest capacity stagefor a few minutes, before it stops.

During short periods of standstill, it is notnecessary to shut off the suction stop valveand the discharge stop valve. The heatingrod must be energized.

If the compressor is cooled by means of cool-ing water, the water flow must always bestopped during periods of standstill. This is normally done by means of a solenoidvalve in the water inlet line to the compres-sor.Connect the solenoid valve to the start/stoprelay of the compressor motor.

Compressor start-up must always take placeat the lowest capacity stage, after which ca-pacity is increased stepwise at suitable inter-vals, in order to avoid that a sudden exces-sive pressure reduction in the evaporationsystem causes liquid hammering in the com-pressor and oil foaming in the crankcase.

Stopping plant for brief periods(until 2-3 days)

� Shut off liquid supply to evaporators for afew minutes before stopping the plant.

� Stop compressor and shut off suction anddischarge stop valves. Close valve in oilreturn.

� Stop condenser cooling, pumps, fans andany compressor cooling.

� Cut off power supply to both master andcontrol currents.

0178-910-EN 37

Stopping plant for lengthy periods(more than 2-3 days)

� Shut off main valve after receiver andpump down evaporators. If necessary, ad-just low-pressure cut-out on unit to a lowerpressure during evacuation.

� Allow temperature in evaporators to rise,then repeat evacuation.

� When suction pressure has been reducedto slightly over atmospheric, stop com-pressor. Shut off suction and dischargestop valves and close off stop valve in oilreturn.

� Shut off condenser cooling. If there is arisk of freezing, draw off coolant.

� Cut off power supply to master and controlcurrents.

� Inspect receiver, condenser and pressurevessels as well as piping connections andapparatus for leakage.

Automatic plants

� Refrigeration plant should normally be putinto operation as described in the Start-upsection.Once started, switch over to auto-matic operation.

� Special instructions for automatic plant inquestion should be followed to the letter.

� The following should be checked daily,even on automatic plants:

– correct oil charging,

– automatic oil return,

– correct oil pressure,

– suction and condenser pressures, discharge pipe temperature,

– correct setting of safety automatics.

Pressure testing refrigeration plant

Before charging the plant with refrigerant, itmust be pressure tested and pumped down.

Pressure test the plant with one of the follow-ing:

� dry air - pressurized cylinders containingdry atmospheric air may be used - butnever oxygen cylinders;

� air compressor for high pressure;

� nitrogen.

ImportantThe plant compressors must not beused to pressurize the plant.

Water or other fluids must not be usedfor pressure testing.

If nitrogen is used, it is important to place areducing valve with a pressure gauge be-tween the nitrogen cylinder and the plant.

During pressure testing, it is important to en-sure that pressure transducers and othercontrol equipment are not exposed to thetesting pressure. The compressor stopvalves must also be closed during pressuretesting.

Plant safety valves must normally be blankedoff during pressure testing, as their openingpressure is lower than the testing pressure.

ImportantDuring this pressure testing, no personshould be allowed to be present inrooms housing plant parts or in the vicin-ity of the plant outside the rooms.

38 0178-910-EN

� The entire unit must be pressure tested inaccordance with the local regulations forpressure testing.

� The test pressure must never exceed thedisign pressure.

� If it is required that the compressor shouldbe pressure tested together with the unitor with the plant, the testing pressure mustnot exceed:For reciprocating compressors:

HP side: 24 barLP side: 17.5 bar

� Please observe that manometers, pres-sure controls, pressure transmitters andother control equipment are not exposedto testing pressure.

� Afterwards, reduce pressure to 10 bar fora period of 24 hours - as an initial tight-ness test - as a tightly sealed plant willmaintain this pressure throughout the peri-od.

During the tightness test, it is permitted toenter the room and approach the plant.

� By way of a second tightness test, ex-amine all welds, flange joints etc. for leak-age by applying soapy water, while main-taining the 10 bar pressure.

When pressure testing, compile a pressuretest report containing the following:

� date of pressure testing,

� person carrying out the test,

� comments.

Pumping down refrigeration plant

Following pressure testing, the refrigerationplant must be evacuated in order to eliminate

atmospheric air and moisture. Evacuationmust be carried out on all types of refrigera-tion plant, regardless of the type of refriger-ant with which the plant is to be charged.

Observe that HCFC and HFC refrigerantsmix only minimally with water, and it is there-fore necessary to effect evacuation of suchsystems with particular care.

The boiling point of a fluid is defined as thetemperature at which the steam pressureequals atmospheric pressure. For water, theboiling point is 100°C. Lowering the pressurealso lowers the boiling point of the water.

The table sets out the boiling point of waterat very low pressures:

Boiling point ofwater °C

At pressuremm HG

5

10

15

20

6,63

9,14

12,73

17,80

For evacuation, use a vacuum pump whichbleeds the plant of air and steam.

The vacuum pump must be able to lower thepressure to approx. 0.1 mm Hg (mercury col-umn) and must be fitted with a gas ballastvalve. This valve should be used whereverpossible to prevent water vapours condens-ing in the vacuum pump.

ImportantNever use the refrigeration compressorto evacuate the plant.

0178-910-EN 39

For a satisfactorily performed evacuation, thefinal pressure must be lower than 5 mm Hg.Attention is drawn to the fact that there maybe a risk of any water left in the refrigerationplant freezing if ambient temperatures arelower than 10°C. In such instances, it will benecessary to supply heat to the componentsurroundings, as ice evaporates with difficul-ty.

It is recommended to carry out evacuation asfollows:

� Evacuate to a pressure lower than 5 mmHg.

� Blow dry air or nitrogen into system to apressure corresponding to atmospheric.Never use OXYGEN cylinders.

� Repeat evacuation to reduce pressure toless than 5 mm Hg.

� Shut the vacuum pump off from refrigera-tion plant and check that the pressuredoes not rise for the next couple of hours.If the system still contains water, this willevaporate and cause the pressure to rise,thereby indicating unsatisfactory evacua-tion and necessitating a repetition of theprocedure.

40 0178-910-EN

Operating log

In order to keep tabs on the operating state

of the refrigeration plant, it is recommended

that an operating log be kept.

This operating log should be kept at regularintervals, thus providing important informa-tion about the cause of any undesiredchanges in the operating state. (See following page)

• Electrical panel

Oil level incompressor

Compressor motor’sconsumption in amps.

• Oil level sight glass

in compressor

• UNISAB II Control

• Compressor pressure gauge


Observation Measuring point Measurement unit

Date and timeTime

Suction pressure

Oil pressure

Oil temperature

Suction gas temp.

Discharge gas temp.

Recharding of oil oncompressor

Discharge pressure





• Thermometer in suction pipe immediately

before compressor


• Thermometer in discharge pipe immediately after compressor but before oil separator


• UNISAB II (additional)

• See section on oilcharging

°C or bar

bar

°C

°C

Must be visible in oilsight glass

Number of litres

°C or bar

Amps

°C

At the same time, attention should be paid to the following: (tick these off in the log, if you wish)� whether the compressor’s cooling system is functioning correctly,� whether any unusual noise is coming from the compressor,� whether there are unusual vibrations in the compressor.

0171

-462

-EN

99.0

3

0178-910-EN 41

��

In order to ensure problem-free operation, itis advisable to carry out regular servicing tothe refrigeration plant. In this section, SABROE indicates some periodic servicesfixed on the basis of the number of operatinghours from the first start-up or after overhand of the compressor.

The servicing schedules also depend on thespeed of the compressor. If the compressoris running at less than 1200 rpm, SABROEpermits extended service intervals. However,the compressor must always operate withinthe speed recommended by SABROE. SeeDescription of compressor. Providing thecompressor operates within the specifiedpressures and temperatures and the pre-scribed periodic services are performed, thecompressor will have a long and efficient ser-vice life.

S The following must therefore be checkeddaily:

Operating pressure,Operating temperatures,Oil level and pressure, Abnormal noise and vibrations.

The actual operating conditions should beentered in an operating log daily. See the Op-erating log section.

Pressure drop test:

Using the pressure drop test, it is possible tocheck the internal tightness of the compres-sor from discharge to suction side. The pres-sure drop test is performed with the compres-sor at standstill, as described below:

S Immediately after stopping compressor,read off pressure on discharge and suc-tion side of compressor.

S Close discharge stop valve quickly and,from moment of closure, time how long ittakes for pressure to drop on high pres-sure side of compressor. Normally, thepressure drop should not be more than 3bar over a period of 5 minutes or so.

If the pressure falls more quickly, this isdue to internal leakage, which may occur:

S where pressure valve ring plates are inbad contact with their seats (Pos. 20Cagainst Pos. 20A and 19H);

S with defective seal Pos. 19T; ( not CMO)

S with defective seal Pos. 19K;

S because cylinder lining and top cover have been tightened without long mount-ing stopper having been fitted. Cylinderlining is thus resting on rocker arms, Pos.15A; (not CMO).

S on safety valve, because valve cone doesnot fit tightly against seat, or outer O-ringPos. 24B or inner O-ring Pos. 24C is de-fective. (See Safety valve section.)

During pressure drop testing, pay attention toany piping connections to the discharge sideof the compressor, which may have an influ-ence on the test result.

Removing refrigerant from compressorBefore the compressor can be dismantled,the refrigerant must be removed from thecompressor, which can be done in the follow-ing ways:

42 0178-910-EN

1. Run compressor at lowest capacity stage

and throttle suction stop valve slowly until

completely closed.

2. The compressor will then stop on the low

pressure cut-out. This can be adjusted to

stop compressor at a pressure lower than

normal.

3. Close discharge stop valve and other pip-

ing connections to compressor.

4. On HFC and HCFC compressors, remove

remaining refrigerant gas using a pump-

down compressor connected to purge val-

ve Pos. 42.

R22

Evacuating pump

42

S On the R717 compressor, adopt the fol-

lowing method:

Water

R717

42

Connect the purge valve Pos. 42 to a sealed,empty vessel which in turn is connected to anopen tank containing water.

The water will absorb the refrigerant, whichcan then be dispatched for proper destruc-tion. The moment the pressure is equalized,the valve must be reclosed in order to pre-vent water being sucked back into the com-pressor.

Note:The following instructions apply to thecompressor only. Servicing of the refrig-eration plant is described in a separatesection. Service the compressor motor ac-cording to your own instructions. For thevarious scheduled services, SABROE cansupply ready-made spare-part sets, whichit would be an advantage to have beforecarrying out the scheduled service.

In the event that the compressor cannot op-erate, start evacuation as described under pt.3, and remember also to close the suctionstop valve.

0178-910-EN 43

Operatinghours

< 1200 rpm

Operatinghours

> 1200 rpm

Activity

75 50

1.1 Remove and discard filter bag in suction filter. Clean suction filter. Following major repair work orin event of severe soiling of filter bag, it is recom-mended that a new filter bag be fitted for anotherperiod of 50 operating hours.

1.2 Check tension of driving belts.

300 200

2.1 Check or change oil. When changing oil, change oilfilter cartridge, too. See following section:Assessing the oil.

2.2 Clean suction filter.

2.3 Check that following function correctly: Solenoid valves Compressor coolingThermopumpSafety automaticsHeating rod V-belt drive.

2.4 Retighten external piping connections.

2.5 Check oil return system from oil separator.

2.6 Retighten coupling.

Scheduled services

No.

1

2

3.1 Check or change oil. When changing oil, changeoil filter cartridge, too. See following section:Assessing the oil.


3.3 Check that following function correctly:Solenoid valves Compressor cooling Thermopump Safety automaitcsHeating rodV-belt drive Oil return system from oil separator.

3.4 For heat pump operation, inspect: Valve seats Cylinder linings Pistons, gudgeon pins and gudgeon pin bearingsPiston and oil scraper rings.

Change suction and discharge valve ring plates.

3.5 Finish off with a pressure drop test.

7500 50003

44 0178-910-EN

Operatinghours

< 1200 rpm

Operatinghours

> 1200 rpmActivity

15000 10000

4.1 Check or change oil. When changing oil, change oilfilter cartridge, too. See following section: Assessingthe oil.


4.3 Check following: Solenoid valves Oil cooling system Water cooling system for any deposits and cloggingThermopump Safety automaticsHeating rod V-belt drive Coupling and alignment Oil return system from oil separator Valve seats Cylinder linings Pistons, gudgeon pins and gudgeon pin bearingsPiston and oil scraper rings Unloading mechanism Seal for tightness

4.4 Change: Suction and discharge valve ring plates V-belts


No.

4

22500 15000

5.1 Check V-belt drive

5.2 For heat pump operation, inspect:Valve seats Cylinder linings Pistons, gudgeon pins and gudgeon pin bearings Piston and oil scraper rings.

Change:Suction and discharge valve ring plates.

5

0178-910-EN 45

OperatingHours

< 1200 rpm

OperatingHours

> 1200 rpmActivity

30000 20000

No.

6

6.1 Change compressor oil, Change oil filter cartridge, Clean crankcase.


6.3 Check following:Solenoid valves Oil cooling system Water cooling system for any deposits and cloggingThermopump Safety automatics Heating rod V-belt drive Coupling and alignment Valve seats Cylinder linings Pistons, gudgeon pins and gudgeon pin bearingsPiston and oil scraper rings Unloading mechanism Seal for tightness Oil pump and drive Check valves.

6.4 Change: Suction and discharge valve ring plates V-belts Half-sections of bearing for connecting rod (does not apply to CMO compressors)


60000 40000 Major overhaul; contact SABROE Refrigeration

37500 25000 As for service no. 5



7

8

9

10

Then repeat scheduled services from no. 3 inclusive.

46 0178-910-EN

��

Lubricating oil requirements

Above all, the refrigerator oil must providesatisfactory lubrication of the compressor,even at the relatively high temperatures oc-curring during compression. It must be inca-pable of coking at such high temperaturesand must not precipitate solid constituentssuch as paraffin or wax at the lowest occur-ring temperatures. The oil must not have anycorrosive effect, whether alone or mixed withrefrigerant. According to the oil companiesthe oils mentioned in the Oil Recommenda-tion in this instruction manual comply withthese conditions. See section on Choice oflubricating oils.

General rules for use of lubricatingoil in refrigeration compressors

S Only fresh, clean refrigeration machine oilmay be charged. Oil tapped from theevaporator system in an ammonia plantmust not be reused in the compressor.

S Use grade of oil originally prescribed forcompressor.

S As far as possible, avoid mixing differenttypes of oil. Mixed oil is generally inferiorto the two original oils. Mixing varioustypes of oil may give rise to formation ofsludge, which will lodge in valves and fil-ters.

S If necessary to switch to another brand ofoil, this must be done at the same time ascompletely changing the oil in the com-pressor and tapping off all oil from the re-frigeration plant.

S The refrigeration oil must be free of mois-ture, which may give rise to operating mal-functions and attacks of corrosion.

The oil should therefore be purchased in con-tainers corresponding to the quantity to beused for a single, or at most, two top-ups.The oil containers must be kept carefullysealed. If all the oil in a container is not usedin one go, the container should be tightlysealed and stored in a warm place to preventthe absorption of moisture.

Note:It is inadvisable to reuse oil which hasbeen drawn from a compressor or plant.This oil will have absorbed moisture fromthe air and may cause operating prob-lems. Always switch off the power to the heatingrod before drawing off the oil.

If, after reading the above, any doubt existsas to the type of oil which has been used onyour compressor, you are recommended tocontact SABROE, rather than risk chargingwith unsuitable oil.

Instructions for choosing lubricating oil for refrigeration compressorsThe instructions in Choice of lubricating oilsoffer more detailed guidelines for choosingthe lubricating oil best suited to each individ-ual case on the basis of the anticipated oper-ating conditions.

Charging refrigeration compressorwith lubricating oilSince all SABROE piston compressors aresupplied with a special oil-charging valve on

0178-910-EN 47

the crankcase, refrigeration oil may betopped up while the compressor is in opera-tion.

For this purpose, use a manual oil pump oradopt the following procedure:

Note:When charging for the first time, use theoil pump; it goes without saying that thecompressor must not be started unlessalready charged with oil.

S Reduce pressure in crankcase, e.g. bythrottling suction stop valve, until suctionpressure gauge shows pressure slightlybelow atmospheric.

S Fill pipe connected to oil charging valvewith refrigerator oil and insert free end ofpipe down into a receptacle containingfresh refrigerator oil.

S Open oil charging valve carefully, therebycausing external air pressure to force oilinto crankcase.

S Avoid getting air or other impuritiessucked into compressor.

Note:In order to achieve pressure below atmo-spheric, it will sometimes be necessary toreset the low-pressure cut-out so that thecompressor can aspirate down to thispressure. Remember to reset the pressurecut-out to its normal setting after chargingwith oil.

When in operation, the compressor may berefilled with oil using the manual oil pump.

Note:Since halocarbon refrigerants such asR22 mix with refrigeration oils, there willalways be a good portion of oil blendedwith the refrigerant in the plant. Often,

therefore, it is necessary to refill with re-frigeration oil after starting up for the firsttime and after charging with fresh refriger-ant.

For a while after the plant is started for thefirst time, keep an extra sharp eye on the oillevel in the compressor, therefore.

Changing oil in refrigeration com-pressorS Cut off power to heating rod.

S Close compressor stop valves and valvein oil return line from oil separator.

S Reduce pressure in compressor crank-case to slightly above atmospheric bythrottling suction stop valve while com-pressor is running at its lowest capacitystage. Alternatively, raise to slightly aboveatmospheric pressure by stopping com-pressor and closing suction stop valve.Pressure in crankcase will then rise gradu-ally.

S Oil in the crankcase can then be forcedout through drain valve Pos. 23 whencompressor is at a standstill.

S Equalize pressure in compressor to atmo-spheric through purge valve pos. 42. Seesection on Environmental protection.

S Dismantle side covers.

S Replace oil filter cartridge with a new one.

S Clean crankcase thoroughly, wiping with aclean, dry linen cloth (not cotton waste).

S Reassemble side covers.

S Charge to correct level with fresh, cleanrefrigerator oil according to SABROE’s oilrecommendations.

S Connect heating cartridge.

48 0178-910-EN

S Connect vacuum pump to compressor andpump down to 5-7 mm Hg; close off con-nection.

Then open suction stop valve a few turns,filling compressor with refrigerant gas. Inthe case of R717, it will suffice to blast thecompressor through by carefully openingsuction stop valve while purge valve Pos.

42 is open. See section on Environmentalprotection, however. When smelling R717,close purge valve.

S Open discharge stop valve and valve in oilreturn line; compressor is then ready forstart-up as described in sectionGeneral operating instructions.

0178-910-EN 49

��

Compressor

Type Size

Volume of oil in crankcase

Litres

BFO

CMOTCMO

SMC 100TSMC 100

Mk 3

SMC 180TSMC 180

345

242628

104106108112116

186188

1,545

141618

2628304750

8090

4 13

S-L-E

The volume of oil stated in the table is theamount which must always be present in thecrankcase.

As a rule, the compressor should be chargedwith oil after the plant is started for the firsttime, as some of the oil – especially on anHCFC installation – will be absorbed by therefrigerant in the plant.

The following determinants decide the totalvolume of oil a refrigeration plant should con-tain:

S type of refrigerant

S refrigerant charge (volume)

S size of plant

S temperature range in which refrigerationplant is to operate.

The oil level must be checked with extremecare, particularly when starting and chargingwith refrigerant.

The oil level must always be visible in theoil level sight glass. The below diagramillustrates, how many litres of oil a drop inthe oil level of 10 mm is approximatelyequal to.

T0177162_0

Compressortype size

10 millimeter difference in

oil levels equals

SMC /TSMC100S-L-E

SMC /TSMC180

CMO/TCMO

242628

~1 litre of oil

104106108

~2 litres of oil

112116 ~6 litres of oil

186188 ~6 litres of oil

Assessing the oilRefrigeration machine oil is a vital part of thecompressor, as it not only lubricates andcools the movable parts of the compressor, italso prevents abrasive particles from en-tering the bearings.

An analysis of the oil can give important in-formation on how the compressor is running.

50 0178-910-EN

We would, therefore, advise that the oil anal-yses be carried out at the intervals prescri-bed.

An oil sample must be drawn off while thecompressor is in operation, which gives arepresentative sample. Before taking thesample, clean the drain valve and tap a littleoil off, to prevent any impurities which mayhave accumulated in the valve or the pipingfrom mixing with the sample.

Visual assessmentIf you pour the sample into a clean, transpar-ent glass bottle or a test-tube and hold it upto a clear light source, it will be easy to as-sess the quality. You can also compare thesample with the fresh oil of the same makeand grade.

An oil which you approve on the grounds of avisual assessment must:

S be clear and shiny

S not contain any visible particles

S feel viscous, smooth and greasy when adrop is rubbed between two fingers.

If you don’t feel that you can approve the oilby visual assessment, charge with new oil orsend a sample to a laboratory for analysis.

WarningIf the oil sample is poured into a glass bottle,this must not be hermetically sealed until allthe refrigerant in the oil sample has evapora-ted. Refrigerant in the oil may produce ex-cess pressure in the bottle with subsequentrisks of explosion. Never fill a bottle up com-pletely. Do not send glass bottles throughthe postal service – use purpose-made plas-tic bottles. Please see below.

Analytical evaluationNaturally, the oil sample can be analysed bythe oil company which supplies the oil.

As a special offer to our customers SABROE has developed an analytical con-cept, in cooperation with Mobil Oil, which isable to analyse all oil makes. This will meana uniform reporting of the results.

The analysis allows the following to be deter-mined:

S Whether or not the oil is still usable, if nec-essary after filtering.

S Whether solid particles possibly present inthe oil originate from the bearings or othercomponents exposed to wear and tear inwhich case the compressor must be in-spected.

S Each report will include the correspondingmeasuring results from the previous 3 oilanalyses. In this way you will be able tofollow up on the state of both the oil andthe compressor from one analysis to thenext.

Procedure

� A form set with a plastic sampling bottleand a dispatching envelope can be re-quested from the local Sabroe Refrigera-tion representation.

� The oil sample must be drained from thecleaned oil drain valve into the samplebottle. Screw the lid loosely on and let thebottle stand for a few hours to enable re-frigerant contained in the oil sample toevaporate before sending it to the labora-tory.

� Please follow the Sampling and ShippingInstructions enclosed in the form set inwhich the addresses of the laboratory inHolland are also mentioned.

0178-910-EN 51

The analysis

The following section states some averagevalues that can be applied in practice. How-ever, you should be on the alert wheneverthe results of the analyses approach thesevalues. In some cases the water content of100 ppm in HCFC plants may be too muchand thus lead to Cu–plating in the shaft seal.Similarly, a rise in the oil viscosity of max.65% normally does not cause any operatingproblems as the refrigerant reduces the oilviscosity in the plant.

Kinematic viscocity at +40°C.Max. indication from the specified value at +40°C stated in the tables of Selectinglubricating oil for SABROE compressors –15% specified value +65%

� Acid number (TAN). max.0.1

� Oxidation. max.7

� Water content (ppm). max.100 (HCFC)

� Water content (ppm). max.600 (R717)

� pH value. min.4 (HCFC)

� pH value. min.5 (R717)

� Strong acids (SAN). max.0

� The oil is filtered through two filters (1,2 micron and 5 micron).

Wear particles expressed im ppm, are mea-sured for:

Lead max. 10Copper max. 10Silicon max. 25Iron max. 100Chrome max. 5Nickel max. 5Aluminium max. 10Tin max. 10

A report is drawn up for every sample re-ceived. This report indicates:

Whether the oil can still be used – withouttaking any further action.

Whether the oil can be used after it hasbeen filtered through a very fine filter.

If this is necessary, the oil must bepumped directly from the compressor unitthrough a 3 micron filter and back to theunit. The system must be completelyclosed, to prevent the oil being affected bymoisture in the air.

Whether the oil is no longer fit for use.

The report will always be sent to the addressstated on the sample label included in theform set. A copy will be sent to SABROE Re-frigeration, so that we are in a position to ad-vise you, if required.

0170

-012

-EN

96.0

4

��

��

Safety valveon the compressor

High and intermediate

Low-pressure

Oil pressure cut-out

Discharge pipe

Oil thermostat

Thermostat forcompressor cooling

Injection valve for

By-pass valve

Oil pressure

Refrigerant

22 bar (special)

24 bar (standard)

Set so that the compressor stops ata pressure 2 bar lower than the

°

3,5 bar

regulating valve

HP

IP

MP 55

* 120

* 150

° C° C

KP 98

KP 98 ° C 80

° C 55KP 77

Thermo valve forcompressor cooling

T(E) XT(E) YT(E) F

Normally set at 4 superheat.Change to min. 10 superheat

°C°C

TEAT

PMC +CVC

°C 45° C 75

° C° C-15

4.5 bar

x x x x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

*

**

**

12 bar

cut-out

cut-out

thermostat

safety valve setting.KP 5

(KP15)

KP 1(KP15)

Saf

ety

equ

ipm

ent

Co

ntr

ol e

qu

ipm

ent

Factory setting - can be adjusted, if required, to a breaking point 20°C higher than the highest normal discharge pipe temperature.For TCMO, R717 TEAT 20-2 spec., the factory setting is 85°C.Adjust the TEAT valves so that the expected discharge pipe temperature (-5°C/+10°C) is achie-ved at 100% compressor capacity.Increase the opening temperature 10°C by turning the spindle 5 turns clockwise.NB: Factory setting must always be increased by min. 10°C.

Adjustment of the TEAT valve must be carried out with the thermopump out of operation

SMC - TSMC - CMO2 - TCMO2 CMO4 0.8-1.2 bar

SMC - TSMC - CMO2 - TCMO2 CMO4

3.5 bar1.3 bar4.5 bar1) 2)

-25

2)

1)

intermediate cooling

Factory set.

Factory set.

See below.

See below.

x

x

Adjust to min 10°C superheat

Adjust to min 10°C superheatT(E) X

TEA

R22

R13

4a

R40

4A

R50

7

Set to a pressure with saturation temp.

temperature.C lower than the lowest evaporating5

R71

7

x

xx

x

x

x

x

x

x

x

x

x

x

52 0178-910-EN

0170-105-EN 96.02

0178-910-EN

53

��

��

� ��

��

��

Su

ction

gas su

perh

eat°

C

Co

nd

ensin

g tem

p. °

C

HFC - HCFC

bar

bar

bar

10

20

30

20

25

30

35

40

45

8.8

10.1

11.5

5.7

6.6

7.7

8.8

10.1

11.5

5.7

6.6

7.7

8.8

10.1

11.5

20

25

30

35

40

45

20

25

30

35

40

45

38

44

49

53

57

61

48

54

63

67

71

58

64

69

73

81

41

45

50

54

59

63

51

55

60

64

69

73

61

65

70

74

79

83

43

48

53

58

63

67

53

58

63

68

73

77

63

68

73

78

83

87

48

52

58

64

69

74

58

62

68

74

79

84

68

72

78

84

89

94

55

59

66

74

79

82

65

69

76

84

89

92

75

79

86

94

99

8.2

9.5

11.1

14.5

16.5

8.2

9.5

11.1

12.7

14.5

16.5

8.2

9.5

11.1

12.7

14.5

16.5

37

47

55

68

72

81

48

57

65

73

82

90

59

69

75

84

92

99

48

57

65

74

82

90

59

68

76

84

92

98

70

78

86

95

101

108

61

69

77

85

94

100

72

80

88

96

103

109

83

91

98

106

111

117

76

84

92

99

106

112

88

95

102

109

115

121

97

105

111

118

123

128

91

101

108

115

120

126

103

110

117

123

128

133

113

120

125

131

135

139

53 71 91 110 131

10.7

12.6

14.6

16.9

10.7

12.6

14.6

16.9

10.7

12.6

14.6

16.9

65

77

89

101

110

65

77

89

100

111

121

78

90

102

112

123

132

83

95

106

117

126

83

95

106

116

127

136

96

106

118

128

138

148

102

113

123

133

143

103

114

125

134

144

154

115

126

136

146

155

165

121

133

141

151

161

122

132

142

152

162

171

134

144

154

163

–

–

142

151

160

170

–

143

153

162

–

–

–

153

163

–

–

–

–

+10 0 -10 -20 -30 +10 0 -10 -20 -30 0 -10 -20 -30 -40 +10 0 -10 -20 -30

° CDischarge gas temp.° C

°C °C

Co

nd

ensin

g p

ressure

10

20

30

20

25

30

35

40

45

5.7

6.6

7.7

20

25

30

35

40

45

20

25

30

35

40

45

8

9

11.

12.7

14

8

9

11

12

14

16

8

9

11

12

14

16

37

47

55

68

72

81

48

57

65

73

82

90

59

69

75

84

92

99

48

57

65

74

82

90

59

68

76

84

92

98

70

78

86

95

101

108

61

69

77

85

94

100

72

80

88

96

103

109

83

91

98

106

111

117

76

84

92

99

106

112

88

95

102

109

115

121

97

105

111

118

123

128

91

101

108

115

120

126

103

110

117

123

128

133

113

120

125

131

135

139

7.6 53 71 91 110 131

9.1

7.6

9.1

7.6

9.1

65

77

89

101

110

65

77

89

100

111

121

78

90

102

112

123

132

83

95

106

117

126

83

95

106

116

127

136

96

106

118

128

138

148

102

113

123

133

143

103

114

125

134

144

154

115

126

136

146

155

165

121

133

141

151

161

122

132

142

152

162

171

134

144

154

163

–

–

142

151

160

170

–

143

153

162

–

–

–

153

163

–

–

–

–

+10 0 -10 -20 -30 +10 0 -10 -20 -30 0 -10 -20 -30 -40 +10 0 -10 -20 -30

R134a R22 R404A/R507 R717

° C

°C

orintermediate temperature

°C


or

77

59

102

16.2

18.2

20.5

11.0

12.5

14.3

16.2

18.2

20.5

11.0

12.5

14.3

16.2

18.2

20.5

40

44

49

54

59

65

50

54

64

69

75

60

64

69

74

85

42

47

52

57

62

67

52

57

62

67

72

77

62

67

72

76

82

87

46

51

56

61

66

71

56

61

66

71

76

81

66

71

76

81

86

91

53

58

63

67

72

77

63

68

73

77

82

87

73

78

83

87

92

97

62

67

71

75

79

83

72

77

81

85

89

93

82

87

91

95

99

11.0

12.5

14.3

79

59

103

Co

nd

ensin

g p

ressure

Co

nd

ensin

g p

ressure


intermediate temperature

bar

Co

nd

ensin

g p

ressure °C

or



°C

or



Discharge gas temp. Discharge gas temp.° C ° CDischarge gas temp.

0171

-470

-EN

97.0

7

54 0178-910-EN

��

During both start-up and operation it must bemade sure that the plant is working correctly.

Compressor and condenser must be able towork satisfactorily, safety devices must beintact and the evaporator must function underload - that is to say:

� the desired temperatures are observed,

� the oil pressure and discharge pipetemperature on the compressor arecorrect,

� the condenser pressure is not excessivelyhigh, and

� the plant otherwise works as it is sup-posed to.

The service instructions outline some generalguidelines for servicing the refrigerationplant, with some references to the instructionmanual. The service instructions shouldtherefore be read and followed carefully.

Some installations are providedwith a sight-glass featuring mois-ture indicator; if the indicator col-our switches from green to yellow,there is moisture in the refrige-rant.

Change the drying filter regularly.

Check Interval Activity

Condensing pressure Excessively high pressure may bedue to:• reduced cooling effect• air in the condenser.Too low condenser pressure im-plies a risk of restricting the refri-gerant supply to the evaporator.

Pressureand temp. Daily

Discharge pipe temperature Normal discharge pipe tempera-ture acc. to instructions.

Filter in– liquid line– thermostatic valve– suction line– oil return

Accumulated dirt causes reducedrefrigerant supply to the evapora-tor.

If a filter has a hot inflow and colddischarge, this may be due toclogging of the component.

FiltersClean whenneeded

Moisture in the sight-glass(on HFC/HCFC installations)

Dehumidi-fier When

needed

0178-910-EN 55

Check Interval Activity

Refrigerant charge Inadequate charge results in re-duced plant capacity and oftenleads to an excessively high dis-charge pipe temperature.Refrige-

rant Periodically

Oil draining (ammonia plant) Check evaporator, intermediatecooler, receiver, etc. for oil accu-mulation. Exercise caution; use agas mask.

Periodically

Leak detection The plant must be searched regu-larly for leaks. Flanges and jointssettle during the plant’s initial op-eration period. They must therefo-re be tightened and checked.

Safety pressure controlsAutomatic operating controlsAlarms

Adjust operating point and checkthe function. Replace switch sys-tem if sticking.

Automaticcontrols

Periodically

Lubrication of electric mo-tors

Clean and lubricate according tosupplier’s instructions. At temper-atures lower than -25°C, use spe-cial lubricant.Electric

motor Periodically

Alignment of couplingV-belt drive

Check in accordance with theinstructions of the instructionmanual.Tighten loose V-belts, if any,or replace by new ones.

Corrosion Marine condensers are normallyprotected against galvanic corro-sion by the mounting of corrosionplugs in the condenser covers.

Metallic contact between corro-sion plug and cover is essential toproper functioning.

Con-denser

Periodically– normallymin. 4 times a year

Frosting-up Problem-free operation is condi-tional on the evaporator beingkept free of ice. Defrost as andwhen required.

Evapora-tor

Whenneeded

0171

-468

–EN

00.0

1

56 0178-910-EN

��

SMC 104-106-108 Mk3, TSMC 108 Mk3 - S, L and ESMC 112-116 and TSMC 116 Mk3 - S, L and E

General

When the compressor requires maintenance,it is important to follow the instructions givenbelow. In order to make sure that the com-pressor is working correctly, the gauge mea-surements and screw torques must be strictlyadhered to. Before opening the compressor,it is expedient to ensure that you have sparesof those seals and gaskets to be strippeddown or dismantled. An O-ring which hasbeen exposed to oil and heat for any lengthof time may have expanded so much as toprevent it being refitted.All seals and gaskets used are resistant tooil, HFC/HCFC and ammonia. All O-rings aremade of neoprene rubber.

Pump-down

Before opening up the compressor for in-spection, the pressure inside must be low-ered to slightly above atmospheric. This canbe done in the following way, depending onwhether the compressor is operational or de-fective.

1. If the compressor is operational

Run the compressor at minimum capacity atnormal operating temperature.

Adjust the low-pressure cut-out so that thecompressor stops at a suction pressure ofapprox. 0.1 bar.

Throttle the suction stop valve very slowly.Keep an eye on the suction pressure gauge.

The suction pressure must be lowered slowlyenough to give the refrigerant dissolved in

the oil time to escape without the oil foaming.This is of great importance in compressorsrunning on HFC/HCFC. An ammonia com-pressor can stand having the pressure re-duced somewhat more quickly without the oilfoaming.

Once the pressure is down to approx. 0.1bar, stop the compressor and perform thefollowing steps in the order specified:

� Close suction stop valve.

� Cut off power to compressor motor.

� Close discharge stop valve.

� Draw off last remains of refrigerant gasthrough purge valve Pos. 42.

� Having ensured that power to compressormotor cannot be inadvertently connected,the compressor is ready for opening.

� Remove all fuses, if any.

2. If the compressor is inoperative

� Leave heating rod in crankcase connectedfor a couple of hours before compressoris due to be opened in order to heat up oil.Warm oil does not contain as much refrig-erant.

� Suction stop valve must be open whileheating rod is connected.

� Keep discharge stop valve closed.

� Close suction stop valve and disconnectheating rod.

� Equalize pressure in compressor throughpurge valve Pos. 42.

0178-910-EN 57

� Once pressure has been equalized to at-mospheric, compressor is ready foropening. Remember to make sure thatpower cannot be inadvertently connected,thereby starting the motor.

� Remove all fuses, if any.

Dismantling and assembly

The following sections describe the individualcomponents. When dismantling and assem-bling, parts should generally be fitted in thesame position from which they were taken,and should therefore be marked as they areremoved. Further they should be thoroughlycleaned, checked and lubricated prior to be-ing reassembled.

Top covers

Dismantling top cover

Before dismantling the top cover, the reliefmechanism must be deactivated; this isdone by dismantling the short plug Pos. 12Dand mounting the long plug from the tool kitinstead. This moves the piston Pos. 12B tothe opposite end of the relief cylinder.

Loosen and remove screws Pos. 2E, exceptfor the two screws shown on the drawing.

These screws should be loosened approx. 1mm, then checking that the cover lifts off thegasket. If, to the contrary, it remains fastenedto the gasket, loosen it with a blow on the si-

de from a soft hammer while keeping thetwo screws fitted. This must be done be-cause of the powerful spring pressure bene-ath the top cover. After dismantling the two bolts - unscrewing them alternately - thetop cover can be removed.

Fitting top cover

Before fitting the top cover, the long plugmust be fitted into the relief cylinder. Check,in addition, that the gasket Pos. 2C is intactand, if necessary, check that the clearancevolume and lifting reserve have been ad-justed as described later on in these instruc-tions.

If the gasket Pos. 2C needs to be replaced atall, the graphitized side must face the com-pressor frame. After placing the top coverloosely on top of the springs Pos. 21, it isrecommended that all screws be mounted byhand, as they will jointly guide the top coverinto position. Now tighten the top cover firmlywith the two screws mentioned above, thenwith the remaining ones.

Finally, cross-tighten all the screws to theprescribed torque in the following sequence:

7 1 3 5

8 4 2 610

9

14

13

16

15

12

11

Once the top cover has been fitted, removethe long plug and insert the short plug. Thetop covers must be mounted as shown onthe following chart.

58 0178-910-EN

Mounting top and water covers

SABROE

SABROESABROE

SABROESABROE SABROESABROE

SABROESABROE SABROESABROE

SABROE

SABROE

SABROE

SABROE

SABROE

SABROE

SABROE

SABROE

SABROE

SABROE

SABROE

SABROE

SABROE SABROE

SABROE

SMC 112 SMC 116 TSMC 116

SMC 104 SMC 106 SMC 108 TSMC 108

Right top covers

Left top covers

Side covers

Water covers

Control end

Shaft end

SABROE

SABROE

SABROE

SABROE

SABROE

SABROE

SABROE

SABROE

SABROE

SABROE

SABROE

T0177092_0

Sh

aft

end

Sh

aft

end

Sh

aft

end

Sh

aft

end

Sh

aft

end

0178-910-EN 59

Discharge valve

Pos. 20

20E

20D

21

20F

20B 20A 20C 20G

As shown on the above drawing, the functionof the discharge valve Pos. 20 is partly to al-low the compressed gas to pass from thecompression chamber of the cylinder to thedischarge chamber beneath the top coversand partly to create a seal from the dischargechamber to the cylinder.

Furthermore, the discharge valve acts as asafety device in the event of liquid refrigerantpassing the valve together with the dischargegas, also called liquid stroke. Such strokeshould normally not occur, as liquid cannotpass the valve as quickly as the compressedgas. This produces a violent increase in pres-sure in the compression chamber.

In order to avoid pressure of such intensitythat it may damage the bearings in the com-pressor, the discharge valve is retained inposition by the safety spring Pos. 21, whichallows it to lift a little under the strain of in-creased pressure.

Liquid strokes are heard as a distincthammering in the compressor; the causemust be found immediately and the mal-function rectified.

Discharge valve types:

Depending on the refrigerant and operatingconditions under which the compressor oper-ates, various discharge valves need to beused to achieve an optimal function. The dis-charge valves are selected as shown in thediagram below on the basis of the conden-sating or intermediate pressure temperature.

Refri- Conditions Valve

R717LPTC � 15°C

TC � 15°C HP

LPTC � 15°C

HFC/HCFC

15°C � TC <

gerant

45°C R404A-R50750°C R2270°C R134a

HP

VHPTC �45°C R404A-R50750°C R2270°C R134a

type

Marking

All pressure valves supplied from SABROEtoday are marked as described below andshown on the sketch.

Refrigerant R717 : All discharge valves are marked with onegroove.

60 0178-910-EN

Refrigerants HFC/HCFC : All discharge valves are marked with twogrooves.

Marked withone groove for R717

Marked withLP-HP or VHP

two grooves for HFC/HCFC

Dismantling

� When top cover has been removed, springPos. 21 and discharge valve Pos. 20 canbe lifted out by hand. See dismantling oftop cover.

� Tighten discharge valve in a soft-jawedvice, then dismantle two nuts Pos. 20Etogether with spring guide Pos. 20F.

� Screw Pos. 20D, discharge valve seatPos. 20A and ring plate Pos. 20C can nowbe disassembled by hand.

� Remove valve springs Pos. 20G by hand.

Assembly

Before assembling the discharge valve, youmust make sure that the valve springs Pos.20G are in good order and fixed firmly in theirapertures.

Assemble the discharge valve in reverse se-quence to that described above. Note the fol-lowing, however:

� Tighten bottom nut Pos. 20E to torque of10.2 Kpm ≅ 100 Nm. If need be, exertcounterpressure with 5 mm Allen key onbolt head.

� Fit spring guide Pos. 20F and tighten topnut to same torque: 10.2 Kpm ≅ 100 Nm.

Tightness testing of discharge valve

This is done by means of the pressure droptest as described elsewhere in this instructionmanual.

Service life of discharge and suction valves

In order to ensure that the compressor al-ways works perfectly, it is advisable - at suit-able intervals - to replace the suction and dis-charge valve ring plates.

It is difficult to give altogether precise timesfor such replacements, as the durability ofthe valve ring plates depends on the follow-ing factors:

� If the compressor is exposed to liquidstroke or moist refrigerant gas, the servicelife is reduced.

� Speed of the compressor: At 900 rpm, the service life of the valvering plates is considerably longer than at1500 rpm.

� The compressor ratio at which the com-pressor operates:At high compression ratios, the load onvalve ring plates and springs is appreci-ably larger than at low compression ratios.When the valve ring plates are changed,the valve springs should also be replaced.

0178-910-EN 61

Cylinder lining with suction valve

Marking of suction valve stop:

one groove for R717two grooves for

Marking ofsuction valve

T0177131_0 v3

HFC/HCFC

The cylinder lining and suction valve form anintegral unit which can be dismantled by re-moving the screws 19N.

In order to gain access to the cylinder liningor suction valve, the top cover, spring Pos.21, and discharge valve Pos. 20 need to bedisassembled.

Extracting cylinder lining

� Rotate crankshaft to position relevant pis-ton at top dead centre.

� Fit the two T-shape extractors no. 3 fromtool kit into threaded holes in guide ringPos. 19J.

� Carefully pull out cylinder lining with suc-tion valve, checking that gasket Pos. 19Kremains in frame.

� Insert protective plate no. 5 (from tool kit)between piston and frame so the pistoncan rest on it. This will enable piston andpiston rings to slide onto the protectiveplate without being damaged when thecrankshaft is turned.

Dismantling suction valve

Dismantling the screws Pos. 19N makes itpossible for the guide ring Pos. 19J, suctionvalve stop Pos. 19H and ring plate Pos. 19Fto be removed from the cylinder lining. Thepaper gasket Pos. 19T can be expected todisintegrate during dismantling and requirereplacement.

Mounting suction valve

Before reassembling the suction valve, youmust ensure that the valve springs Pos. 19Gare in good order and fixed firmly in their apertures.

Perform the assembly in reverse sequence tothat described above. Note the following,however:

� Change paper gasket.

� Before tightening screws 19N, ensure suc-tion valve plate can be moved freely in itsguide. Tighten screws Pos. 19N to torqueof 1.4 Kpm ≅ 14 Nm.

Inserting cylinder lining

� Rotate crankshaft to position piston at topdead centre.

� Check that long plug from tool kit isscrewed into relief cylinder; see Top cov-ers section.

� Check that gasket Pos. 19K is in positionon frame.

� Lubricate piston, piston rings and cylinderface with clean refrigeration machine oil.Likewise, grease O-ring Pos. 19M on HPcylinder of TSMC compressor with cleanrefrigeration oil.

� Rotate piston rings on piston in order tostagger ring gaps at 120° to each other.Press cylinder lining down over pistoncarefully. The chamfering on the cylinder

62 0178-910-EN

interior will catch the piston rings andsqueeze them to the diameter of the cylin-der. If possible, fit cylinder in same placefrom which it was taken.

� Press cylinder lining down manually, andwith no rotary movements, until it makescontact with gasket Pos. 19K.

� Check clearance volume, which is de-scribed in section Control measurementsfor insertion of new cylinder lining.

� Discharge valve Pos. 20 and safety headspring Pos. 21 can then be fitted.

� Fit gasket and top cover.

� Once top cover is in position - see Topcovers section - remove long threadedplug and screw in short plug, having firstchecked aluminium gasket Pos. 12E andfound it fit for use.

Connecting rod

The connecting rod pos. 17 is made of twoparts carefully adapted to each other.The two parts are held together by means oftwo bolts secured with lock nuts.

Procedure for removing piston andconnecting rod

� Bleed compressor of oil and refrigerantand safeguard against any unintendedstart-up.

� Disconnect any water hoses and otherpiping connections to top and side covers.

� Dismantle top and side covers.

� Remove spring Pos. 21, discharge valveand cylinder liner.

� Remove nuts Pos. 17D; following this, thebottom part of the connecting rod can betaken out by hand.

� Piston and connecting rod can then belifted out through the top cover opening onthe frame.

The connecting rod Pos. 17 is equipped withindependent bearings at both ends. The bigend is fitted with two bearing half bushesPos. 17A, consisting of a half-cylindrical steelplate internally coated with white metal.These bearing half bushes are secured in theconnecting rod, partly through their fit in theconnecting rod bore and partly by a springwhich fits into a milled groove in the connect-ing rod. The opposite end of the connectingrod is fitted with the gudgeon pin bearingPos. 17B, of which the following two typesare found: See spare-parts drawing.

� The bearing bushing Pos. 17B-1 is madeof special bronze and is also used inR717 compressors. The bearing bushing is used in all SMCcompressors and in the low pressurestage on TSMC compressors.

� The needle bearing Pos. 17B-2 is 2 mmgreater in outside diameter than the abovebearing bush and must therefore be fittedin a piston rod bored to the diameter ofthis bearing. The needle bearing has noinner ring but fits the diameter of the gud-geon pin directly.

� If the bearings in the connecting rod areworn so that the clearance is greater thanthat prescribed in the table entitled Vari-ous clearances and adjustment measure-ments, they must be replaced with newbearings. In this connection, note that un-dersized half sections of bearing can besupplied for use in the crankshaft wherethe journals have been ground to a corre-

0178-910-EN 63

sponding undersize. See table in sectionon Diameters for undersized bearings.

Fitting bearings

� The bearing bushing or needle bearingcan be squeezed into or out of the con-necting rod in a vice or hydraulic press.Use softjaws in the vice and use toolswhich do not damage any components.The bearing bushing must be fitted asshown on the sketch, with the lubricatingducts facing sideways.

T0177131_0 v2,a

Fig. 1

Sleeve to befitted with lubri-cating ductspositioned asshown on dra-wing.

Note:Fig. 1

Fitting connecting rod

Before fitting the connecting rod in the com-pressor stand, piston and piston rings must befitted onto the connecting rod. See the follow-ing sections. In addition, the two connectingrod bolts Pos. 17C must be fitted as shown onthe spare parts drawing.

� Fit bearing bushes into both parts of con-necting rod.

� Introduce connecting rod down throughtop cover opening in frame and guide intoposition on crankshaft manually. Take careso that connecting rod bolts do not leavemarks in crankshaft journals.

� Position connecting rod interior throughlateral opening on frame, and fit nuts.

Note:The two parts of the connecting rod arenumbered with the same number; this isonly of importance when assembling.Parts with different numbers must not beassembled and it is important that thenumbers are fitted in the same directionas shown in Fig. 2.

916 916

T0177131_0 v2,b

Fig. 2Note:Stamped number onthe same side on as-sembly

� Tighten nuts Pos. 17D alternately with in-creasing torque and finish off with torquewrench. Torque: 4.4 Kpm ≅ 43 Nm.

64 0178-910-EN

PistonThe piston is made of aluminium and fittedwith two piston rings, nearest the piston top,and an oil scraper ring.

The piston comes in three versions:

For compressors with:80mm stroke lengths, type S, 100mm stroke lengths, type L, and with120mm stroke lengths, type E. The difference is clearly seen from fig. 3.

PistonType L

60

PistonType S

T0177131_0 v1

Fig. 3

50

110

70

50

120

PistonType E

60

40

100

The same piston and piston pin are used,irrespective of whether the connecting rodcontains a sleeve or a needle bearing.

Fitting piston rings in piston

Before mounting the piston rings in the pis-ton, their fit in the cylinder lining should bechecked by measuring the ring gap. See sec-tion entitled Various clearances and adjust-ment measurements.

Assembling and stripping down pistonand connecting rod

Adopt the following procedure when assem-bling piston and connecting rod:

� Fit one of the circlips pos. 18D into borereserved for piston pin.

� Heat piston to 70°C in oil or on hotplate.

� After inserting bearing bush or needlebearing, guide connecting rod into place inheated piston. The piston pin can now bepositioned without the use of tools.It is sometimes possible to fit the pistonrod by hand without a preliminary heatingof the piston.

� Fit last Seeger ring

To strip, reverse sequence; however, do notheat piston, but press piston pin out using apunch or mandrel.

0178-910-EN 65

Shaft seal

10H

T0177131_0 V13

2 mm

8C

8H

8A

8F

10A

10E

10D

8G

10F

8B

10B

10G

5.5 mm

3126-176-R

10J

The purpose of the shaft seal is to create atight seal along the crankshaft between theinside of the compressor and the atmo-sphere.

It comprises a slide ring Pos. 10E, manufac-tured from special-purpose cast iron, which issecured to the crankshaft by means of thelocking ring Pos. 10H, tightening flange Pos.10A and the four screws Pos. 10J with springwashers Pos. 10K.

The carbon slide ring Pos. 10F is pressedagainst the flat-machined, lapped slide ring atthe end of Pos. 10E by a series of springsPos. 10B. The carbon slide ring is preventedfrom rotating by means of the retention pinPos. 8H.

The spring pressure, combined with theflat-lapped faces of the two slide rings, ensur-es an optimal seal between the faces, eitherwhen rotating or stationary.

It is recommended to exercise great carewith the lapped slide surfaces. Even theslightest scratch or other damage to theslide surfaces will result in leaks.

The O-ring Pos. 10D creates a seal betweenthe slide ring Pos. 10E and the crankshaft.O-ring Pos. 10G seals between the carbonslide ring Pos. 10F and the shaft seal coverPos. 8A.

When the shaft seal is operating, a tinyamount of oil drifts out between the slidefaces to lubricate them. An oil throw ring Pos.8F has therefore been fitted to prevent this oilmigrating along the axle to the transmissionlinkage.

The thrower ejects the oil into the groove inthe shaft seal cover Pos. 8A and the oil ispiped via the plastic hose to a plastic bottlepositioned under the compressor.

66 0178-910-EN

1. Dismantling and stripping down shaftseal

1.1.Once the gas pressure in the compres-sor has been eliminated and the motorsafeguarded against inadvertent start-up,dismantle coupling or V-belt disk.

Note:On units featuring coupling, there is noneed to move the motor, as the couplingand the shaft seal can be taken out be-tween the two shaft ends.

1.2.Dismantle shaft seal cover Pos. 8A byalternately loosening bolts Pos. 8C so asto displace shaft seal cover outwards wit-hout jiggling. This will avoid damage tointernal parts of the shaft seal.

1.3.Once the spring force is equalized andthe bolts removed, the shaft seal covercan be taken off the shaft end by hand.Take care so that no damage is done tothe carbon slide ring Pos. 10F which co-mes out with it.

1.4.The carbon slide ring Pos. 10F can beextracted by dismounting circlip pos. 8Gas follows:

Mount tool no. 2 as illustrated in fig. 3and tighten screw A so that the carbonslide ring does not touch the locking ring.

Take care not to tighten screw A toomuch as this could damage the car-bon ring.

Circlip pos. 8G is now easily extracted bymeans of a screw driver without damag-ing the slide surface of the carbon slidering.

After removing tool no. 2, the carbonslide ring pos. 10F, O-ring pos. 10G andsprings pos. 10B (see fig. 2) can now bedismantled.

Fig. 3

••

10G 8A8G 10F

••

A

•

•

8C

1.5.Dismantle slide ring 10E by turning thefour Allen screws 10J a max. of 2-3turns; the entire unit can then be takenout with the fingers or using two screwd-rivers inserted into the external grooveon the slide ring Pos. 10E and moved inthe direction of the arrow as illustrated infig. 4.

Fig. 4

•

10A

1.6.O-ring Pos. 10D can now be removed.

Assembling and mounting shaft seal

After thoroughly cleaning the crankshaft,check that its sealing faces are smooth andfree of scratches, blows and wear marks.Then oil the crankshaft and the shaft sealcomponents thoroughly with the same type ofoil as used in the compressor.

0178-910-EN 67

2. Unit with slide ring, Pos. 10E

2.1.Before fitting slide ring Pos. 10E, tightenscrews Pos. 10J until there is approx. 2mm spacing and parallelism between thetwo flanges. Check also that locking ringPos. 10H is mounted as shown in thedrawing and that O-ring Pos. 10D is inposition.

2.2.Position slide ring Pos. 10E on shaft andensure tightening flange makes contactwith shaft shoulder.

2.3.Crosswise, tighten screws Pos. 10J alter-nately with Allen wrench from tool kit.The torque is specified in the instructionmanual.

2.4.Check axial position of shaft seal bymeasuring distance from frame sealingface to slide face on Pos. 10E. This mustmeasure approx. 5.5 mm, as shown inthe drawing.

3. Unit with shaft seal cover Pos. 8A

3.1.Mount O-ring Pos. 10G and the ten spiralsprings 10B in shaft seal cover Pos. 8A,then position carbon slide ring Pos. 10Fcarefully. Rotate carbon slide ring so slotfits in over retention pin Pos. 8H.

3.2.With tool no. 2 fitted as shown in fig. 3press carbon slide ring pos. 10F againstspring pos. 10B. Locking ring Pos. 8Gcan now be fitted. Observe closely thatthe carbon slide ring is not overloaded bymisbalanced pressure and that its slideface is not damaged.

3.3.Give complete shaft seal cover an extraoiling on slide face of carbon slide ringand guide it in over shaft together withgasket Pos. 8B.

3.4.Gently pressing shaft seal cover and car-bon ring in against slide ring Pos. 10Ewithout compressing springs Pos. 10B,

measure distance from gasket Pos. 8B tosealing face of shaft seal cover. This distance must be about 3 mm.Make sure the hose branch Pos. 8D fa-ces down.

3.5.Mount screws Pos. 8C and tighten even-ly, crosswise. This will avoid damagingthe carbon slide ring. Tighten screwsPos. 8C to prescribed torque accordingto table in instruction manual.

3.6.Mount oil throw ring, as shown in drawing.

3.7.After mounting coupling half or V-beltdisk, it must be possible to turn thecrankshaft easily by hand.

Crankshaft

The crankshaft is made of heat-treated SGcast iron with fine strength and glide proper-ties. The bearing journals are superfinishedand oil channels are bored for all lubricatingpoints.

At the centre and end of the crankshaft, theoil channels are blanked off with 3 blind plugson the SMC 104 - 106 - 108, and 6 plugs onthe SMC 112 and 116.

When fitting the crankshaft, it should bechecked that the plugs are mounted andtightened. By way of bores in the counter-weights, the crankshaft is dynamically bal-anced with regard to 1st and 2nd orderforces.

The crankshaft is available in three versions:an S type for compressors with short strokes(80mm), an L type for longer stroke (100mm)and an E type for the longest strokes(120mm). The crankshafts have an S, L or Estamped into the connecting end.

68 0178-910-EN

Dismantling crankshaft

Dismantle the crankshaft through the pumpend of the frame in the following way:

� Bleed compressor of oil and refrigerantand safeguard against inadvertentstart-up.

� Dismantle top and side covers.

� Dismantle all cylinder linings.

� Extract all pistons and connecting rods.

� Pull off V-belt pulley or coupling half .

� Dismantle shaft seal cover and shaft seal.

� Dismantle cut-outs and pipes to manome-ters, or piping connections to UNISAB.

� Dismantle end cover, Pos. 4A.

� Dismantle oil filter.

� Dismantle oil pump drive and oil pump.

� On SMC/TSMC 112-116 loosen themiddle bearing by dismantling the plugspos. 49H as well as gasket pos. 49J inboth sides of the compressor.Next, dismantle screws pos. 49F and lock-ing plates pos. 49G.

� Rotate crankshaft to place connecting rodjournals on horizontal level.

� Dismantle bearing cover at pump end andsupport the crankshaft by means of aboard inserted through the side openings.

� After this the crankshaft can be drawn outof the framne. The crankshaft must still besupported.

� The middle bearing on SMC/TSMC112-116 can be dismantled by removingscrews pos. 49B and shims pos. 49C aswell as guide pins pos. 49D.

Inspection

Check bearing journals on connecting rodsfor wear and tear and, if necessary, measurediameter of journals. The maximum wear onthe bearings is shown in the section Variousclearances and adjustment measurements. In most instances, the permissible play in thebearing can be obtained by replacing thebearing half bushes. The bearing journals onthe main bearings are normally subject tovery little wear, but should be check mea-sured during main overhauls. If wear and tearexceeds the play stated, the crankshaft cannormally be ground to 0.5 mm undersize. Forthe ground crankshaft, main bearings andconnecting rod bearings with an undersize of0.5 mm can be supplied as stated in theparts list.

The drawing for grinding the crankshaft toundersize is found in this instruction manual.

Note:After grinding the crankshaft, all lubricat-ing channels must be thoroughly cleanedwith an approved cleansing fluid andblasted with compressed air. Rememberto refit the blind plugs.

� Check sealing face for O-ring seal, Pos.10D, on shaft seal. The surface must bebright and free of scratches and marks.

Refitting crankshaft

Refit the crankshaft in the reverse order tothat for dismantling. Note the following, however:

� After the crankshaft has been inserted intothe housing, mount main bearing coverPos. 5A using gasket Pos. 5D as a shim.

� Check end play on crankshaft by pressingshaft up against pressure bearing Pos.6C and measure clearance in the otherbearing, using a feeler gauge.

0178-910-EN 69

The permissible end play is indicated inthe section Various clearances and adjust-ment measurements.

End play adjustment is achieved bymeans of the gasket Pos. 5D.

The gasket can be supplied in the follow-ing thicknesses, see the spare parts list: 0.25mm 0.50mm 0.75mm 1.0mm

Main bearings

The main bearings pos. 5C and 6C aremounted on the main bearing covers andtheir purpose is to guide the crankshaft bothradially and axially.

They consist of a steel bushing with collar.The collar and the inside of the bushing areprovided with a thin white metal coating.

The bushing can be pressed out and re-placed by new ones and need no further machining after mounting.

On mounting the bushings it is recommendedto secure them with Loctite 601.

When a new bearing bushing pos. 6C at theshaft seal end is put into place in cover pos.6A the in- and outlets of the lubricating chan-nels must be positioned in a four o’clockposition as illustrated on fig. 1 below. The bearing bushing pos. 5C is positionedwith in- and outlets in a 12 o’clock position.

T0177167_0

Fig. 1

12 o’clock

4 o’clock

Mounting of bearing bushing pos. 6C

Cover pos. 6A seen from the insideof the compressor

The bearing bushings can be delivered withcrankshafts ground to undersize. See SpareParts List.

The crankshaft for the SMC 112 and 116, andfor the TSMC 116, is fitted with a centre bear-ing. This is fitted with four sets of bearing halfbushes of the same type as used in the con-necting rods. The centre bearing housing ismade up of two half parts which must beclamped around the crankshaft before this isinserted into the compressor stand.

The half parts are assembled by means offour screws and guided together with the aidof cylindrical guide pins. The bearing housingis prevented from rotating by two screwsPos. 49F. These screws are accessible onlywhen the threaded plug Pos. 49H has beenremoved. The screws can be removed usinga box wrench NV 17 and crank from the toolset.

70 0178-910-EN

Compressor lubricating system

33

T0177131_0 V10

38A11

19D

22

15D

19B

15B

13

15A12

33A

33J/K

The oil pump pos. 11 sucks oil from thecrankcase, through the filter element Pos. 33,where the oil passes the filter element pos.33A and past the magnetic filter pos. 33J/K,as shown on the spare parts drawing. Thepump forces the oil through an internal pipe,pos. 38A, until it reaches the shaft seal hous-ing.

The filter element Pos. 33A is a disposablefilter which cannot be cleaned. See descrip-tion of oil filter.

The shaft seal housing forms a distributionchamber for the oil. The oil pressure in theshaft seal housing is adjusted by means ofthe oil pressure regulating valve Pos. 22,which is mounted in the shaft seal housing.The regulating valve can be adjusted fromthe outside by means of a screwdriver.Clockwise rotation increases the pressure;anticlockwise rotation lowers the pressure.

Excess oil is returned through a bored chan-nel to the crankcase.

From the shaft seal housing, the oil is distrib-uted as follows:

� Through the bored channels in the crank-shaft to lubricate main and connecting rodbearings. Lubrication of piston pin bear-ings is done by splash lubrication througha countersunk hole in the top of the con-necting rod.

� To the differential oil pressure cut-out andthe pressure gauge. The effective oil pres-sure can be read straight off the manome-ter (the suction pressure gauge of thecompressor).

� Through external oil pipes, on to the regu-lating cylinders Pos. 12 for unloaded startand capacity regulation.

0178-910-EN 71

Oil pump

11H

11Q

11R

11G

11J

•4A

•11T11M• •

11L

•

11N•

11P•

11S

The oil pump is a gearwheel pump driven bythe crankshaft via a pinion drive.

It is therefore important to ensure that thedirection of rotation of the crankshaft is asindicated by the arrow on the bearing coverPos. 6A.

If the crankshaft is to turn in the opposite di-rection of rotation, the oil pump can be fittedwith a chain drive. See next section.

Dismantling the oil pump

Having bled the compressor of oil and refriger-ant and secured it against inadvertent start-up,proceed as follows:

� Dismantle end cover Pos. 4A and sidecovers Pos. 3.

� Dismantle internal oil pipes and nipplesscrewed into pump.

� Dismantle nut Pos. 11J and extract gear-wheel pos. 11G.

� When the four M6 screws pos. 11M secur-ing the oil pump to the bearing cover havebeen removed, it can be taken out byhand.

Note:The oil pump normally has a very longservice life. Therefore, it is not worthwhilerepairing it. Rather replace it with a newone.

Mounting the oil pump

Before finally tightening the oil pump firmly tothe bearing cover, the following adjustmentmust be made to the gearwheel drive:

The play between the two teeth when en-gaged must be 0.05-0.08mm measured witha feeler gauge. Repeat the measurement sixtimes, turning the crankshaft 60° betweeneach measurement, and adjust until thesmallest play is measured to be as startedabove.

72 0178-910-EN

Chain-driven oil pump with inversedirection of rotation

If the SMC 100 compressor is to run in theopposite direction of rotation to that shown bythe arrow on the bearing cover Pos. 6A, thegearwheel drive on the oil pump must be re-placed with a chain drive.

To this end, use a set of replacement parts,

stores no. 3141-127. This set contains a chain,a chain wheel (springs for old shaft seals only)and a baffle for lubricating oil, as well as allscrews needed.

In case the compressor is driven by an elec-tric motor, attention should be paid to the pre-scribed direction of rotation of the motor.See section: Direction of rotation of the com-pressor.

531

67842

1

2

3

4

Hub for the chain wheel 5 Endless chain

Hub for bottom chain wheel 6 Baffle for lubricating oil

Top chain wheel 7 Set screw M6 x 12

Bottom chain wheel 8 Spring washer for M6

Assembling instructions

The chain system can be mounted on alltypes of SMC/TSMC compressor. On oldercompressors, however, a little adjustmentmay be necessary, as detailed below:

� Dismantle the two gear wheels by remov-ing screws Pos. 11Q and nut Pos. 11J.

� On older compressors, the oil pump islinked to the principal bearing cover Pos.5A by 2 guide pins and retained by fourM6 screws. Remove two guide pins hereand bore the free holes for screws up to adiameter of 8 mm. This should be doneafter the oil pump has been dismantled.On more recent compressors, the free

0178-910-EN 73

holes are oval-cast to give scope for ad-justment, and there are no guide pins.

� Mount lubricating oil baffle as shown ondrawing. Drill two M6 threaded holes andtap, using baffle as template; position sothat the baffle is at a tangent to the exter-nal diameter of the bearing bush D = 92mm.

T0177085_0

D92

Screw dimensions: M6 x 12 mmThread depth: 5 mm Drilling depth: 20 mm Core drill: 5 mmSecure screws with spring washers.

� Slightly tighten four screws securing oilpump to bearing cover.

� Place chain wheel with hub Pos. 4 and 2on pump shaft. The retainer nut can betightened once the entire chain drive hasbeen mounted.

� Place the assembled chain, hub and chainwheel, Pos. 5, 1 and 3, in position; tightenwheel firmly with screws Pos. 11Q fromgearwheel drive.

Adjusting the chain drive:

� Tighten chain by shifting oil pump. Thecorrect tension of the chain is shown onthe sketch.

T0177085_0

3.5 – 5.5mm

Finally, when the proper centre distancehas been established, secure oil pumptightly.

� Tighten chain wheel on oil pump.

Marking direction of rotation

The arrow on the end cover of the compres-sor should be cancelled out and replaced byone painted on the indicate the new directionof rotation.

74 0178-910-EN

Oil pressure valveThe oil pressure valve pos. 22 regulates theoil pressure in the compressor. Mounted inthe cover Pos. 6A, it connects directly withthe oil pressure chamber in the shaft sealhousing.

The oil pressure is regulated by a springloaded cone, the spring pressure being ad-justed by turning an adjusting screw at thevalve end. Use a screwdriver for this pur-pose.

Turning to the right (clockwise) raises the oilpressure; turning to the left (anticlockwise)lowers the pressure.

T0177083_0

22B

22A

Fig. 1

locking screw

Adjustment

Oil pressure: 4.5 bar.

The oil pressure can be read off the suctionpressure gauge or on UNISAB II.

On more recent compressor models theadjusting screw may be locked by meansof an M6 pointed screw, fig. 1, which mustbe loosened before adjustment can takeplace.

Service

Since the oil pressure valve is not subject toany appreciable wear or soiling, it should notbe disassembled during routine services.

In the event of a malfunction, the complete val-ve should be replaced.

0178-910-EN 75

By-pass valve pos. 24

The compressor is equipped with a built-inmechanical by-pass valve, fig. 1, which safe-guards it against any inadvertent excesspressure if the electrical safety equipmentfails. The by-pass valve safeguards againstany excess pressure between the dischargeand suction sides of the compressor.

If the by-pass valve goes into action, thecompressor must be immediately stoppedand the cause established.

The by-pass valve is supplied ready-set andsealed in accordance with the adjustmentpressures indicated in the table Pressure andtemperature settings. The actual set pressureis stamped on the rating plate, pos. A.

The by-pass valve is of the high-lift typewhich makes it very sturdy and durable.

Further, the by-pass valve is independent ofthe pressure on the compressor suction side.Consequently, it only opens when the pres-sure on the discharge side exceeds the setpressure in relation to atmospheric.

Thus, watch out that hole pos. B does notget covered or clogged.

In case the pressure on the discharge sideexceeds the set pressure so that the by-passvalve opens, the valve will remain open untilthe pressure on the discharge side has fallento approx. half the set pressure. The valvethen closes automatically. However, at greatdifferential pressures across the compressorthe valve may remain open. In that case,stop the compressor and close the dischargestop valve entirely. The equalization of pres-sure in the compressor will then close thesafety valve and the compressor can be re-started.

The by-pass valve is supplied factory-set andsealed and need normally not be disassem-bled and readjusted.

If necessary, control of function and set pres-sure must be made in accordance with localregulations for safety valves.

On the outside the by-pass valve is sealedwith two O-rings, pos. 24B and 24C. Fasten it to the compressor housing by means ofscrews pos. 24D and washers pos. 24E.

T3137T02I_1

Fig. 1 24C 24B

•

B

•

A

76 0178-910-EN

Oil filter

All oil to the lubricating system of the com-pressor is filtered through a oil filter installedin the crankcase. The filtration element is afilter cartridge (Pos. 33A on the drawing)which is non-cleanable and must be replacedwith a new one when the filter capacity isused up.

It is important, therefore, always to havean extra filter cartridge available.

Filter cartridge

As shown in fig. 1 the filter cartridge pos. 33Ais a single unit consisting of a 60 � primaryfilter, a magnetic filter and a shield which co-vers half of the filter.

The filter cartridge is fastened to bracket pos.33F by means of a lock nut pos. 33M and awasher pos. 33L. The gasket pos. 33B sealsoff the filter cartridge and the bracket pos.33F.

Changing filter cartridge

The filter cartridge should be replaced at reg-ular intervals. See the section entitled Servic-ing compressors on this point. In particular, itshould be remembered that the filter car-tridge must often be replaced after a relative-ly short operation time following initial start-up.

This is due to small particles of dirt origina-ting from the plant during the initial operatingperiod.

33A33B

33F 33M33L

Fig. 1

Before changing the oil filter cartridge all pre-parations in connection with the opening ofthe compressor must be carried out in accor-dance with the instruction manual.

� Dismount the lock nut pos. 33M andwasher pos. 33L and remove manually the

filter cartridge pos. 33A and the gasketpos. 33B.

Proceed as follows:

� Let the bracket pos. 33F stay mounted inthe compressor.

0178-910-EN 77

� When mounting the new oil filter cartridgeas illustrated in Fig. 1, first place the gas-ket pos. 33B on the bracket pos. 33F.

� Then place the oil filter cartridge pos. 33Aon the bracket pos. 3Fand turn it so that

the closed shield on the filter faces up-wards.Then fasten the filter by means of the locknut pos. 33M and the washer pos. 33L.

� Tighten the nut pos. 33M to a torque of4.5 Nm.

78 0178-910-EN

Suction filters

The purpose of the filters is to collect impuri-ties conveyed from the plant to the compres-sor with the suction gas and thus preventthem from penetrating into the compressor.

The suction filters therefore have a very finemesh and as an additional precaution have afilter bag insert, which should normally beused for 50 operating hours from the initialstart-up of the compressor. The filter bag isthen removed and disposed of.

If the filter bag is badly soiled after the 50 op-erating hours mentioned, it is recommendedthat a new bag be fitted for an additional 50operating hours. Similarly, a filter bag oughtto be fitted for a period of 50 operating hoursafter any major repair work to the refrigera-tion plant.

Note:Do not forget to remove the filter cartridgeafter 50 operating hours, as a blocked fil-ter bag may cause the suction filter toburst and thus contaminate the compres-sor to an extreme degree.

There are always two suction filters in thecompressor and these are removed throughthe flanged opening in the bottom end of thefilter housing. Attention is drawn to the factthat there are two types of suction filter, asdetailed below:

On SMC compressors, the two suction fil-ters are identical and should only be fittedwith an O-ring in the end facing up towardsthe suction stop valve. The filters are open atboth ends.

TSMC 108

LP HP

TSMC 116

LP HP

On TSMC compressors, the suction filter

located on the lefthand side opposite the low-

pressure cylinders (see drawing) is the same

type as on SMC compressors, i.e. open at

both ends and having an O-ring in the end

facing up towards the suction stop valve.

The suction filter fitted on the righthand side

opposite the high-pressure cylinders has a

closed end-bottom which must face upwards

and close towards the suction stop valve.

This suction filter must be fitted with O-rings

at both ends.

0178-910-EN 79

Stop valves

Z AG Q G N

POS. 25

T0177131_0 V14

Y

C

D

H

F

E

AD

S

T

U

M

B

J

AK AC A AJ L P K R

The suction and discharge stop valves areused to isolate the compressor from the re-frigeration plant.

They are closed completely by manual tight-ening and it is therefore advisable not to useany tool to close the valve, as this will simplyoverload the valve parts.

The valve seat is sealed with a teflon ringPos. 25H which, if necessary, can be re-placed as follows:

Dismantling of valve:

� Once the pressure on the inlet and dis-charge sides of the valve has been equal-ized to atmospheric, dismantle screwsPos. 25AJ. The valve throat Pos. 25B, andwith it the entire valve insert, can then beremoved.

� Turn spindle clockwise until cone andthreaded piece Pos. 25G can be removedby hand.

� Mount threaded piece Pos. 25G in asoft-jawed vice and dismantle screw Pos.25E.

Note:The screw has a lefthand thread, and itis therefore inadvisable to leave thethreaded piece in the valve holder whiledismantling the screw, as the guide pinPos. 25N will be overloaded.

� The front and rear pieces Pos. 25C and25D can now be separated and the Teflonring Pos. 25H removed. The Teflon ring will be flattened on oneouter edge, which is normally of no impor-tance to its sealing ability providing it isfree of scratches and marks.

� If required, the Teflon ring can be reversedwhen reassembling so that the other outeredge seals towards the valve seat in thehousing.

80 0178-910-EN

Reassembly of valve:

Reassembly is done in the reverse order tothat above. Note the following, however:

� Before mounting the complete valve in-sert, the valve cone with threaded piecePos. 25G must be screwed right into thevalve neck Pos. 25B.

� The O-ring Pos. 25J may have expandedunder the influence of the oil in the plantand will normally have to be replaced witha new one.

The stop valve has a so-called retroseal,which enables the packing screw joint

Pos. 25M to be serviced even when thereis excess pressure in the valve housing.

Adopt the following procedure:

� Using handwheel, open valve completelyto achieve a seal between valve cone andvalve throat. The gasket Pos. 25Q acts asa sealing element.

� The packing screw joint Pos. 25M canthen be screwed out for inspection or re-placement of the O-ring Pos. 25R and25P. Thoroughly lubricate all parts with oilbefore reassembling.

0171

-907

-EN

96.0

2

0178-910-EN 81

��

��

SMC and TSMC compressors are equippedwith an automatic unloader system to providefull relief to the compressor during thestart-up phase. This reduces the startingtorque of the compressor considerably.

The unloader system is also used to regulatethe capacity of the compressor.

The following schematic outline shows thelubrication and hydraulics system on thecompressors together with unloader me-chanism.

T0177131_0 V10

38

19D

15D

19B

15B

15A

33

11

20

50

22

12

12J

13

2

2

2

13

Fig. 1

Description of unloader mechanismand capacity regulation

No-load starting and capacity regulation areachieved by keeping the suction valve ringplate in the open position; the refrigerant gasthus aspired into the cylinder is not com-pressed but thrust back out through the suc-tion valve.

See the blue spare parts drawing of the cylin-der linings at the end of this manual.

Around each pair of cylinder linings a framePos. 13 is fitted, controlling two sets of rockerarms Pos. 15A. The frame is connected bymeans of a piston rod to the regulating pistonin the unloading cylinder pos. 12.

82 0178-910-EN

When the regulating piston is unaffected by theoil pressure - i.e. when the connected solenoidvalve is de-energized or when the compressoris at standstill - the regulating piston and the en-tire frame are shifted to the right by the pres-sure from the springs Pos. 12J (see fig. 1) .

The tension springs Pos. 15D will thus raisethe rocker arms Pos. 15A into the vertical po-sition, as these rotate in the ball sockets Pos.15B.

This movement lifts the relief ring and thepins Pos. 19B, opening the suction valve byforce.

If oil pressure is placed on the relief cylinderduring operation, the unloader system isshifted to the left (see sketch). This lowersthe rocker arms Pos. 15A, and the relief ringwith pins Pos. 19B is moved away from thesuction valve ring plate, allowing this to oper-

ate freely and close during the compressionphase.

During operation, the unloader system cantherefore regulate the capacity of the com-pressor by causing the solenoid valve - whichis linked to the relief cylinder - to open orclose for oil pressure to the relief cylinders,controlled by an electrical regulation system.

On TSMC compressors, attention is drawn tothe two types of relief cylinder - for the LPand HP stage, respectively, as shown on thespare parts drawing.

Note:Adjust the oil pressure on the regulatingvalve Pos. 22 to 4.5 bar. At an oil pressurelower than 3.5 bar (the breaking pressurefor the safety automatices), there is a riskof the unloader system not being movedeffectively and thus being damaged.

0178-910-EN 83

Pilot solenoid valvesThe pilot solenoid valve is an electromagnet-ic three-way valve which with a dead coilconnects the unloading cylinder to the crank-case (the path for the oil flow from pipe 2 topipe 3 is open). See fig. 1. If the coil is ener-gized, the valve switches so that the path forthe oil flow from pipe 1 to pipe 2 is open andthe connection to pipe 3 is closed off.

The solenoid valves are integrated in blocks(fig. 2) with 1,2,3, or 4 solenoid valves ineach block. In these blocks the solenoidvalves have a collective supply of pressureoil (pipe 1) and a collective connection to thecrankcase (pipe 3). Each individual solenoidvalve has its own oil connection to the rele-vant unloading cylinder (pipe 2).

Sectional drawing of capacity regulating valve

Danfoss 034F9034_1

Fig. 2

2

3

1

84 0178-910-EN

Schematic outlines

The following schematic outlines shows theoil pipe connections and the wiring diagramwith cut-out functions.

The schematic outlines also indicate the per-centual capacity at which the compressor op-erates at the various capacity stages.

The lowest capacity percentage indicated onschematic outlines 1 corresponds to the low-est permissible capacity step at which thecompressor may work by continous opera-tion.

In special instances, e.g. where the start-upphase is lengthy, it may prove necessary torelieve the compressor altogether until themotor has achieved a sufficient torque. Insuch cases, an extra solenoid valve marked’S’ can be mounted as shown on schematicoutlines 2.

The S-valve is connected to the regulatingcylinder(s) not involved in capacity regula-tion.

The valve is designed to prevent fast risingoil pressure actuating the compressor cylin-ders before the motor starter has changedover to the delta position, or a gas or dieselmotor has reached full rotation speed.

TSMC compressors are always equippedwith S-valves and thus feature totally un-loaded start as standard.

Note:Please note that the solenoid valve Smust not be wired so as to form part ofthe capacity regulation. The compressor may operate totally un-loaded for no more than 5 minutes, as itsoperating temperature will otherwise be-come too high.

0178-910-EN 85

Standard unloaded start and capacity regulationThe SMC and TSMC compressors alwaysstart totally unloaded and in their standarddesign will activate a number of cylinderscorresponding to the lowest capacity stageonce the oil pump has built up the necessaryoil pressure.

See discussion of the ’S’ solenoid valve inthe Totally unloaded start and capacity regu-lation section, however.

It is recommended that solenoid valves bewired so as not to receive the openingsignal until the drive motor has achievedfull torque.

Regulating sequence

The unloading is effected for two cylinders ata time by cutting off the voltage to the ac-companying solenoid valve.

The unloading must be effected in numericalorder (1 - 2 - 3 - 4), while loading should bedone in reverse order (4 - 3 - 2 - 1).

Note:TSMC 116 must always have valves 3and 4 connected simultaneously, as thiscapacity stage includes both low- andhigh-pressure cylinders.

The regulating sequence may be seen from theschematic drawings.

Schematic drawings 1

1

LN

24

1007550

25

31

123

LN

2463

50

37

25

68

246

NL

3S 4

S50

33

0

LN

1006733

12

13

100

87

75

75

135

1

2 S5

100

67

83125S

13

2

LN

50

LN

267

50

83 100

33

46

24

LN

67330

S12

2

100 1

1

100

53

13

SS

21

SMC/HPC 104

SMC/HPC 106SMC 186

SMC 112TSMC 188

TSMC 116

TSMC 108

SMC 116

SMC/HPC 108SMC 188

%%

%

%%

%

%

T1534070_1 rev.3

HP

HP

34

S

86 0178-910-EN

Totally unloaded start and capacity regulationFuther to the standard equipment, as shownon the previous page, the compressor mayfeature an extra solenoid valve marked S.TSMC compressors, however, are invariablyequipped with this S-valve.

The ’S’ solenoid valve makes total unloadingof the compressor possible, i.e. 0% capacityover a shorter period during operation. How-ever, the ’S’ solenoid valve must never beinvolved in normal capacity regulation, asthere is a risk of the compressor overheatingif operated for some length of time at 0% ca-

pacity. The ’S’ solenoid valve may thereforebe used only as follows:

� Where total unloading is required until themotor has achieved max. torque.

� Where a refrigeration plant is occasionallysubject to brief operating stops and com-pressor stop is not desirable. The com-pressor may then be allowed to run for amaximum of 5 minutes at 0% capacity.

The regulating sequence may be seen fromthe schematic drawings:

Schematic drawings 2

L

2

N

7550

25

0

31

23

LN

33

0

2

4

NL

37

25

0

6

S

LN

6733

0

S100

1

2

2

67

50

1

100

83

S3

4

S

13

2

4

63

506

S

1

3100

87

75

S

5

24

1

35

21S

100

L

1

LN

0N

S 1

100

500

150

25

2

75

S

100

1

3123

Compressor seen from

Relief cylinder

Oil return

Oil pressure

SMC 116

SMC 188

SMC 112

SMC/HPC 104

SMC/HPC 106SMC 186

SMC/HPC 108

%

%

%

%

%

%

3

1

2

T1534070_2 rev.3

the shaft end

S

S

SS

S

S

S

S

0178-910-EN 87

Service

It will normally not be necessary to servicethe solenoid valves, and it is therefore re-commended not to strip them down. Should itbe considered necessary to replace the sole-noid valve, however, unscrew it from theblock and replace by a new one. See thespare parts list.

Regulating sequence

The schematic outlines show that disconnec-tion of a cylinder pair is done by cutting offthe current to the relevant magnetic coil. Dis-connection must be done by numerically as-cending sequence, while connection shouldbe done by numerically descending se-quence.

The automatic gear which controls the sol-enoid valves must cut off or connect the cur-

rent to the number of solenoid valves neededto supply the compressor with the capacityrequired.

Note:When starting a compressor this must bedone at the lowest capacity stage and itshould be allowed to run for a few minutes(e.g. 3 to 5 minutes) before its capacity is in-creased. This will prevent the oil in the com-pressor from heavy foaming and the refriger-ant from being sucked into the compressorfrom the evaporating system; somethingwhich can lead to liquid strokes. For thesame reasons the compressor should al-ways, when a new stage has been loaded,be allowed to run for 3 to 5 minutes at thisstage before the next higher capacity stage isloaded. Unloading of capacity on the com-pressor can usually take place more quickly.

Automatic capacity regulationWhere there is an automatic capacity regulat-ing facility, solenoid valve control can be ef-fected in the following ways:

- using pressure cut-outs - using thermostats- using microelectronics such as e.g. the UNISAB II.

Relief cylinders

The relief cylinders vary in type, dependingon the position they have on the compressor.The chart below shows the number and di-mensions of the relief cylinders for the indi-vidual compressor types.

Pos. Dimensions Cylinder SMC 100 TSMC 100

S mm L mm Part no. 104 106 108 112 116 108 116

Number in each compressor

12-1

12-2

12-3

12-4

12-5

12-7

21.5

46.5

71.5

96.5

24.5

49.5

75

100

125

150

82

107

3135-149

3135-150

3135-151

3135-152

3135-161

3135-154

1 1 1 2 2 1

1 1

1

1

1

1

2

2

2

2

2

1

1

1

1

1

2

2

1

1)

1

SMC 180

186 188

TSMC 180

188

12-1

12-2

12-3

49

94

139

122

167

212

3135-019

3135-020

3135-021

1) See spare parts drawing at the end of this instruction manual

12-4 184 257 3135-022

1

1

1

1

1

1

1

1

1

1

ReliefPiston rod

0170

-017

-EN

98.0

5

88 0178-910-EN

��

In order to keep the lubricating oil in the com-pressor warm during a period of standstill,the oil reservoir has one or two heating rodsbuilt in. Before start-up, the heating rod (s)must have been activated for 6-8 hours inorder to ensure that there is only a minimumof refrigerant in the oil. When containingmuch refrigerant, the oil will lose its lubricat-ing property and the following operational in-terruptions may occur:

In reciprocating compressors there is aserious danger of vigorous oil foaming whenthe compressor starts as a result of a fallingsuction pressure.

For screw compressors starting with muchrefrigerant dissolved in the oil, there is a riskof the compressor being stopped by the FlowSwitch as the oil will be foaming owing to thefall in pressure through oil pipe and oil filter.

As illustrated on the drawing the heating rodconsists of an electric heating element, incor-porated in a dia. 30 mm pipe. The entire hea-ting cartridge is screwed on tight at theG 1 1/4” thread.

Note:The heating rod must not be energized ifthe oil level in the reservoir is below theminimum mark in the sight glass, and itshould generally be switched off duringcompressor operation. Remember to turnoff the heating rod whenever the crank-case of the reciprocating compressor isopened for inspection.

The following table indicates which heatingrods are used for the various compressor

types. In the spare parts lists for compressoror unit you will find the current part numbers.

Marking: Prod. nr.WattVoltManu. date

L1

L2

NV 50G 1 1/4”

80

50

30 Ø 3

0

Heating rods

PowerWatt

VoltageV

L1mm

L2mm

Used for:

270270270

250230115*

CMO - TCMO - SMC 100 - TSMC 100

460460460

250230115*

158 175HPO - HPC, SMC 180 - TSMC 180 VMY 347 /447 – 536SAB 110 – 128 – 163 – 202 – 330

* Can be delivered with a UL approval.All heating rods are executed in Degree of Protection IP54.

0171

-463

-EN

95.0

3

0178-910-EN 89

��

42DT0177156_0

42B

42G

42F 42E 42C

42A 42H

23A 23D

23G

23F 23C 23B 23E

Dan

v

��

��

The compressor is fitted with stop valvespos. 23 for charging of oil and pos. 42 fordraining of oil. They are service-free valvesand should as a rule not be dismantled.

The valves are safeguarded against inadver-tent opening by means of a red cap.

The red cap can further be used for openingor closing the valve by unscrewing it andturning it upside down. The square hole inthe top of the cap fits the square in the valvespindle.

The valves are equipped with a blank nutpos. 23G/42H that prevents dirt from pene-

trating the valves whenever they are notused.

� If the valve is used as an oil chargingvalve it is fitted with a nut pos. 23C andthreaded nipple pos. 23B as shown byfig. 1.

� If the valve is used as a purge valve it isfitted with a screwed connection as illus-trated by fig. 2.

The purge valve is fitted either directly onthe top cover or by means of an intermedi-ate connection in the cast pressure chan-nels in the frame.

0171

-467

-EN

98.0

1

90 0178-910-EN

��

When reassembling the slide linings, it is im-portant to check the clearance volume asdescribed in section 1 below.

When mounting new cylinder linings, boththe clearance volume and the so called lift-ing reserve must be checked in the ordermentioned and as described in sections 1and 2. It is recommended that the cylinderlinings be marked so that they can be reas-sembled in the same place as before.

1. Checking clearance volume

After each cylinder lining assembly, it is rec-ommended that the clearance volume bechecked. Adjustment of the clearance volume is doneby means of gasket pos. 19K which, in addi-tion to its sealing function, is also used as anadjusting element. Consequently, the gasketscome in two sizes and may sometimes beused at the same time under the same cylin-der lining.

0.5mm

0.8mm

2356-111

2356-233

2356-116

2356-249

SMC 100part no.

SMC 180

part no.thickness

HPCGasket

19K

Adjustment is made as follows:

� The rocker arm system is lowered by fit-ting the long plug no. 4 from the tools kit inthe unloading cylinder pos. 12 instead ofscrew pos. 12D.

� Insert an 0.5mm gasket pos. 19K andmount cylinder lining.

� Press cylinder lining against gasket pos.19K by means of two locking devices –

no. 1 from the tools kit. Fit the locking devices diagonally asshown in fig. 1.

•

Fig. 1

pos. 19K

•S-L for SMC 100 type S E for SMC 100 type E

� Turn crankshaft until piston is in top posi-tion.

� Using a depth or slide gauge, measure ”X”as shown in fig. 2

Piston

Cylinder liningX

T0177131_0 v6

Fig. 2

� ”X” must lie between the below mentionedlimits and may, as mentioned earlier, beadjusted by the use of gasket pos. 19K.

0178-910-EN 91

0.6

0.9

1.0

1.5

mm mm

SMC 100

SMC 180

min. max.

Mk1, Mk 2, Mk 3

Mk1, Mk 2

HPC

Clearancevolume

”X”

� Adjustment of the lifting reserve can nowbe performed if necessary. See point 2.

2. Checking lifting reserveWhen fitting a new cylinder, or if the com-pressor is to be changed from running onR717 to some other refrigerant, or vice versa,or in the event of any major overhaul to thecompressor, the lifting reserve must bechecked.

Note:The lifting reserve must not be checkeduntil the clearance volume has been ad-justed. Start by checking that the mutualheight of the rocker arms is the same asdescribed in the following:

Having removed the cylinder lining, mea-sure distance ”Y” from the contact face ofthe cylinder lining in the frame to the top ofthe two rocker arms which interact on ei-ther side of the cylinder lining. See fig. 3.

T0177131_0 v4

Y1

Rocker arms

Y2

Block

Fig. 3

The rocker arms must be in their vertical

position i.e. with the short screw pos. 12D

and gasket 12E fitted. The measured dis-

tances ”Y1 and Y2” may not vary more

than max. 0.25mm.

In case this difference is greater, a shim

Pos. 15E must be placed under the lowest

rocker arm bearing pos. 15B or a shim re-

moved from the highest bearing. Normally,

there is no shim or max. 2 shims under

the rocker arm bearing.

Check lifting reserve:

� The lifting reserve of the rocker arm is im-

portant in order to make sure that the

rocker arm in its upright position can keep

the suction valve ring plate open while the

cylinder is unloaded. However, it must not

be possible for them to be so upright that

there is a risk of their jamming, this mak-

ing them unable to be lowered again

when the cylinder is put into service. Per-

form the adjustment as follows:

� Position cylinder lining incl. the correct

gasket pos. 19K in the compressor block

and press down against rocker arms by

hand.

� The rocker arms are in their upright posi-

tion as the normal plug pos. 12D as well

as gasket pos. 12E have been mounted in

the unloading cylinder.

92 0178-910-EN

T0177131_0 v5

Z

Fig. 4

pos. 19K

•

� Measure distance ”Z” as shown in fig. 4.Note down the ”Z” measure.

� Replace normal plug pos. 12D with thelong plug no. 4 from the tools kit, loweringrocker arms in the process.

� Press cylinder lining down against gasketpos. 19K using the two locking devices no.1 as shown in fig. 1, and repeat measure-ment ”Z”.

� The difference in the two measurementsof ”Z” must be within the limits stipulatedin the following table.

SMC 100

SMC 180

0,6

0,8

1,0

1,5

Min.mm

Max.mm

Mk 1, Mk 2, Mk 3

Mk 1, Mk 2

HPC

Lifting reserve”Z”

� If the difference between the two mea-surements does not fall within the parame-ters stated, it must be regulated by insert-ing or removing shims pos. 15E under therocker arm bearings.

� It is important that the long threaded plugis fitted while the top cover is beingmounted.

Note:Remember to put the normal plug in oncethe top cover has been tightened.

0170

-161

-EN

95.0

6

0178-910-EN 93

��

The analog instrumentation on the compres-sor includes two pressure gauges: one thatmeasures the discharge pressure on thecompressor and one combined suction andoil pressure gauge. These pressure gaugesare filled with glycerine, which both attenu-ates the deflections of the indicators and lu-bricates the gauge works.

However, a fluctuating ambient temperaturehas an influence on the volume of the glycer-ine (warm glycerine takes up more spacethan cold glycerine), which can affect themeasuring accuracy of the gauge.Furthermore, it is essential that no excesspressure can possibly occur in the gaugehousing, as this involves a risk of explosionof the housing.

Both these considerations have been effec-tively solved in the gauges by a combinationof internal temperature compensation andthe so-called blow-out safety device which isfitted in the back plate of the pressure gaugehousing.

Adjustment to other temperatureranges:

A balancing screw on the rear of the instru-ment is firmly tightened at a temperature of20°C – the normal ambient temperature.

If ambient temperatures change considerablythus requiring a general shift in the com-pensation range, slacken the balancingscrew for approx. 1 minute, then retighten.This must be done at the average operating

temperature under which the instrument willbe functioning.

Example:

If the mid–compensation range is to bemoved from 20°C to 10°C, equalization mustbe performed at 10°C. When the screw isthen retightened, the middle of the com-pensation range will have been moved downto 10°C. The total stretch of the compensa-tion range remains unchanged.

50°C

60°C

70°C

T0177086_0

-10°C

0°C

+10°C

10°C

20°C

30°C

The middle of the compensation range.Tighten the balancing screw at this temperature

Cleaning and refilling glycerine-filled gauges

� Remove blow-out disk and temperaturecompensator from back of housing.

� Wash gauge interior with warm water andallow to dry carefully.

� Fill gauge housing with fresh glycerine un-til it flows out of bleeder hole.

Note:The glycerine must be absolutely wa-terfree.

� Refit compensator and blow-out disk ingauge housing and cover centrehole inblow-out disk with a piece of tape.

94 0178-910-EN

Note:Glycerine should be refilled at a room tem-perature of 20°C; when mounted, and thecompensator must be its normal shape asshown at the top of the following drawing.

� Clean gauge exterior with warm water.

� Remove tape from centrehole.

� Refit gauge.

Balancing screw

T0177086_0

Compensator

+20°C

-10°C

+60°C

Blow-out

0171

-904

-EN

96.0

5

0178-910-EN 95

��

��

134.0

3559.5

79.5

134.0

59.5

79.5

134.0

54.5 54.5

79.5

134.0 70

Ra=0.35

Ra=0,63 Ra=0,63

Ra=0.35

40

50

1.0

Ra=0,20Ra=0,20

Compressor type

CMO 2

SMC/TSMC100 S

SMC/TSMC100 L

SMC/TSMC180

A

First

Main bearingSuper

orFinal

BConnecting rod bearing

a b c dC

mm mm mm mm mmmmmm mm mm

–0.060

–0.070

–0.070

–0.080

–0.110

–0.120

–0.060

–0.090

–0.070

–0.090

–0.110

–0.140

–0.030

–0.049

79.50.000

–0.010

0.000

–0.010

–0.035

–0.050

0.000

–0.020

–0.015

–0.040

0.0

–0.1

0.0

–0.1

0.0

–0.1

0.0

–0.1

0.16

0.2

0.2

1.15

1

0.0

–0.3

5

2.5

3

6

2.5

3.5

grinding finish

grinding

First Super

orFinal

grinding finish

grinding

Undersize bearings: See SABROE spare parts list.

HPC,

HPO

B

B

A

R=2.5

a

A

C

R=2.5

c

b

R=d

45°

T0177137_0

SMC/TSMC100 E 60

0.0

–0.1

0171

-901

-EN

91.0

4

96 0178-910-EN

��

Bearing clearance

Main bearings

Connecting rodbearings

Piston pinbearings

Parallel topiston pin

At right anglesto piston pin

manufacturedmax.

manufacturedmax.

manufacturedmax.

manufacturedmax.

manufacturedmax.

0.080.20

0.080.15

0.040.10

0.18 –

0.110.30

0.080.20

0.080.15

0.040.10

0.18 –

0.110.30

0.080.20

0.080.15

0.040.10

0.18 –

0.110.30

0.080.20

0.100.20

0.040.10

0.20 –

0.150.40

0.080.20

0.100.20

0.040.10

0.20 –

0.150.40

0.140.35

0.140.30

0.090.20

0.25 –

0.350.90

CMO 1 CMO 2 SMC 65 SMC 100 SMC 100 SMC180CMP 1TCMO1

TCMO 2 TSMC 65 TSMC 1004–10 cyl.

TSMC 10012–16 cyl.

TSMC 180

Mk1 & Mk2

If the maximum value has been exceeded, replace the parts.

Crankshaft end-playmin.

max.

0.30 0.30 0.30 0.40 0.75 0.95

0.55 0.55 0.55 0.64 1.00 1.20

The end–play can be adjusted by means of the gasket under the bearing cover.The gasket is available in the following thicknesses: 0.3, 0.5, 0.75 and 1.0 mm.

Piston ring gapmin.

max.

0.25 0.25 0.25 0.33 0.33 0.66

1.00 1.00 1.00 1.30 1.30 2.50

The piston ring gap must be measured with the ring placed in the cylinder liner.

Main bearing journals

Connecting rodbearing journals

Intermediate journals

Main bearing journals

Connecting rodbearing journals

Intermediate journals.

Bushing and bearing halves can be supplied for all above journals.

–0.06 –0.06 –0.06 –0.07 –0.07 –0.11

–0.09

–0.025

–0.040

–0.06

–0.09

–0.025

–0.040

–0.030 0 0 0 –0.015

–0.049 –0.02 –0.02 –0.02 –0.040

–0.06 –0.06 –0.07 –0.07 –0.11

–0.09 –0.09 –0.09 –0.09 –0.14

–0.025 0 0 0 –0.015

–0.040 –0.02 –0.02 –0.02 –0.040

–0.010

–0.029

–0.010

–0.029

55

50

54.5

49.5

60

55

59.5

54.5 54.5 79.5 79.5 134

55 80 80 135

55 80 80 135

80

54.5 79.5 79.5 134

79.5

Dimensions of crankshaft bearing journal

–0.09 –0.09 –0.09 –0.09 –0.14

All measurements stated are in mm

Pis

ton

New

Gro

und

dow

n

CMO4 HPO HPC

0171

-465

-EN

94.1

2

T0177082_0

0178-910-EN 97

��

Metric thread (ISO 8.8)

M 4 5 6 8 10 12 14 16 18 20 22 24 27

0.28

2.1

2.7

0.53

3.9

5.2

0.94

6.8

9.2

2.2

16

22

4.1

30

40

7.0

50

69

11

80

108

15

110

147

23

170

225

30

220

295

38

270

375

52

370

510

68

490

670

Kpm

ft.lbf.

Nm

Metric thread (ISO 12.9)

M 4 5 6 8 10 12 14 16 18 20 22 24 27

Kpm

ft.lbf.

Nm

0.42

3.0

4.1

0.78

5.7

7.6

1.4

10

14

3.2

23

31

6.1

44

60

10

75

98

16

120

157

23

160

225

34

240

335

44

320

430

55

400

540

76

550

745

100

720

980

Connecting rods with UNF thread

HPO/CMO HPC/SMC 100 SMC 180

UNF

Kpm

ft.lbf.

Nm

5/16”

2.1

15

20

3/8”

4.4

32

43

5/8”

17

130

167

A

A

A

AMR

NORMEX

Series 52

98 0178-910-EN

Bolt on discharge valve

HPO/CMO HPC/SMC 100 SMC 180

Kpm

ft.lbf.

Nm

3.2

23

32

10.2

75

101

35

255

344

Compressor type Coupling ThreadTorque (A)

Kpm. ft.lbf. Nm

34

55

128

275

22

22

34

34

41

55

128

177

245

275

25

40

95

200

16

16

25

25

30

40

95

130

175

200

3.5

5.6

13

28

2.2

2.2

3.5

3.5

4.2

5.6

13

18

25

28

5/16”

7/16”

1/2”

11/16”

M8

M8

AMR225

AMR312S

AMR350S

AMR450S

H148

H168

200

225

262

312

350

375

425

450

HPO/CMO/TCMO

104-108

112-116

186-188

128

163

depending

on the

motor size

HPC/

SAB

VMY

5/16”

5/16”

3/8”

7/16”

1/2”

9/16”

5/8”

11/16”

SMC/TSMC

Ser

ies

52N

OR

ME

X

34

41

25

30

3.5

4.2

5/16”

3/8”

225

262

128

163

Ser

ies

52

type

202 55405.6312 7/16”

0171

-464

-EN

94.0

5

0178-910-EN 99

��

Operational reliability

The prime causes of operating malfunctionsto the plant are:

1. Incorrect control of liquid supply to theevaporator.

2. Moisture in the plant.

3. Air in the plant.

4. Anti-freezing liquid is missing.

5. Congestion due to metal shavings anddirt.

6. Congestion due to iron oxides.

7. Congestion due to copper oxides.

8. Inadequate refrigerant charge.

Below, some information is given about waysof keeping contaminants out of the refrigera-ting system and at the same time facilitatingday-to-day supervision of the refrigerationplant.

Pumping down the refrigerationplant

Before dismantling any parts of the refrigera-tion plant for inspection or repair, pump-downmust be carried out.

1. Open suction and discharge stop valveson compressor.

2. Close liquid stop valve after condenser orreceiver so that liquid refrigerant can becollected in the tank. Any solenoid valvesin the liquid line should be opened byforce, adjusting the thermostat to its low-est position so that the liquid line can be

bled of refrigerant. Adjust any constant-pressure valves to bring evaporator pres-sure down to atmospheric.

3. Start up the compressor. Adjust regulat-ing system to lower suction pressure.

4. Keep a close eye on the suction pres-sure gauge! When the suction pressure isequal to atmospheric, stop the compres-sor and quickly shut off the discharge stopvalve. Shut off any stop valve in the oil re-turn line.

If the receiver has an extra stop valve inthe feed line, this can be closed; practical-ly the entire refrigerant charge will thenremain shut off in the receiver.

Note:The receiver must not be overfilled! Thereshould be a minimum gas volume of 5%.

5. A slight overpressure should normally re-main in the piping system - this safe-guards the system against the penetrationof air and moisture.

6. Before dismantling parts, the operatorshould put a gas mask on.

Dismantling plant

In order to prevent moisture penetrating intothe refrigeration plant during any repair work,it is advisable to follow the rules below:

1. No component should be opened un-necessarily.

2. When dismantling the system, the pres-sure in the system should be a little higherthan atmospheric.

100 0178-910-EN

3. Note: If the piping system is colder than the sur-roundings, there is a considerable risk ofdamp precipitation (condensation) on coldplant parts. Plant components to be dis-mantled must be warmer than the ambi-ent temperature.

4. No two points in the system should beopened at the same time.

5. Plug, close or at least cover opening withoiled paper or suchlike.

6. Be aware of the possibility of filters being very moist.

Tightness testing and pump-downof refrigeration plantBefore charging refrigerant into that part ofthe refrigeration plant which has beenopened, this should be pressure-tested asdescribed in the section entitled Pressuretesting.

Afterwards, pump down in order to eliminateair and moisture. In this regard, consult thesection on Evacuation.Otherwise, follow the instructions given in theseparate instruction manual on plant compo-nents.

Note:If the oil in the crankcase of the pistoncompressor or the oil separator of thescrew compressor has been in contactwith the atmospheric air for any length oftime, it must be replaced with fresh oil ofthe same grade and make.

0170

-335

-EN

91.0

5

0178-910-EN 101

��

��

Operating condition

Experience shows that pressure and temper-ature variations in a refrigeration circuit canprovide information about the operating con-dition of the refrigeration plant.

In particular, suction and condenser pres-sures as well as the temperatures of suctionand discharge gases may provide importantinformation as to the operating conditionsof the plant.

It often takes only very slight modifications tovariable pressures and temperatures to pro-duce considerable changes in operating con-ditions.

Using the following troubleshooting chart, it ispossible to ascertain the cause of and reme-dy for any operating disturbance.

Using the trouble-shooting chart

In the following chart, each individual erroroption is indicated by a code number in the

lefthand column, the error being briefly de-scribed in the next column. The third columnstates code numbers for the possible causesof the error.

The code numbers refer to the subsequentchart.

The section entitled Remedying malfunctionsstates how to remedy the observed error.

See the following example for the correctprocedure.

Example

Observed error: discharge pipe temperaturetoo low - error code 15.

Cause codes: 26 (Liquid in suction line) 32 (Too much coolant/air to condenser) 39 (Expansion valve produces too little su-perheating)

Any explanatory comments will be stated inthe section that follows.

102 0178-910-EN

1 Compressor fails to start 1, 2, 3, 4, 5, 6, 7, 9, 10, 12, 14.2 Compressor starts and stops too often 9, 10, 11, 13, 21, 22, 23, 24, 32, 34, 35, 36, 37,

40, 41, 43, 44, 51, 52, 54, 56, 59.3 Compressor starts but stops again immediately 3, 5, 6, 9, 10, 11, 12, 13, 14, 15, 17, 18, 41,

42, 49, 50, 55, 61.4 Compressor operates continuously 8, 21, 22, 24, 41, 46, 52, 53, 56, 60.5 Abnormal noise from compressor 16, 17, 18, 19, 26, 48, 49, 50, 51, 52, 53, 54, 56,

57, 58.6 Insufficient capacity on compressor 13, 15, 17, 18, 20, 21, 22, 23, 24, 32, 34, 35, 36,

37, 40, 41, 44, 45, 46, 49, 50, 51, 52, 53, 56, 60.7 Liquid stroke in compressor during start up 16, 18, 26, 37, 38, 39, 44, 56, 61.8 Liquid stroke in compressor during operation 21, 23, 26, 37, 39.

9 Excessive condenser pressure 9, 25, 28, 29, 30, 31, 33.10 Too low condenser pressure 22, 32, 51, 52, 54, 60.11 Excessive suction pressure 13, 17, 26, 34, 39, 52, 53, 54, 5,. 60.12 Too low suction pressure 11, 13, 20, 21, 22, 23, 32, 35, 36, 37, 40, 41, 42,

44, 45, 56, 59.13 Too low oil pressure 12, 15, 17, 18, 26, 49, 50, 55.

14 Excessive discharge pipe temperature 11, 21, 22, 23, 28, 29, 30, 31, 33, 34, 35, 36, 37,40, 41, 46, 52, 54.

15 Too low discharge pipe temperature 26, 32, 39.16 Excessive oil temperature 33, 34, 35, 36, 37, 40, 50, 52.

17 Oil level in crankcase falling 16, 18, 20, 26, 51, 57, 58.18 Oil foaming vigorously in crankcase 16, 26, 39, 61.19 Crankcase sweating or frosting up 16, 18, 26, 37, 39.

20 Capacity regulating oscillating 13, 15, 16, 17, 18, 49, 55, 56.21 Impossible to bleed plant 10, 43, 51, 52, 53, 54, 60.

Errorcode Observed error Cause code

0178-910-EN 103

1 No power - master switch not cut in 2 Blown fuses - loose wiring or

connections 3 Electrical voltage too low 4 No control current 5 Motor protection device activated 6 Control current circuit open 7 Pump/fan not started 8 Welded contracts in motor protection9 High-pressure cut-out has cut

10 Low-pressure cut-out has cut 11 Low-pressure cut-out differential too

small 12 Oil pressure cut-out has cut 13 Capacity regulator incorrectly set 14 Defrosting timer breaks current 15 Oil charge insufficient16 Compressor capacity too high

during start-up 17 Oil pressure too low (adjust oil pres-

sure regulating valve) 18 Oil foaming in crankcase 19 Oil overcharge20 Poor oil return - oil in evaporators

21 Restricted supply of refrigerant22 Refrigerant charge insufficient 23 Refrigerant vapour in liquid line 24 Leaky refrigeration plant 25 Refrigerant overcharge26 Liquid in suction line 27 At low temperature operation, de-

gree of charge in evaporators rises 28 Insufficient coolant/air to condenser29 Temperature of coolant/air too high30 Non-condensable gases in

condenser 31 Condenser needs cleaning 32 Too much coolant/air to condenser 33 Water valve closed

34 External pressure equalization on expansion valve closed

35 Expansion valve partly clogged by ice, dirt, wax

36 Expansion valve has lost charge 37 Expansion valve sensor misplaced 38 Expansion valve is leaky 39 Expansion valve provides too little

superheating 40 Expansion valve produces excessive

superheating 41 Filters in liquid/suction line clogged 42 Solenoid valve in liquid/suction line

closed

43 Solenoid valve leaky 44 Evaporator iced up or clogged 45 Cooling air being recirculated

(short-circuited)46 Excessive load on plant 47 Refrigerant collecting in cold con-

denser (close off by-pass)48 Coupling misaligned or loose bolts 49 Oil pump defective 50 Bearings worn out or defective 51 Defective piston rings or worn

cylinder52 Discharge valves defective or leaky 53 Suction valves defective or leaky

54 Compressor by-pass open - leaky safety valve

55 Compressor oil filter clogged 56 Capacity regulator defective 57 Solenoid valve in oil return clogged/

defective 58 Filter in oil return clogged 59 Compressor capacity too high60 Compressor capacity too low61 Heating element in crankcase

defective

Code CodeCase Case

104 0178-910-EN

Remedying malfunctions1. Compressor fails to start

1.6 Control current circuit open owingto activated: pressure cut-outsthermostats motor protection device defrosting timer

Pinpoint open switch andremedy cause of interruption.

1.9 High-pressure cut-out has cut Reset pressure cut-out and investigate causeof high condenser pressure.

1.10 Low-pressure cut-out has cut Compressor cannot start before suction pres-sure has risen above set point for pressurecut-out restarting.

Oil-pressure cut-out has cut Compressor starts at reset. Check oil level. If oil foams in crankcase, see section 18.

1.12

2. Compressor starts and stops too often

Low-pressure cut-out cuts at toolow suction pressure.

High-pressure cut-out cuts at high pressure

High condenser pressure - see section 9.

Check condenser cooling and adjust pressurecut-out to correct breaking pressure -see table Pressure and temperature settings.

Replace defective pressure cut-out.

2.9

Low suction pressure - see section 12.

If low-pressure cut-out is set too high, adjustpressure cut-out.

2.10

Low-pressure cut-out differential istoo small between stopping andstarting

Increase differential pressure - see also specialinstructions.

2.11

Compressor capacity too high Check operating conditions and, if need be,reduce capacity.

2.13

discharge valves on compressorare leaky.

At compressor stop, pressure equalizes rela-tively quickly between suction and dischargeside

Clean or change discharge valves.

2.52

Filter in suction line clogged Check suction filters on compressor.2.41

Solenoid valve in liquid line doesnot close tight.

Check direction of flow.

Replace defective valve.

2.43

0178-910-EN 105

3. Compressor starts but stops again immediately

Oil charge insufficient Top up with oil and investigate cause of oilshortage.

3.15

Low-pressure cut-out has cut Open any suction stop valve which is closed.3.10

Oil pressure failing owing to for-mation of foam in oil.

Reduce capacity. See sections 17 and 18.3.18

Defective oil-pressure cut-out Replace cut-out - see special instructions.3.12

Motor protection cuts Look for cause of overloading.

If star-delta start, set starting time to minimum.

3.5

4. Compressor operates continuously

Thermostat or low-pressurecut-out does not cut at too lowtemperature/pressure

Adjust operating points.4.10

Refrigerant charge unsufficient Top up with refrigerant of correct type.4.22

Restricted supply of refrigerant toevaporator. Compressor workingat too low suction pressure.

Remove dirt in filters and check function of ex-pansion device as per special instructions.

4.21

106 0178-910-EN

5. Abnormal noise from compressor

Compressor capacity too high du-ring start-up

Reduce capacity.5.16

Capacity regulation oscillatingowing to failing oil pressure

Low oil pressure - see section 13.5.56

Oil pressure too low See section 13.5.17

Liquid refrigerant in suction line Liquid stroke. See points 7 and 8. Adjust expansion or float valves.

5.26

Incorrect alignment of motor andcompressor Loose bolts in coupling

Check alignment as per special instructions.

Tighten with torque wrench

5.48

Worn or defective bearings Overhaul or replace.5.50

Too much oil circulatingthrough the plant, resulting in toolow oil level in compressor

Check oil level.

Solenoid valve, filter or jets in oil return systemmay be clogged. Leaky suction valve ringplates, piston rings and worn-out cylinder mayalso produce such oil consumption.

5.515.535.575.58

6. Too little capacity on compressor

Insufficient oil charge Top up with fresh oil of same type and make.6.15

Iced-up evaporator Defrost evaporator; adjust defrosting time ifrequired.

6.44

Defective oil pump and hence fail-ing oil pressure

Repair or replace oil pump6.49

Defective capacity regulating sys-tem

Cause is most often failure in oil pressure orrefrigerant in oil; see section 4.5.

6.56

0178-910-EN 107

7. Liquid stroke in compressor during start-up

Refrigerant has condensed in suc-tion line or crankcase

Heating element in crankcase should be con-nected for 6-8 hours before starting, so thatrefrigerant dissolved in oil can be boiled outbefore starting compressor up.

7.26

Liquid stroke in the compressor should not occur, as in the worst instance this cancause rupture to the valve ring plates and damage to the inbuilt relief devices. Fur-thermore, it can result in damage to the connecting rod bearings and cylinders if thecoolant degreases the faces and impairs the lubricating capacity of the oil.

Adsorption of (H)CFC refrigerantin oil

Sudden reduction in pressureacross the oil sump (suction pres-sure) produces foaming

Reduce compressor capacity or start withthrottled suction stop valve.

Follow instructions in section 18.

7.18

Suction line has free fall towardscompressor

Start with throttled suction stop valve - stopwhen hammering is heard.

Liquid separator should be mounted in suctionpipe.

8. Liquid stroke in compressor during operation

Refrigerant gas in liquid line Expansion valve is oscillating.8.23

Superheating of expansion valveis set too low

Adjust superheating, which should normally be5-8°C.

8.39

108 0178-910-EN

9. Excessive condenser pressure

Overfilling with refrigerant Refrigerant fills condenser and reduces its ef-fective area.

Draw off coolant.

9.25

Presence of non-condensablegases (especially air) in conden-ser.

Blow air out at condenser. Follow instructionsfor condenser.

9.30

In the event of abnormally high pressures in the refrigeration system, there is a risk ofdamage to the compressor. At very high pressures (see pressure testing), the risk ofthe components in the refrigeration plant exploding can constitute a threat to life.

Abnormally high pressures can occur in the case of:

- extreme heating of plant parts (fire, solar radiation or other abnormal heating);

- volumetric expansion of fluids in sealed-off premises.

Insufficient condenser cooling,e.g. if cooling water fails, fan/coling water pump clogs, soiling,scaling or fouling of heat-transmit-ting surfaces

Regulate water/air supply or reduce compres-sor capacity, if called for. Check condenser asper instructions for same.

9.28

10. Too low condenser pressure

Excessive condenser cooling Regulate condenser cooling.10.32

Compressor lacks capacity. Check whether compressor capacity corre-sponds to load on plant. Reduce condensercooling.

10.60

Defective piston rings or worn cy-linders

Replace worn parts. See compressor instruc-tions.

10.51

Discharge valves are defective orleaky

See compressor instructions. Check valve ringplates and piston rings.

10.52

Bypass between high-pressureside and suction side of compres-sor

Check compressor for internal leakage by per-forming pressure-drop test.

See compressor instructions.

10.54

0178-910-EN 109

11. Excessive suction pressure

Error in setting of liquid regulationvalve

Liquid refrigerant in suction line.

Adjust, repair or replace expansion valve.

11.26

Compressor lacks capacity. Regulate compressor capacity.

Check whether all cylinders are operating.

Check function of capacity regulator.

11.60

Leaky suction valves See compressor instructions. Remove cylindercovers; check valve plates. Renew if needed.

11.53

Open by-pass between suction si-de and high-pressure side of com-pressor. Safety valve leaky, oropens prematurely.

Check system for any by-pass detectable as awarm connection.

Adjust or repair leaky valves.

11.54

12. Too low suction pressure

Oil in evaporator Draw off oil.12.20

Abnormally low pressure in the refrigeration plant will increase the compression ratioof the compressor with a subsequent risk of damage to the compressor.

The danger of air being sucked into the refrigeration plant also increases at abnor-mally low pressure.

Refrigerant charge on plant insuffi-cient

Bubbles in liquid line sight glassand possibly a warm liquid line

Check refrigerant charge.

Charge plant with refrigerant.

Find and seal any leak.

12.22

Freezing-up of expansion valve(HFC/HCFC plant)

Thaw out expansion valve with hot, wet cloths.

Replace dessicant in drying filter.

12.35

Thermostatic expansion valve haslost charge

Valve fails to open - change valve.12.36

Excessive superheating of suc-tion gas

Regulate expansion valves to higher capacity.12.40

110 0178-910-EN

Compressor has excessive capa-city

Reduce compressor capacity.

Check capacity regulating system.

12.59

Filter in liquid line clogged Check and clean filter in liquid line.12.41

Solenoid valve in liquid line fails toopen

Coil may have blown. Control signal lacking.12.42

13. Oil temperature too low

Too little oil in compressor Top up compressor with oil and investigatecause of oil consumption.

13.15

Oil filter clogged Change filter cartridge13.55

Oil foams in compressor See point 18.13.18

Oil pump defective Repair or replace.13.49

Bearings worn Repair or replace.13.50

14. Excessive discharge pipe temperature

If, after approx. 1 hour’s operation, the discharge pipe temperature is more than10°C higher than indicated in the table, the error may be due i.a. to:

Open by-pass between high andlow-pressure side of compressor,e.g. leaky safety valve

Localize by-pass and remedy any leakages.

14.54

Excessive suction temperature asresult of reduced refrigerant sup-ply to evaporator (extensive su-perheating) owing to insufficientrefrigerant charge.

Check refrigerant charge14.21

Excessive suction temperature asresult of reduced refrigerant sup-ply to evaporator (extensive su-perheating) owing to incorrectlyadjusted liquid regulating valves

Check thermostatic expansion valves14.22

Leaky discharge valves Leaking in discharge valves gives rise to gen-eration of heat.

Change defective valves.

14.52

0178-910-EN 111

15. Too low discharge pipe temperature

Low suction temperature as resultof overflow of liquid refrigerantfrom evaporator

Adjust liquid regulating valve. Increase super-heating.

15.26

16. Excessive oil temperature

During operation, the heat of the compressor crankcase must be 40-70°C. Whenworking with R717 and R22, it may be necessary to supply the compressor with oilcooling.

See point 14.

17. Oil level in crankcase falling

Where HFC/HCFC refrigerants are used, there will be some blending of refrigerantand oil during the initial operating period. It may therefore prove necessary to top upthe oil after initial start-up of the plant.Note:The oil level must always be visible in the oil level sight glass on the compressor.

Filter in solenoid valve or jet in oilreturn line clogged

Oil return pipe must be warm during opera-tions. Clean filter.

17.20

Liquid in suction line and crank-case may cause foaming in oiland thus increase oil consumption

Examine evaporator system and check superheating of suction gas.

17.26

Worn-out piston rings or cylinders Renew piston rings and, if need be, renew pis-tons and cylinder linings.

17.51

Solenoid valve in oil return line de-fective

Coil in solenoid valve defective. - Replace coil. - Electrical control signal lacking.

17.57

112 0178-910-EN

18. Heavy oil foaming in crankcase

Liquid in suction line See 17.26.18.26

Too much refrigerant dissolved inoil

- Before starting compressor, heating elementmust have been on for at least 8 hours in order to boil refrigerant out of oil. During start-up phase, capacity should be con-nected at a slow rate to prevent sudden dropin pressure on suction side with resultant foaming.

- Under normal operating conditions, com-pressor should operate under as stable pressure conditions as possible.

18.61

19. Crankcase sweating or frosting up

Liquid in suction line See 17.26.19.26

Expansion valve sensor misplaced Check positioning of expansion valve sensor -cf. instructions for expansion valve.

19.37

Liquid regulating valve or float val-ve producing too much liquid

Increase superheating on thermostatic expan-sion valve.

19.39

20. Capacity regulation oscillating

Oil foaming in crankcase See point 18.20.18

21. Impossible to bleed plant

Solenoid valve leaky Pinpoint and seal leak, or change leaky com-ponent.

21.43

Defective piston rings Check and replace any defective parts.21.51

Defective discharge valves Check and replace any defective parts.21.52

Defective suction valves Check and replace any defective parts.21.53

0170

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-EN

99.0

2

0178-910-EN 113

��

During the past few years YORK Refrigeration has experienced a number ofproblems with mineral oils, particularly inR717 plants. The problems can be dividedinto two groups:

a: The oil changes viscosityb: The oil decomposes (becomes very black)

The problems have been seen with severalmineral oil brands, often occuring within afew operating hours and resulting in severeconsequences for both compressor andplants.

Following the careful investigation undertak-en by YORK Refrigeration during the pastfew years, it has been decided to introduce arange of synthetic oils which can fulfil the de-mands of modern refrigeration plants.

Mineral oils may continue to be used in re-frigeration plants, providing the lubricatingquality is carefully monitored. For modern,high capacity refrigeration plants, where longlifetime for both lubricants and moving partsis expected, YORK Refrigeration recom-mends the choice of synthetic lubricating oils.

The application areas and specifications forthese synthetic oils can be found in the fol-lowing pages. Installers and/or users are atliberty to choose either YORK Refrigeration’sown or alternative oil brands which fulfil thenecessary specifications.

General

This recommendation only deals with the lu-brication of the compressor. The perfor-mance of the lubricant in the plant (receiver,evaporator, etc.) must, however, also be tak-en into consideration.

Lubricating oils with relatively high viscositiesmust be used to ensure satisfactory lubrica-tion of refrigeration compressors.

To obtain the best lubrication, the oil must:

� Provide the required fluidity at the lowestevaporating temperature encountered inthe plant and at the highest permissibletemperatures in the compressors.

� Provide acceptable fluidity at start-up.

� Provide sufficient oxidation stability (the oilmust be moisture-free when added to thesystem).

� Provide sufficient chemical stability whenused together with the particular refriger-ant.

In addition, the extent to which different re-frigerants dissolve in the oil must be deter-mined, so that the oil return systems, etc. canbe designed to function properly.

Stratification

It should be noted that in certain plants, par-ticularly with HFC and HCFC refrigerants, theoil may stratify into layers in the refrigerantreceivers and evaporators at certain operat-ing conditions and at particular oil concentra-tions.

The Oil recommendation diagrams for SABROE compressors for HFC and HCFCwill indicate the limits for Sabroe oils at whichthis stratification occurs. The oil concentra-tions stated in these diagrams must not beexceeded. This will enable suitable oil rectifi-cation/return systems to be designed to bal-ance with the compressor oil ”carry-over” sothat the maximum concentration is not ex-ceeded. For area A in the diagrams, the max oil con-centration in liquid phase must not exceed

114 0178-910-EN

2%. For the other area, the max. oil con-centration must not exceed 5%. For area B:please contact YORK Refrigeration.

Plants with several different compressortypes/makes

In plants comprising several different inter-connected compressor types and makes, it isstrongly recommended that all compressorsshould use the same type of oil. This is es-sential where automatic oil return systemsare employed.

If it is intended to change the oil from onetype to another, please refer to the Oil chang-ing on SABROE compressors later in thispublication.

Selecting the lubricating oil

There are a number of operating diagramsfor the selection of lubricating oils for Sabroecompressors operating with various refriger-ants. Once the general conditions concern-ing the lubrication of the compressor and oiltype in the plant have been considered, thespecific plant conditions must be takeninto consideration.

Use the Oil recommendation diagrams to se-lect the appropriate oil code number.

The oil code number consists of letters de-signating the oil type together with theSabroe viscosity grade number.

Codedesign Oil types

M Mineral oil

A Synthetic oil based on Alkylbenzene

PAO Synthetic oils based on Polyalphaolefin

AP Mixture of A and PAO-oils

E Synthetic ester-based lubricants

In the oil recommendation diagrams for eachrefrigerant and compressor type, it is pos-sible to determine the code number for theoil best suited to the operating conditions.With this code number, it is possible to se-lect the correct Sabroe oil for the application.The marked area on each side of the sepa-rating line in the diagram shows the zonewhere both oils are useable.

Oil types and oil companiesAs a result of the large number of oil compa-nies world-wide that deals in oil for refrigera-tion plants, it is impossible for YORK Refrigeration to test the many differentbrands of oil on the market. It is our experi-ence, however, that some oil brands duringuse can change character and thus no longerfit the specifications given by the companiesat delivery. We have thus experiencedchanges in the specifications as well as inthe formula and performance without havinghad any information about this from the oilcompany. This makes it very difficult forYORK Refrigeration to give a general ap-proval of the various oil brands.

For this reason YORK Refrigeration has, incooperation with a large recognised oil com-pany, developed a series of three oils whichcover most purposes. YORK Refrigerationhas however, also listed a limited number ofoils which can be supplied through YORKRefrigeration. The typical data of these oilscan be found in the Data Sheet for SabroeOils. We suggest you to use these Sabroeoils, which are delivered in 20 litre pails and208 litre drums and can be ordered using theparts no. listed in the List of Oils.

It is of course possible to use similar oils fromother oil companies, and in this connection,

0178-910-EN 115

the Data Sheet for Sabroe Oils may be help-ful.

Please note, however, that YORK Refrigeration has not tested any other oilsthan our own brand, and hence we cannotanswer for the quality, the stability or the suit-ability of other oils for any purposes. The oilcompany in question is thus solely responsi-ble for the quality and suitability of the oil de-livered, and if any problems are experiencedwith these oils in the compressors or in therefrigeration plant, the oil supplier should becontacted directly.

When choosing oils from other oil compa-nies, please pay particular attention to theoil’s effectiveness in the compressor and therefrigeration plant as a whole.

Pay particular attention to the following as-pects:

� Oil type

� Refrigerant type

� Compressor type

� Miscibility between refrigerant and oil

� Operating data for the compressor

• Discharge gas temperature

• Oil temperatures:

Reciprocating compressors:

Normal oil temp. in the crankcase50-60 °C

Max. permitted oil temperature = Set-ting point for alarm

Min. permitted oil temperatures = set-ting point for alarm - if fitted

Screw compressors:

The oil temperature before injection inthe compressor, but after the oil cooler

Max. permitted oil temperature = set-ting point for alarm

Min. permitted oil temperature = set-ting point for alarm

• Condensing pressure

• Evaporating pressure

� Oil viscosity in the compressor duringoperation and under the influence of:

• Refrigerant type and solubility of refrig-erant in the oil

• Operating temperatures

• Vapour pressure in the oil reservoir

Reciprocating compressor: Suctionpressure and oil temperature in thecrankcase.

Screw compressor: Discharge pressureand gas temperature.

� Compatibility with the neoprene O-rings:the aniline point gives an indication of howthe O-ring material reacts to the oil. At an aniline point less than approximately100°C the material tends to swell, and atan aniline point higher than approximately120°C it tends to shrink.

For this reason it is not recommended tochange oil type from M oil to PAO oil as aleakage may occur if the O-rings are notchanged. YORK Refrigeration thereforerecommends using the Sabroe AP68 oilas it reduces the risk of leaks considerablyin this case.

116 0178-910-EN

YORK Refrigeration can supply a calculationshowing the operating data on request.

Attention is drawn to the following viscositylimits during operation:

� Optimum viscosity range (to be designed for) = 20 to 50 cSt

� Max. permissible viscosity =100 cSt

� Min. permissible viscosity =10 cSt(only applicable to HCFC and HFC undercartain operating conditions: 7cSt)

� Max. permissible viscosity during thestarting of the compressor = 500 cSt

Maximum refrigerant concentration in the oilat running condition: 25% - also if viscosityrequirements are met.

Use of mineral oil

Lately we have experienced a number ofproblems with mineral oil, particularly in R717plants. The problems can be divided into twogroups:

a: The oil changes viscosity within a few operating hours.b: The oil decomposes (becomes very black) within a few operating hours.

The problems have been seen with severaloil brands and have resulted in severe con-sequences for both compressors and plants.

When using mineral oil, it is thus importantthat the plant is monitored very closely, thatoil samples are taken regularly (every1-2,000 hours) and that the condition/colourof the oil is checked on a weekly basis.

YORK Refrigeration therefore recom-mends only to use M oil at moderate oper-ating conditions - cf. the attached oil rec-ommendation diagrams.

YORK Refrigeration is aware, however, thatseveral customers have been using mineraloils for many years without problems. Thosecustomers who wish to continue using mine-ral oils in existing, as well as new, compres-sors can do so, providing the compressortype and operating conditions are similar tothe existing ones (excepting the HPC andHPO series compressors).

YORK Refrigeration has therefore decided tomarket a brand of mineral oil which has beentested and found to be suitable for most ge-neral refrigerating purposes.

If another brand of mineral oil is chosen, thespecifications in the data sheet in this recom-mendation should be followed as a guideline.

Mineral oil can be used in refrigeratingplants, providing the lubricating quality iscarefully monitored. For modern, high capac-ity refrigeration plants, in which a long life-time for both lubricant and moving parts isexpected, YORK Refrigeration recommendsusing synthetic lubricating oils.

A benefit of using the synthetic lubricant oil isa much lower oil carry-over to the plant andlonger intervals between oil changes. A better fluidity at lower temperatures alsogives an easier drainage at the cold parts ofthe plant.

How to use the oil recommendation dia-grams:

To determine the code number, first refer tothe Oil recommendation diagram for the re-frigerant and compressor type and then plotthe proposed operating conditions.

0178-910-EN 117

Example (recip. compressors):Refrigerant: R134aCondensing temp. TC +35°CEvaporating temp. TE –3°C

Please observe !Plants may operate at different conditionsfrom time to time, for example at differentevaporating temperatures due to plantvariations or at different condensing tem-peratures due to seasonal changes.By plotting TC and TE in the oil recom-mendation diagram, this example wouldrequire a No 1 oil. If, however, TEchanges at certain times, e.g. from –3 to+7°C, a No 2 oil should be utilised. But, as+7°C is inside the marked area, the No 1oil can be utilised also at this TE.

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R134a

By referring to the Oil recommendation tableplaced at the bottom of each oil recommen-dation diagram, it is possible to select thecode number for the appropriate oil type. In

the example above, a oil code number E5can be selected.

E5 �

E9 �

1 2

Code no Area no

In plants which incorporate both screw andreciprocating compressors and where therecommendations indicate the use of differ-ent oil types, please contact YORK Refrigeration for advice.

Changing oil on Sabroe compressors

The oil should never be changed to anothertype without consulting the oil supplier. Nor isit advisable to ”top up” compressors with another oil than the one already used for theparticular plant and compressor.

Mixing different oils may result in operatingproblems in the refrigerant plant and damageto the compressors. Incompatibility betweenthe different oil types may degrade the lubri-cating properties or may cause oil residues toform in the compressor or oil separator or inthe plant. These oil residues can block filtersand damage the moving parts in the com-pressor.

Furthermore, changing the oil from one typeor make to another should only be undertak-en in connection with a careful procedure in-volving the drainage and thorough evacua-tion of the refrigeration plant. Information ona suitable procedure can be obtained fromYORK Refrigeration as well as from a num-ber of oil companies.

118 0178-910-EN

It is imperative that oil is only used from theoriginal container and that both the make andtype complies with the specification for theplant.

Ensure that the original container is sealedduring storage to prevent moisture from theair being absorbed into the oil - many oils,particulary the polyolester oils, are extremelyhygroscopic. Consequently, it is recom-mended that the oil is only purchased in con-tainers corresponding to the amount to beused on each occasion.

If the oil is only partially used, make sure thatit is effectively re-sealed in the original con-tainer and that it is stored in a warm, dryplace. Ideally with nitrogen blanking of the oilto keep the water content below 50 ppm.

Oil drums should, ideally, be ”racked” andmounted with a proper barrel tap to ensurean effective airtight seal.

Oil changing intervals

A list of the recommended intervals forchanging the oil can be found in the com-pressor instruction manual. These are pro-vided for guidance only. The actual intervalbetween oil changes will often be determinedby a variety of operating parameters withinthe plant.

It is strongly recommended to monitor thequality of the oil by carrying out oil analyseswith regular intervals. This will also give agood indication of the condition of the plant.The service can be supplied by YORK Refrigeration or the oil suppliers.

��

�� : In case of a new plant. Very suitable.

�� : In case you wish to change from mineral oil

: Max oil concentration in liquid phase at: TE: 2% W

: Max oil concentration in liquid phase: contact YORK Refrigeration

: Min suction temperature –50°C: at TE< –50°C superheating must be introduced.

* : Dry expansion systems only. Flooded systems to be considered individually: contact YORK Refrigeration

SH : Suction gas superheat, K (Kelvin)

: Zone in which both oils are useable

: Calculation must be performed using COMP1

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0178-910-EN 119

��

Typical data for lubricating oils for Sabroe compressors

Sabroe Viscosity Viscosity Spec. Flash p. Pour p. Anilin Acid no.

code cSt40°C

cSt100°C

Index grav. at15°C

COC°C

°C °Cpoint

mgKOH/g

M1 63 6.4 14 0.91 202 –36 81 0.02

A3 97 8.1 13 0.86 206 –32 78 0.05

AP1 64 9.3 121 0.858 195 –51 121 0.04

PAO3 66 10.1 136 0.835 266 <–45 138 0.03

PAO5 94 13.7 147 0.838 255 <–45 144 0.03

PAO9 208 25 149 0.846 260 <–39 154 0.03

E3

E5Due to the big difference between polyolester-based lubricants from various suppliers, it isnot possible to present typical data for these oils. When using another oil brand than the one

E9 recommended by YORK Refrigeration, please contact the oil supplier to select the correct

E11oil type.

The listed data are typical values and are intended as a guideline only when selecting a similaroil from a different oil company. Data equivalence alone does not necessarily qualify the oil foruse in YORK Refrigeration’s Sabroe compressors.

120 0178-910-EN

List of part numbers for available Sabroe oils

Part no.Oil brand Oil code no.

20 litre pail 208 litre pail

Mobil Gargoyle Arctic 300 M 1 (M68) 1231-264 1231-296

Sabroe Oil A100 A 3 (A100) 1231-263 1231-262

Sabroe Oil AP68 AP 1 (AP68) 1231-257 1231-260

Sabroe Oil PAO68 PAO 3 (P68) 1231-256 1231-259

Mobil Gargoyle Arctic SHC 228 PAO 5 (P100) 1231-282 1231-283

Mobil Gargoyle Arctic SHC 230 PAO 9 (P220) 1231-284 1231-285

Mobil EAL Arctic 68 E 3 (E68) 1231-272 1231-273

Mobil EAL Arctic 100 E 5 (E100) 1231-274 1231-275

Mobil EAL Arctic 220 E 9 (E220) 1231-279

Sabroe H oil E11 (E370) 3914 1512 954 1) 9415 0008 000

1) 18.9 litre pail (5 US gallons)

The oils recommended by the former Stal Refrigeration correspond to the following oils:

Stal Refrigeration oil type Sabroe oil

A Mobil Gargoyle Arctic 300 – M1 (M68)

B Sabroe Oil PAO 68 – PAO 3 (PAO 68)

C Mobil Gargoyle Arctic SHC 230 – PAO 9 (PAO 220)

H Sabroe H oil – E 11 (E 370)

0178-910-EN 121

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Note: YORK Refrigeration recommends that the use of M oils is restricted to moderately loaded compressors andthat the oil quality is monitored carefully via regular oil analyses.

� : In case of a new plant. Very suitable.


122 0178-910-EN

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0178-910-EN 123

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Please observe: PAO 5 oil is the only oil which can be used in the HPO and HPC compressors.


124 0178-910-EN

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0178-910-EN 125

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: Zone in which both oils are useableÑÑÑÑ

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0178-910-EN 127

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128 0178-910-EN

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0178-910-EN 129

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0178-910-EN 131

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132 0178-910-EN

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0178-910-EN 133

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134 0178-910-EN

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0178-910-EN 135

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Using the calculating programme COMP1 it is possible to optimize the requirement for suction superheat values (SH) as stated in the diagram. See Oil types and oil companies in this section. Due to the ongoing development oflubrication oils, please contact YORK Refrigeration for an update on the requirement for superheat.




* : Dry expansion systems only. Flooded systems to be considered individually: contact YORK Refrigeration



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HLI: Calculation must be performed using COMP1.

SH20

SH5

SH25

SH10

SH20

0178-910-EN 137

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Area noCode no

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20

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50

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Using the calculating programme COMP1 it is possible to optimize the requirement for suction superheat values(SH) as stated in the diagram. See Oil types and oil companies in this section. Due to the ongoing developmentof lubrication oils, please contact YORK Refrigeration for an update on the requirement for superheat.




: Calculation must be performed using COMP1ÜÜÑÑ

SH20

SH5

SH10

SH20

SH30

ÒÒÒÒÒÒÒÒÒÒÒÒÒÒÒÒÒÒÒÒÒÒÒÒÒÒÒÒÒÒÒÒÒÒÒÒÒÒÒÒÒÒ

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(See note)

Note: For the compressors type ”S”, ”Rotatune”, ”SAB 81”, ”SAB 83”, and ”SAB 85” only Sabroe oil H is approved.

138 0178-910-EN

E 3 �

E 5 �

E 9 �

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Using the calculating programme COMP1 it is possible to optimize the requirement for suction superheat values (SH) as stated in the diagram. See Oil types and oil companies in this section. Due to the ongoing developmentof lubrication oils, please contact YORK Refrigeration for an update on the requirement for superheat.







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0178-910-EN 139

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140 0178-910-EN


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0178-910-EN 141

List of major oil companies

The oil from the companies listed below are NOT tested by YORK Refrigeration and are there-fore NOT approved by YORK Refrigeration either. The following list reflects the information pro-vided by the companies themselves. The assessment of durability and suitability of specific oilsfor specific purposes are entirely at the companies’ own discretion. Oils tested and approved byYORK Refrigeration can be found in the ”List of part numbers for available Sabroe oils”.

Oil Oil Types

Company M A PAO AP E

Aral • •Avia •BP • • • •

Castrol • • • •Chevron (UK: Gulf Oil) • • •

CPI Engineering Services • • •DEA • • • •

Elf / Lub Marine 1 • • •Esso/Exxon • • •

Fina • • •Fuchs • • • •

Hydro-Texaco • • • •ICI •

Kuwait Petroleum (Q8) • •Mobil • • • • •

Petro-Canada •Shell • • • •Statoil • •Sun Oil • •

142 0178-910-EN

Notes:

0171

-460

-EN

95.0

3

0178-910-EN 143

��

Where the compressor and motor are directlyinterlinked, an AMR coupling is used; this is atorsionally rigid coupling with enough radialand axial flexibility to assimilate small move-ments between the two machines.

In order to ensure compressor and motor along life as well as noise- and vibration-freeoperation, compressor unit and coupling need to be aligned with care. Misalignment ofthe compressor unit or coupling may produce stresses and vibrations which canbe transmitted to the compressor and motorbearings and thus cause major damage.

Vibrations may be caused by the following:

� Distortion between compressor unit andfoundation.

� Distortion between compressor and baseframe.

� Distortion between motor and base frame.

� Strains from pipe connections betweencompressor and plant.

� Misalignment of coupling linking compres-sor and motor.

� Untruth in compressor or motor shafts.

� Untruth in coupling.

� Imperfect balancing of coupling.

� Imbalance in compressor or motor.

The points up to and including coupling align-ment are the responsibility of the fitter settingup the unit. The other points must bechecked by the compressor or motor

manufacturer prior to delivery. The followingsections will deal with the individual pointsconcerning the fitter.

Alignment of unit with foundation

Whenever installing a unit directly onto thefoundation or machine floor, it should standfree of stresses and press down evenly on allsupports.

The unit can be installed in the followingways:

� on vibration dampers

� straight onto a foundation, using founda-tion bolts.

Whichever method is used, the unit must bealigned before hooking the connection pipesup to the installation.

Vibration dampers are supplied as shown atthe top or bottom of drawing T0177040, de-pending whether the compressor unit is in-tended for use on land or at sea.

The purpose of the vibration dampers is todiminish the vibrations from the compressorunit to the foundation. In addition, the marinevibration dampers serve to cushion vibrationsfrom the foundation to the compressor unit,at the same time securing the unit to thefoundation.

It is imperative that the vibration dampers beplaced correctly, as shown in the completeddrawing forwarded to customer or distributor.This drawing is valid only for the unit inquestion .

144 0178-910-EN

Installation on vibration dampers

A2

A1

T0177040_0

2

H

A1

Hmax

A2

1

The vibration dampers supplied are markedwith a code, for instance LM6-60. LM6 indi-cates the size; 60 indicates the rubber hard-ness and is therefore an expression of bear-ing and damping ability.

When using vibration dampers, the machineroom floor is assumed to have the necessarybearing stregth and to be level enough to en-able adjustment of the vibration dampers tobe made within the adjusting measurementsstated on the drawing submitted.

In order for the individual vibration damper tocushion properly, a sufficient load must beimposed. Measure A1 and H in an unloadedand A2 in a loaded set-up, as shown in draw-ing T0177040.

Industrialtype

Marine-type

1 2

Flexion

Height adjustment

A1-A2

min 1,0 min 3,0

with diskssupplied as shown

H = H+12max

max 2,0 max 5,0

The flexion of a damper is adjusted by in-creasing or decreasing the load in relation tothe other supports. The foot can be raised byscrewing the adjusting rod down or insertingmore disks between damper and foot (marinedesign), thereby increasing load and hencealso the flexion.

Once the installation has cooled down, checkduring operation that the flexion of the damp-ers is still correct!

0178-910-EN 145

Installing directly on foundation

When installing a unit directly on a concretefoundation, the foundation should be cast inaccordance with the foundation drawings dis-patched.

When the foundation has been cast - with theholes shown for foundation bolts - and hasset, place the unit in position, allowing it torest on beams levelled at a suitable height sothat the foundation plates are recessedslightly into the foundation.

Check that the foundation plates are rightnext to the base frame. This can be achievedby binding them to the resting surfaces of thebase frame with steel flex.

The concrete cast down around the founda-tion bolts should contain only a small amountof water, so that it can be well tamped aroundthe bolts. Low water content produces nocontraction of the setting concrete.

10-14 days should be allowed to elapse be-fore removing the beams and tightening thenuts for the foundation bolts. Before that, however, remove the steel flexand check that there is no space between thebase frame and the foundation plates. Ifthere is, place shims between the plates be-fore tightening.

Alignment of compressor with baseframe

Check that the entire footing of the compres-sor makes full contact against the milled-offfaces of the base frame.

Perform this check with the bolts loosened. Ifslip occurs at one or more resting surfaces,shim up before tightening. If unaligned, thereis a risk of stresses occurring in the compres-sor frame, which will damage the bearings.

Alignment of motor with base frame

Check the contact faces of the motor againstthe base frame in the same way as for thecompressor.

Stresses from piping connections

In order to prevent stress being transmittedfrom piping connections between unit andplant, pipes must be laid so as not to gener-ate compressive stresses or tensile strains inthe event of expansions or contractions dueto temperature changes. Steel piping ex-pands approx. 1 mm per metre per 100°C.

We recommend that piping be laid as shownin example 2 of the sketch. Example 1 dem-onstrates too rigid pipe laying.

1 2

> 1.5 m

T0177057_0

Final alignment of compressor and motor canbe performed once all piping has been con-nected to the unit.

146 0178-910-EN

Fitting and alignment of AMR-type coupling

Installation and alignment

In principle, alignment involves manoeuvringthe motor so as to make the shaft form anextension of the crankshaft.

ImportantBefore any work on the coupling, ensurethat the compressor motor cannot bestarted inadvertenly.

T0177120_0/V2

B

C

X

2Z

a

1

Compressor Motor

A

Fig. 1

Compressor

Pos. 1 Pos. 2A

Nm

B

Nm

Verticalmax.mm

Horizontalmin./max.

mmmax.mmmm

HPO/CMO 2

HPC/SMC104-108

SMC112-116

SMC180

225

312 S

350 S

450 S

76,0

103,5

114,5

149,0

147

147

295

34

55

128

275

0,1

0,2

0,2

0,3

0,1/0,2

0,1/0,3

0,1/0,3

0,1/0,4

0,1

0,2

0,2

0,3

AMR type of coupling

DistanceC

nominal*

Torque momentMax. variation measured with a feeler

gauge at a 180° turning of the af coupling

* See Final mounting, pt. 4

0178-910-EN 147

Preliminary installation

� Check tightening of coupling flange oncompressor.

� Tighten 8 coupling bolts securing lamellarsegments to intermediate piece to pre-scribed moment stated in table. It is worth-while doing this before placing the inter-mediate piece in position.

� Mount retaining plate from couplingscreen onto compressor and insert sup-port ring for coupling screen over motorflange.

� Insert coupling intermediate piece. Createspace between flanges either by shiftingentire motor or just motor coupling flange. The intermediate piece should only besecured to the compressor flange. Donot insert the last four bolts in the mo-tor flange until the coupling has beenaligned.As the compressor shaft rotates during thealignment procedure, the motor must turnwith it, as the bolts in the intermediatepiece engage in the free holes in the mo-tor coupling flange.

� Line up motor so that free holes in motorfeet are right over threaded holes in baseframe.

� Shift motor coupling flange to make updistance ”C” in table. See fig. 1.

� Tighten two bolts in coupling hub. On CMO units, the motor flange must becorrectly positioned before putting the mo-tor into place.

� Tighten measuring pin on coupling flangeof compressor, as shown in drawing.

Alignment

Check that the motor with loose bolts standswith all four feet on the base frame. Insertany liner plates needed where there is an airgap beneath the feet. Tauten the bolts slight-ly.

Achieving parallel shafts in horizontal plane

� Turn coupling so that alignment gauge isin upper position. See fig. 1.

� Guide measuring pin (Pos. 2) towardscoupling flange, using a 1.0 mm feelergauge, and fix pin. Remove feeler gauge.

� Rotate coupling 180° and measurechange in distance from measuring pin toflange, using feeler gauges. This changeis called ”x”.

� Insert shims of thickness ”y” either underboth front feet or both rear feet, therebytilting motor in direction required. Shimthickness ”y” is calculated using the fol-lowing formula (see drawings):

y = Xb

2 x a•

b

y

� After tightening motor bolts, repeat meas-urement and compare result with values intable under Pos. 2.

148 0178-910-EN

Achieving correct centre height

� Turn coupling so that alignment gaugefaces vertically down.

� Guide measuring pin (pos. 1) towardscoupling flange, using a 1.0 mm feelergauge, and fix pin. Remove feeler gauge.

� Rotate coupling 180° and measure in-crease in distance ”z” from one millimetreusing feeler gauges.

� Then lift motor by placing shims of thick-ness equal to half value of ”z” under allfour feet.

� After securing motor, repeat measurementand compare result with table values inpos. 1 vertical. Remember that the centre-line of the motor shaft must be at least0.05 mm higher than the centreline of thecompressor, corresponding to a minimumof 0.1 mm distance less at the top positionof the alignment gauge.

Achieving parallel shafts in verticalplane

� The motor is now positioned at its correctheight. What now remains is to push andturn the motor at the level on which it isalready lined up.

� Turn coupling so that alignment gaugefaces out to one side horizontally.

� Guide both measuring pins towards coup-ling with a 1.0 mm feeler gauge in be-tween.

� Turn coupling 180° and, using feelergauges, measure deviations from one mil-limetre at both pins.

� Moving and turning motor and repeatingthis measurement, align motor in accord-ance with pos. 1 horizontal and pos. 2 intable. Remember that the motor must befirmly secured during any measurements.

Final installation

� Tighten foundation bolts on motor (seetorque table).

� Fit four bolts into motor coupling flange sothat thin shims are placed between flangeand lamellae, with rounded side facing la-mella. There are no thin shims on cou-plings for CMO and HPO.

� Tighten bolts to torque specified in table.

� Readjust flange distance ”C” so that la-mellae are aligned, by moving motorflange on shaft and fastening motorflange.

� Check alignment of coupling in horizontaland vertical planes for pos. 1 and pos. 2.

� Dismantle measuring pin and tightenscrew to prescribed torque.

� Fit coupling guard.

� Once normal operating temperature hasbeen achieved, double-check couplingalignment.

010-

502-

EN

92.0

3

0178-910-EN 149

��

T0177131_0 V12

B

MAX. 0.02 mm

MAX. 0.02 mm

A

Unless the necessary data for the motor areknown prior to dispatch, the motor flange forthe AMR coupling will not be supplied inready bored form.

In such case, the motor flange is suppliedprebored and balanced.

Finish-boring is done as follows:

� Secure flange in lathe or jig-boring ma-chine. Observe following tolerances foralignment purposes:

Max. axial eccentricity measured at point A

Max. axial eccentricitymeasured at point B

0.02 mm

0.02 mm

� The bore should then be made to the rele-vant dimensions and to the following toler-ances:

H8 for AMR 312, 350 and 450, H7 for AMR 225.

� Cut keyways. For reasons of balance, coupling AMR312, 350 and 450 must be executed withthe two keyways shown.

� Make the width of the keyway to a toler-ance of H7.

� The keyway must be deep enough to al-low a clearance between parallel keysand hub of 0.2-0.3 mm.

Compressor

Coupling size

Max. bore

Boring tolerance

CMO - TCMO - HPO

AMR 225

60 mm

H7

SMC - TSMC 100 - HPC

AMR 312 - 350

95 mm

H8

SMC - TSMC 180

AMR 450

110 mm

H8

Max. boring diameter:

0171

-469

-EN

95.0

6

150 0178-910-EN

��

��

If your SABROE compressor is belt driven, V-belts are used with profiles specified in the table below.

Compressor type Belt profileNom. centre

distance15 mm sag

K. max. K.min.kgkgmm

CMO - TCMO 24-26-28

SMC - TSMC 104 - 108

SMC - TSMC 112 - 116

SMC - TSMC 186 - 188

SPB (16 x 13)

SPB (16 x 13)

SPB (16 x 13)

SPC (21 x 18)

700

900

500

1230

11,00

8,00

14,00

9,00

8,00

6,00

10,00

6,50

K

15 mm

C

C/2

T0177084_0

Fig. 2Fig. 1

Fitting V-belts

� Before fitting V-belts, belt pulley tracksmust be carefully cleaned of oil and dirtand checked of any burrs and marks.

� Move motor on slide rails, shorteningcentre distance sufficiently to enable beltsto be mounted without use of force. Beltsmust never be forced over the pulleys, asthe power-transmitting fibres may be dam-aged, reducing their lifetime considerably.

� After mounting V-belts, separate compres-sor and motor again and align by meansof an alignment plate as shown in Fig. 1.

Tracks must be flush and shafts absolutelyparallel.

� To achieve optimal operating conditions,belt tension must be correct. This isachieved as follows:

a) Measure centre distance C as shown inFig. 2.

b) At half centre distance C/2, place a weightweighing K; if necessary, this can hang ina piece of welding flex or suchlike on oneof the V-belts and be moved from belt tobelt.

c) Weight K must be between the minimumand maximum values for the belt drive in

0178-910-EN 151

question, as stated in the table. Tightenbelt drive so that sag is approx. 15 mm forall V-belts.

� A new belt drive always has to be tight-ened to the max. value.

� Run transmission for a few minutes andthen check tension.

� It is important that the tension is inspectedat regular intervals, as stipulated in thesection Servicing the piston compressor.

� When changing worn V-belts, the wholeset should be replaced.

� A set of V-belts must always be within thesame tolerance group.

� Never use belt lubricant.

RememberThe safety guard always be mounted whe-never the belt drive is in operation.

152 0178-910-EN

��

��

Application

The purpose of the oil separator is, under alloperating conditions, to separate the oil con-veyed out of the compressor with the dis-charge gas in order that it may be returned tothe compressor crankcase.

However, with the hot discharge gas some oilis going to leave the oil separator - the so-called oil consumption.

With a normal standard oil separator the oilconsumption will be approx. 35 to 45 ppm(parts per million) for R717 compressors.

The oil consumption depends, however, onthe discharge gas temperature. Rising tem-peratures often lead to an increased oil con-

sumption. Further, oil products with a lowflame point can lead to an increased oil con-sumption in the R717 compressors.

For HCFC compressors the oil consumptionis of minor importance as the oil normally re-turns to the compressor from the plant.

Functioning

The discharge gas from the compressorflows through the oil separator, fig. 1, frompos. A to pos. B. On its way it passesthrough a number of filters in which the oilis separated from the discharge gas.The filters consist of stainless steel wiremesh which, as a rule, needs no cleaning,nor does it get worn. Consequently, the filterscannot be removed from the oil separator.

Fig. 1

L

A

B

A: Discharge gas inlet B: Discharge gas outlet L: Oil return to the compressor

0171

-475

-EN

97.0

1

0178-910-EN 153

Oil return to the compressor

The separated oil leaves the oil separatorthrough the pipes pos. L, and can be regu-lated by the following systems:

a: Solenoid valve controlled oil return

b: Float valve controlled oil return

a: Solenoid valve controlled oil return

As illustrated in fig. 2 the oil is conveyed fromthe oil separator through the screwed con-nections pos. 80A and 80B. Fig. 2 pos. alsoshows that pos. 80A is of such a length that itpierces the base plate by approx. 10mm. Inthis way any dirt particles may be collectedon the bottom of the oil separator instead ofbeing returned with the oil to the compressor.

��

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Fig. 2

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At point A the oil flows into the valve blockpos. 80 and from point B is led to the com-pressor as illustrated in fig. 3.

The valve block consists of a stop valve pos.80D, which is closed and opened by turningof the spindle. This valve may be dismantledby unscrewing the big union nut from the val-ve block. On mounting, tighten it once morewith a 60 Nm torque.

From the stop valve the oil passes filter pos.

80E, which can be removed by dismountingcover pos. 80F. The filter can be cleaned in acleansing fluid and blown clean with com-pressed air.

On remounting of the cover tighten it with a60 Nm torque. Remember gasket pos. 80G.

Before removing the oil filter, close stop valvepos. 80D and evacuate the compressor toatmospheric pressure as described earlier onin this manual.

154 0178-910-EN

60 Nm

A

80H

80J

1.4 Nm

80M

80P

10 Nm

80Q

80I

80L 50 Nm

80

B

60 Nm

80E80G

80F

Fig. 3

80N

80K

80D

After the oil has been cleaned, it flows to thesolenoid valve, which is always closed atcompressor standstill.

During start-up of the compressor, the sole-noid valve can be kept closed for 20 to 30mins. by means of a time relay, available asan additional equipment. This prevents anyrefrigerant from entering the compressor during start-up.

The seat of the solenoid valve pos. 80I alsoacts as a nozzle that regulates the oil flowback to the compressor.

Select the nozzle size on the basis of table 4.We recommend not to use a bigger nozzlesize than prescribed. In order to replace thenozzle the compressor must first be depres-surized. Next, dismantle coil pos. 80J andarmature tube pos. 80P. The nozzle is screwed into the valve blockand, on remounting, use gasket pos. 80Q for the nozzle and gasket pos. 80L for thearmature tube. Tighten with the prescribedmoments of 10 and 50 Nm – see fig. 3.

On mounting the coil keep it in place byusing hand screw pos. 80N and O-ring pos.80K and 80M.

R717 One stage compr.

CMOMk 2 100 180

Num

ber

of c

ylin

ders 4

6

8

12

16

0.6

0.6

0.6

0.6

0.6

0.6

0.6

0.6

0.6

0.6

0.6

Booster compr.

CMOMk 2 100 180

0.6

0.6

0.6

0.6

0.6

0.6

0.8

0.8

0.8

0.8

0.8

Two stage compressor

TCMOMk 2 100 180

LP HPLP LP HP LP HP

0.6 1.0 0.60.6 0.8

0.60.8

HFC/ One stage compr.

CMOMk 2 100 180

4

6

8

12

16

0.6

0.6

0.6

0.6

0.6

0.6

0.8

0.8

0.8

0.8

0.8

Booster ompr.

CMOMk 2 100 180

0.6

0.6

0.6

0.8

0.8

0.8

1.0

1.0

1.0

1.0

1.0

Two stage compressor

TCMOMk 2 100 180

LP HPLP LP HP LP HP

0.6 0.80.6

0.6

HCFCSMC SMC SMC SMC

TSMC TSMC

TSMC TSMC

SMC SMC SMC SMC

Fig. 4

Num

ber

of c

ylin

ders

0178-910-EN 155

b: Float valve controlled oil return

Fig. 5

To the compressor

�

�

��

As shown in fig. 5, the separated oil isdrained to the float valve pos. C while valvespos. A and B are open. At a rising oil levelthe float valve will open and lead the oil backto the compressor crankcase.

The filter pos. D and the float valve can becleaned by dismantling the threaded nippleon the stop valve housing and removing thecover on the float housing after the valvespos. A and B are closed and the pressure inthe compressor equalized to atmospheric.

0171

-414

-EN

97.1

0

156 0178-910-EN

��

��

T0177087_0/V1

•

E

AC

C

L

O

ABD

2

NGAB

J

K

S

F

S

P

T

U

V

1

2

Z

1 AF,SX

S

QH,

•

•

•

•

••

•• • •

•

•

••

•

•• •••

••

••••

•AM

••

Pos.Thread

RG(Inch)

PressureOil,

gas orliquid

Air-cooledWater-cooled

Air-cooled

w/built-inoil cooler

Ther-mo-

pump

Boosterwith

oil coolerNormal application

ABCDEFGHJKLNOP

Q

ST

UVXZ

ABAF

1 1/4

3/4

1/2

1/2

1/4

1/4

1/2-1/4

1/4

1/4

1/4

1/4

1/4

1/2-1/4

1/4

1/4

1/4

1/4

1/4

1/2-1/4

1/2

3/4

1/4

1/4

suctionsuctionsuctionsuctionsuction

oilsuction

dischargesuction

oilsuctionsuction

oilsuction

discharge

dischargedischarge

dischargesuction

dischargedischarge

oildischarge

oiloiloiloil

gasoil

gasgasgasoil

gasgasoil

gas

gas

gasgas

liquidliquidgasgasoil

gas

+++

pluggedplugged

+plugged

++++++

plugged

plugged

plugged–

–plugged

+++

plugged

++++

plugged+++++++++

plugged

plugged–

–+++++

+++

pluggedplugged

+++++++++

+

++

++++++

++++

plugged++++++++

plugged

plugged

plugged–

–+++++

Heating rodOil charging valveOil temperatureOil temperatureAvailableOil pressure to unloading cylinderReturn from built-in oil cooler *High pressure connection (HP)Oil return from solenoid valvesOil pressure to solenoid valvesLow pressure connection (LP)Oil return from oil separatorOil pressure connectionReturn from built-in oil cooler/equalization from thermopump *Return from oil cooler(thermopump cooled)*Refrigerant cooling to top covers *Equalization to suction pressure end fromthermopumpLiquid inlet to thermopump*Supply to built-in oil cooler*Discharge gas temperaturePurge valvePrelubrication of bearingsReturn from oil cooler (booster) *

AC 1/2 suction gas Used in connection with UNISAB II Suction temperature (superheat temp.)

AM 1/4 oil oil plugged plugged plugged plugged Available

12

Suction stop valveDischarge stop valve

* These connections are not applied on HPC compressors

0178-910-EN 157

Connections on TSMC 108 Mk3

•

E

O

ABDC

3

R

K

F

4

TP

U

V

NGAB

1 AC

L

1

AL

X

S

H

S

AF

M

S

Q2•

••

Z

•

•

•

•

•• •

•

•

••••

• ••••

•

Y

•

•••

•••

••

•

J

•

AM

Pos.Thread

RG(Inch)

Pres-sure

Oil, gas orliquid

Air-cooledWater-cooled

Air-cooledw/built-inoil cooler

Ther-mo-

pumpNormal application

ABCDEFGHJKLMNOPQR

ST

UVXYZ

ABAFAL

1 1/4

3/4

1/2

1/2

1/4

1/4

1/2-1/4

1/4

1/4

1/4

1/4

1/4

1/4

1/2-1/4

1/4

1/4

1/4

1/4

1/4

1/4

1/2-1/4

1/2

1/2

1/4

1/4

1/4

3/4

suctionsuctionsuctionsuctionsuction

oilsuction

highsuction

oilsuctionsuctionsuction

oilsuctionsuctionsuction

highsuction

highsuction

highinterm.interm.

oilinterm.

high

oiloiloiloil

gasoil

gasgasgasoil

gasgasgasoil

gasgasgas

gasgas

liquidliquidgasgasgasoil

gasgas

+++

pluggedplugged

+plugged

+++++++

pluggedplugged

+

plugged–

–plugged

+plugged

++

plugged+

++++

plugged++++++++++

plugged+

+–

–++

plugged++++

+++

pluggedplugged

+plugged

+++++++

pluggedplugged

+

++

+plugged

+plugged

++++

Heating rodOil charging valveOil temperatureOil temperatureAvailableOil pressure to unloading cylinderReturn from built-in oil coolerHigh pressure connection (HP)Oil return from solenoid valvesOil pressure to solenoid valvesLow pressure connection (LP)Intermediate pressure connection (IP)Oil return from oil separatorOil pressure to manometer and cut-outsReturn from built-in oil coolerAvailableSuction pressure to rear of unloading cylinderRefrigerant to HP top coversEqualization to suction pressure end fromthermo-pumpLiquid supply from thermopumpConnection to built-in oil coolerDischarge gas temperatureIntermediate pressure temperature (IP)Purge valvePrelubrication of bearingsReturn from built-in oil cooler (Booster)Purge valve

AC 1/2 suction gas Used in connection with UNISAB II Suction temperature

AM 1/4 oil oil plugged plugged plugged Available

12

Low pressure suction stop valveLow pressure discharge stop valve

3 Connection from intermediate pressure4 High pressure discharge stop valve

158 0178-910-EN

��

��

On halocarbonic piston compressors operat-ing in parallel on the same plant, it is impor-tant to regulate the oil return flow to thecrankcases of the compressors so that theyhave the same oil level.

This is achieved by using an oil distributionsystem as described in this instruction.

Each compressor is fitted, via an intermedi-ate piece, with a mechanical float which re-gulates the oil level in the crankcase.

This intermediate piece is mounted betweenthe compressor frame and the oil level glass,as shown in the drawing. This allows visualinspection of the oil level in the crankcase.

T0177089_0/2

Float valve housing

Oil level glass

Pipe connection Vent valvewith float valve

on compressor

��

��

0178-910-EN 159

Schematic diagram

Parallel system,

2

3

4

Oil receiver

Oil separator with

1 1

2

3

4

76

5

9

10

Compressor 1 Compressor 2

Oil separator withAlternative

5

76

9

8

5

11

12

13

Standard

float valve controlled oil return

1. Compressor 8. Float valve for oil separator2. Float valve for parallel operation (1374-005) 9. Oil receiver3. Filter 10. Non return valve, 1 bar4. Stop valve 11. Solenoid valve for driving pressure line5. Oil separator 12. Nozzle dia. 0.4mm for driving pressure line6. Solenoid valve for oil separator 13. Filter for driving pressure line7. Nozzle for oil separator

fitted on unit

Oil chargingHeating cartridge Liquid level glass

solenoid valve controlled oil return

Function

The piping diagram is based on each com-pressor pos. 1 being equipped with an oil separator pos. 5, from which the oil via solenoid valve pos. 6 and nozzle pos. 7, orthrough float valve pos. 8, is conveyed to an oil tank pos. 9.

The nozzle size for pos. 7 is stated in thesection on Oil Separator.

The oil tank pos. 9 must have a volume equalto approx. 50% of the total oil volume to becontained in the compressors. However, it should never be filled more thanhalfway with oil, corresponding to approx.25% of the total oil quantity.

There should be an oil level glass on the oiltank and a heating element to ensure warm,and hence refrigerant free, oil.

From the oil tank, an oil pipe is drawn directlyto the mechanical float pos. 2 controlling theoil level in the crankcase.

From the top of the oil tank pos. 9, a pipe isrouted to the suction side of the plant.

A non-return valve pos. 10 is inserted in thepipe, opening at a differential pressure of 1bar. Note the flow direction. A pressure 1 barhigher than the suction pressure in the plantis thus obtained in the oil tank. This is suffi-cient to pump the oil through the float valvewithout generating any foaming in the floatvalve housings.

Note:After the initial starting up of the float sy-stem, the float housing must be ventilatedin the following way. See drawing of floathousing.

160 0178-910-EN

Unscrew the cap on the vent valve and acti-vate the spring-loaded valve in the branch bypressing it down with a screwdriver or similar.

If the float-valve controlled oil return Pos.8 is used, the oil tank must - in order to main-tain the driving pressure at 1 bar - also be

connected to the discharge side of the plant,as shown in the schematic diagram.

In the pipe connection to the discharge side,mount a 0.4 mm diameter nozzle Pos. 12and a solenoid valve Pos. 11, which must beopen also when only one compressor is op-erating.

0171

-348

-EN

91.0

6

0178-910-EN 161

��

��

When the CMO or SMC compressor is usedfor air conditioning, you can choose to controlthe compressor capacity by means of one ortwo KP1 pressure cut-outs.

CMO compressors are all controlled by threesolenoid valves. When these are to be con-trolled with pressure cut-outs, cut-out A mustbe connected in parallel with solenoid valvesnos. 1 and 2. Cut-out B must be connectedwith solenoid valve no. 3.

The SMC 108 must be connected in thesame way as CMO.

The SMC 106 is controlled by two solenoidvalves, where pressure cut-out A must beconnected to solenoid valve no. 1 and cut-outB to solenoid valve no. 2.

The SMC 104 is controlled by a solenoid val-ve to be connected to pressure cut-out A.Only one cut-out is to be used for the SMC104.

If the compressor features a solenoid valvefor totally unloaded start, this must not be

connected to any of the above pressurecut-outs.

Pressure cut-out A must be set to a close ata pressure approx. 0.5 bar higher than thesetpoint for cut-out B.

A third cut-out, the low-pressure cut-out,must be set to break at a pressure equal tothe lowest evaporator temperature that canoccur, however, never lower than started insection Pressure and temperature settings.At this temperature, the compressor muststop. This control form provides the followingcapacity stages:

Capacity in %Capacity stage 1 2 3

CMO 24 100 50 25CMO 26 100 50 35CMO 28 100 50 25SMC 104 100 50 –SMC 106 100 66 33SMC 108 100 50 25

AB 2

1

13

2

SMC 106 SMC 108

2

3

2

4

1

1

AB

3

A

2 1

1

SMC 104

1 2 3

CMO

A B

0171

-411

-EN

9999

.11

162 0178-910-EN

��

��

��

��

The reciporcating compressor can be cooledwith water on the top and side covers, thecooling requirement being dependent on theoperating conditions and the refrigerant onwhich the compressor operates.

See page 1 for details.

Water cooling is obtained by mounting an ex-tra cover (water cover) Pos. 2B on the outsi-de of top and side covers with an interveningseal Pos. 2D.

Tighten top and water covers with the boltsPos. 2E, which are longer than the bolts forthe air-cooled version. See the Spare-partslist at the back of this instruction manual fordetails.

For water cooling of the side covers, a spe-cial finned side cover Pos. 3A is used toget-her with a water cover Pos. 3B and a sealPos. 3D. These are also listed in the spare-parts list.

The water cover, together with the cover onwhich it is mounted, forms a channel systemin which the water is channelled back andforth and effectively cools the top or side co-ver. By virtue of their large surface area, thecooling fins on the interior of the side coverPos. 3A provide excellent cooling of the oil inthe crankcase.

When dismantling top or side covers with wa-ter covers, it is a good idea first to dismantlethe topmost covers on the compressor. Inaddition, you should ensure that the two co-vers are kept tight against the intervening ga-

sket. This will prevent water flowing into thecompressor block.

Salt water-cooling

If it is expedient not to use fresh water for thecooling of the top and side covers, salt waterdan be used to cool the side covers. The topcovers must never be cooled with salt wateras the high temperature combined with thesalt water will corrode the covers in a shortperiod of time. For R717 compressors the topcovers may in some cases be cooled by me-ans of a thermal pump, see the diagram ofthe operating range of the compressor inquistion.

Fitting cooling water hoses

� When supplied, the compressor is notfitted with cooling water hoses or any rele-vant assembling parts. These are pro-vided loose. This avoids damage to theparts in transit. Fit the cooling water hosesas shown in the following drawing, corre-sponding to the specification enclosedwith the delivery.

Please note:

� The direction of water throughflow isshown by arrows on the drawing.

� The hose length is indicated opposite therespective Pos. nos. on the drawing.

� The hoses must not be in contact with theframe, covers, discharge pipe or similarcomponents.

0178-910-EN 163

In the supply pipe to the water system a solenoid valve must be fitted which shuts off the water flow inthe refrigeration system at compressor standstill.

However, we do recommend to continue the water cooling for approx. 10 mins after the compressor hasbeen stopped as this protects the cooling water hoses against excessive temperatures

54

3

1*)2

Nr.Pos

SMC 104

T0177088_0/1

Length(mm)

610

750370

160670

54

3

54

3

1*)2

Nr.Pos

6

SMC 106

700160

400

Length(mm)

380

500

820325

150670

1*)2

Nr.

SMC 108TSMC 108

Length(mm)

300

790

Pos

4

3

700

800

12

Nr.

Cooling of side covers only

Length(mm)300

200

Pos

HPC 104

HPC 106

HPC 108

SMC 104-106-108TSMC 108

SMC 188

Length(mm)

TSMC 188

1100300

470

325

1300

Length(mm)

550

760

1300525

3001100

SMC 186

1100

1170

Length(mm)400

300

SMC 186/188TSMC 188

*) To be secured to the vertical oil pipe using two pieces of plastic tape.

43

2

1

3

5

3

2

4

1

34

5

6

3

5

3

2

11

4

2 31

164 0178-910-EN

Necessary water consumption

To achieve satisfactory distribution of coolingwater and hence good compressor cooling,the following limit values should not be ex-ceeded:

Min. water through flow:5.5 litres per hour per Kw motor output.On water circulation plants, greater waterthroughflow is recommended.

Max. permissible inlet temperature: +40°C

Min. permissible inlet temperature: +10°C

Max. permissible outlet temperature: +55°C

Max. permissible temperature rise frominlet to outlet on the compressor:

15°C

0178-910-EN 165

Pressure loss in water coolingon SMC/TSMC/HPC compressors

1

2

100 500 1000 1500

V(l/hour)Volumetric flow

T0177130_0

3

4

5

SMC 106/HPC 106 SMC 104/HPC 104

T/SMC

Pressure lossp(mVS)

TSMC 108SMC 108

116

SMC112

HPC 108

T/SMC188

SMC186

166 0178-910-EN

Structure of the thermo pumpTogether with the cooling cover, pos. 98Q,the side cover, pos. 98A, forms a pump ves-sel, pos. 98, which is supplied with heat fromthe oil bath in the crankcase. The coolingcover is equipped with cooling fins in order toprovide a satisfactory thermal contact withthe oil.

As illustrated in the principle drawings, thepump vessel has the following three pipeconnections:

� Connection pos. A which is linked to thecompressor suction side and which can beblocked by means of solenoid valve pos.98G. Used to lower the pressure in pumpvessel pos. 98. Part of the pumping cycle.

� Connection pos. B emerges from the re-ceiver or the priority tank and goes right tothe valve block pos. 80 which is of the sa-me type as the one described in the sec-tion on: Solenoid valve controlled oilreturn in this instruction manual.Please, note that the size of orificepos. 80I must be 3.3 mm.

� Connection pos. C is connected to the topcovers and the oil cooler pos. 98T througha number of nozzles pos. 98M.

Filling and evacuation of the pump vessel iscontrolled by two level sensors, pos. 98C,which by means of the control box, pos. 98B,

control the solenoid valves, pos. 98G andpos. 98H, so that they are open and shut si-multaneously. The thermo pump is safe-guarded by the following systems:(See principle drawing)

a: A thermostat built into the control box pos.98B with sensors pos. 98X fitted on thecompressor discharge pipe.

Fasten the sensor to the discharge piperight next to the discharge stop valve bymeans of two clips. Ensure a properthermal contact.

The thermostat is factory set to start upthe thermo pump once the discharge gastemperature is above 80°C.

b: An evacuation system emptying the pumpvessel through solenoid valve pos. 98Vwhenever the thermo pump stops.

Please, notice that the pipe connectionpos. D to the plant evaporating side mustbe made at a spot where there is no riskof the liquid flowing back to the compres-sor. Connection should, f.inst., be made tothe liquid separator or the evaporator.

c: A safety circuit with a non-return valvepos. 98Z that opens for the flow at a pres-sure 3 bar higher in the pump vessel thanthe one in the compressor discharge gasline.

98C98E98F

98Q

T3185085_5

98D

98L

��

�

� � �

� ��

��

��

�

�

0178-910-EN 167

Description of pumping cycle

Filling of pump vessel

As soon as the liquid leaves the bottom levelsensor, the control box will activate the sole-noid valves pos. 98H in valve block pos. 80and pos. 98G.

Hereby, solenoid valve pos. 98G opens in thepipe connection to the compressor suctionside and the pressure in the pump vessel de-creases slightly. At the same time solenoidvalve pos. 98H opens and refrigerant liquidstarts flowing to the pump vessel throughpipe connection B.

Evacuation of pump vessel

When the top sensor has registered that theliquid has reached the top level both solenoidvalves will be closed by the control box.

The pressure in the pump vessel now risesas a consequence of the heat impact fromthe compressor oil and - when exceeding thepressure on the compressor discharge side -will make the refrigerant flow through thepipe connections to the top covers and the oilcooler.

At the top covers the refrigerant expandsthrough the nozzles pos. 98M directly into thehot discharge gas, with immediate cooling ofthe discharge gas.

The oil cooler (not always required) is aheat exchanger in which the expanding re-frigerant - after cooling of the oil - is taken tothe compressor discharge side.

Once the liquid in the pump vessel has re-turned its lowest level, it is registered by thebottom sensor and the control box opens thetwo solenoid valves for a new pumping cycle.

Capacity regulation of thermo pump

On reducing the compressor capacity it be-comes necessary also to reduce the coolingeffect of the thermo pump. This is done asfollows:

SMC 104-106-108, TSMC 116CMO 24-26-28

The pipe connection from the pump vessel tothe top covers is on its way divided into twopipe lines. In one of these pipe lines a sole-noid valve, pos. 98U, is fitted. This solenoid valve is connected to the thecapacity regulating system of the compressorand closes when the compressor capacityhas been reduced, as indicated in the follow-ing table:

Compressor

capacity

Solenoid valve pos.98U

open closed

50%100%SMC 104

33%100-67%SMC 106

50-25%100-75%SMC 108

50-33%100-83-67%TSMC 116

50-25%100-75%CMO 24

50-33%100-67%CMO 26

50-25%100-75%CMO 28

SMC 112-116

On the SMC 112-116 two thermo pumpshave been mounted as shown on the prin-ciple drawings.

The total capacity of the thermo pumps isadapted to the compressor capacity by a power disconnection of the thermo pump

168 0178-910-EN

positioned at the compressor shaft end andmarked X on the principle drawing.

The disconnection is achieved through theconnection of the thermo pump via terminals5 and 6/7 or 8 to the capacity regulating sys-tem of the compressor. The supply voltage tothe thermo pump must be switched off oncethe compressor capacity has been reducedto the values indicated in the table below.

Compr.

capacity

Thermo pump at compr.

working not working

50-33%100-83-67%SMC 112

50-37-25%100-87-75-63%SMC 116

shaft end

The pipe connections are shown on the prin-ciple drawings on the previous pages.

When the compressor is stopped the currentto the thermo pump is cut off, closing the so-lenoid valves pos. 98H and pos. 98G. At the same time solenoid valve pos. 98Vopens and drains the liquid in the thermopump back to the evaporating side of theplant. See the previously mentioned point b.

Checking the pumping cycle

On dismantling the cover plate on the controlbox four light diodes are made visible (2 green and 2 red ones).One of the green diodes that is connected tothe top level sensor is switched on for a rela-tively short period, i.e. from the moment thesensor has registered the upper liquid leveland until evacuation of the vessel has low-ered the level below the sensor.

Similarly, the other green diode for the bot-tom sensor will only be switched off from themoment the bottom level has been registeredand until the liquid rises once more on fillingof the vessel.

At the bottom level a time lag of a few se-conds has been built in order to prevent thesolenoid valves from clattering in the event ofany lapping in the vessel.

One of the red diodes, LD3, lights up oncethe temperature of the discharge gas risesabove 80°C. The other red diode LD4 lightsup when the relay to the solenoid valves hasclosed.

Functional testing

When stop valve in valve block pos. 80 isclosed the functioning of the pump may betested as follows:

� Roll off the rubber cap on the external partof the level sensors so that the part with-out insulation can be touched with a fin-ger.

NoteIt is quite safe to touch the level sensorsat this point as the voltage is extremelyweak.

� Touching the sensor alters its capacity asif the sensor were surrounded by liquid inthe pump vessel.

By touching the sensors in the order inwhich they are usually surrounded by liquid at increasing liquid level it is pos-sible to check whether the solenoid valvesreceive any voltage and open when thesensors are released.

0178-910-EN 169

Possible sources of error

In case the above tests should reveal thatone or both of the diodes do not light upwhen touched, this may be due to:

1. No voltage to the control box.

2. Loose power connection.

3. Defective control box.(To be replaced by a new one)

In case both diodes switch on and off correct-ly but the built-in relay is not working, replacethe control box.

If the diodes light up and the relay is working,the error may be found in the solenoidvalves:

1. Loose connections to the solenoid valves.

2. Burnt coils in the solenoid valves.

3. Some other malfunction in the solenoidvalves.

If the above-mentioned sources of error arenot present and the thermo pump still fails,the reason may be:

1. Closed stop valve in the liquid line.

2. Clogged filter in the liquid line.

3. Dirt in the solenoid valves.

4. Flash-gas in the liquid supply pipe or liquidshortage.

5. A very low differential temperature be-tween oil and condensing temperature.

6. Clogged nozzles pos. 98M.

Both diodes are constantly lit

If one or both diodes are constantly lit, evenwith no liquid on the sensor, this may be dueto a conductive connection between the innerand the outer part of the level sensor rod.

Outside the side cover the level sensor rod isprotected by O-rings and a protective cappreventing water and moisture from makingcontact.

An oil drop may have slipped inside the sidecover. In this case it is recommended to stripdown the sensor rod and clean the parts. Onmounting make sure that the sensor rod cen-ters in the sensor tube.

If, after remounting, the error persists, thecontrol box must be replaced.

Ensuring liquid to the thermo pump

The thermo pump must always be ensuredliquid from the plant, no matter whether theplant lacks liquid or some other factor pre-vails.

Thus, the thermo pump must also be en-sured liquid during a possible pump down bymeans of the compressor.

In other words: During operation the com-pressor must never be short of cooling.

This safety is achieved by either taking theliquid directly from the receiver, pipe connec-tion B or by building a priority tank into theliquid line of the plant (see drawing). The liquid volume A of the priority vesselmust be minimum 10 litres per thermo pump.

The liquid tube from the priority vessel to thethermo pump must be dimensioned to pre-vent the formation of flash gas along the way.

170 0178-910-EN

Receiver

1

B 2

3B

1

2

3

T0177101_0/4

Priority tank

1: Refrigerant liquid from condenser/receiver2: Refrigerant liquid to evaporator3: Refrigerant liquid reserve for oil coolingB: Refrigerant liquid for oil cooling

Stopping a compressor equipped

with a thermo pump

When the compressor is stopped there must

still be a pilot current on the unit so that the

solenoid valve pos. 98V is kept open until the

pump vessel has been emptied of liquid.

At the same time, stop valve pos. 98Y is kept

open.

Opening of compressor for repair

Pump down of the compressor must take

place with the thermo pump system set out of

function and after the pump vessel has been

emptied as described above.

During pump down close stop valve in valve

block pos. 80 and pos. 98Y.

Cleaning of filter in the liquid

supply line

Pump down the compressor before opening

the filter in the liquid supply line for cleaning.

Power connection

The control box is geared for 3 different voltages: 110V - 50/60Hz

220V - 50/60Hz 240V - 50HZ

The control box contains a terminal strip asshown in the sketch below.

PT100 sensor

GND

GND

Upper level sensor

GND

Terminal 2

K2

K3

M1

N

M2

N

L

N

VS1

230115

Main voltage selector

K1

Lower level sensor

Terminal 1

Terminal 4

Terminal 1

Terminal 1

Terminal 2

K4

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Depending on the operating conditions andtype of refrigerant, the SMC and TSMC com-pressors can be designed with an oil coolingsystem. This includes a heat exchanger ofthe OSSI (R717) or HE8S (HCF/HCFC) typebuilt into the crankcase of the compressor.

In the heat exchanger (oil cooler), the refri-gerant is expanded and cools the oil pumpedout by the oil pump into the oil system of thecompressor. The oil cooler is mounted in-stead of the oil pressure pipe Pos. 38.

The oil cooling system is controlled by a ther-mostatic injection valve or expansion valveas shown in the following drawings. A ther-mostat KP77 (or UNISAB II Control) ensuresthat the oil cooling system is not activateduntil the oil temperature in the crankcase ex-ceeds +55°C.

A valve block pos. 80 is built into the liquidsystem.

� Connection, pos. B, pipe dimension OD10 mm, emerges from receiver or priorityvessel and is conveyed to valve block pos.80 which is the same type as the one de-scribed in section entitled: Solenoid con-trolled oil return of this instruction manual.

� The solenoid valve should always be closed whenever the compressor is idle.

Please note:that nozzle size pos. 80I must be 3.3mm.

HFC and HCFC compressors:

� On SMC 100 and TSMC 100 compres-sors, the oil cooling system is designed asshown in fig. 1 and 2.

T KP 77/UNISAB II

Oil separator

TX 2-0.5 (R22)

LT

Oil coolerHE8S

R22SMC 100 compressor

CT CT

Fig. 1

80

B

T KP 77/UNISAB II

Oil separator

TX 2-0.5 (R22)Oil coolerHE8S

R22TSMC 100 compressor

CTMT

MT

HT

LT

80

B

Fig. 2

Before putting the oil system into operatingfor the first time, the superheating of the TXvalve must be adjusted from 4K, which is thefactory setting, to 10K. This is achieved byrotating the spindle 1,5 turn clockwise (1 revolution = 4K).

� The SMC 180 and TSMC 180 have nobuilt-in HE8S-type oil cooler.

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At two-stage operation it is necessary to coolthe discharge gas from the LP stage before itenters into the HP stage. This intermediatecooling is done with the systems describedbelow, depending on the type of refrigerantused.

Common for these intermediate cooling sys-tems is the fact that they must cool the inter-mediate pressure gas sufficiently and, at thesame time, ensure that no liquid is admittedinto the HP stage, as liquid can produce li-quid stroke in the HP cylinders and result inwear to the moving parts. It is important,therefore, to check the systems as indicatedbelow.

Intermediate cooling system withintermediate cooler type DVEA,R717

The two-stage R717 plant may consist of twocompressors, one low pressure compressor(LP) and one high pressure compressor (HP)as illustrated in fig. 1. The plant may alsoconsist of two-stage compressors as shownin fig. 2.

In both cases the compressors are con-nected to an intermediate cooler in which thewarm gas from the LP-stage is cooled downbefore it flows on to the HP-stage.

LP

MT

MT HT

CT

LP

HP

Suction

Fig. 1

•

••

•

•

Oil drain off

Intermediate

Oil separatorEqualizing pipe

Float valve

Oil separator

coolerLiquid subcooling

spiral

filter

CMO, SMC 100/180 compressor

Oil drain off

Intermediate

Liquid subcooling

HP

Float valve

Equalizing pipe

Suction filter

TCMO, TSMC 100/180 compressor

Oil separatorOil separator

CTLP IP

IPLP

cooler

Fig. 2

spiral

In the intermediate cooler, the liquid level ofR717 is regulated by the float valve and thedischarge gas from the LP stage is cooled bybubbling up through the refrigerant from thedistributor at the bottom of the intermediatecooler.

0178-910-EN 173

In the liquid subcooling spiral, the refrigerantflowing from the receiver to the evaporatorside of the refrigeration plant is cooled. Theintermediate cooler is dimensioned so thatthe cooled gas is free of liquid refrigerant be-fore leaving the top of the intermediate cool-er. It is important to check that the float valveis functioning correctly and keeping the liquidlevel constant. Frosting of the liquid levelpipe on the intermediate cooler indicates theliquid level.

In order to avoid violent foaming of the liquidin the intermediate cooler, the compressorshould run for a few minutes after start-up atthe lowest capacity stage to stabilize plantpressures. Capacity can then be increasedstage by stage at suitable time intervals.

Make sure that the equalizing pipe on the in-termediate cooler has been connected. Theequalizing pipe safeguards against backflowof liquid from the intermediate cooler to theLP stage of the compressor, when the com-pressor is not working.

At regular intervals, the intermediate coolermust be drained of oil through the oil drainvalve.

Intermediate cooling system withliquid injection into the intermedi-ate discharge gas, R22 and R717

Two-stage compressors can be equippedwith a pipe connection from the LP stage out-let branch to the HP stage suction branch asshown in fig. 3.

In the pipe connection the hot discharge gasfrom the LP stage is cooled by injection of

liquid refrigerant into the intermediate pipe.This is achieved with the following systems 1and 2:

1: Intermediate cooling with thermostaticexpansion valve type: TEA (R717) or TEX (R22)TCMO and TSMC 100/180

TCMO and TSMC

CT

LP HPIP

IPLP

LP

Opt.

Fig. 3

•

B•

80

•

TEA or TEX

•

Mixing chamber

Oil separator

Suction filter (opt.)

In the system in fig. 3 the liquid refrigerantconveyed to the intermediate pipe is regu-lated by a thermostatic expansion valvetype TEA (R717) or TEX (R22) with a sen-sor placed on the intermediate pipe close tothe HP stage.

A valve block pos. 80 is built into the liquidsystem.

Connection, pos. B, pipe dimension OD 10mm, emerges from receiver or priority vesseland is conveyed to valve block pos. 80 whichis the same type as the one described in sec-tion entitled: Solenoid controlled oil return ofthis instruction manual.

Please note:that nozzle size pos. 80I must be 3.3 mm.

174 0178-910-EN

It is essential to make sure that the inter-mediate cooling system functions correctly inorder to prevent too much liquid refrigerantfrom being injected into the IP gas.

Too much liquid refrigerant may impede theevaporation of the liquid before the IP gas issucked into the HP stage of the compressor.This may result in liquid hammer and wearand tear on moveable parts.

The expansion valve must be adjusted to su-perheat the intermediate gas at a temper-ature not below 10 K.

This is done by measuring the pressure andthe temperature of the intermediate gas be-fore it enters the compressor to the HPstage. (For this purpose SABROE hasmounted an empty sensor pocket. To ensurean exact measurement the pocket can befilled with oil before the thermometer isintroduced).

Compare the measured values with thecurves in fig. 4. For any given intermediatepressure the temperature must be close tothe curve, but never below.

XX

��

�

��

��

��

��

� � � � �

��

��

��

�

�

��

��

��

��

��

��

° � temperature HP suction side

R717

R22

X X

• •X

X

X

XX

X

Fig. 4

Intermediate pressure (bar)

Position the sensor of the expansion valve onthe intermediate pressure pipe immediately

before the HP-stage suction filter. The sensormust be fitted on the side of the pipe and in-sulated as shown in fig. 5

��

�

� ��

��

��

Note:

� The necessary superheat of 10 K is in-cluded in the curve, fig. 4.

� An exact measurement of the temperaturecannot be read until after a stabilisationperiod which is not under 5 minutes forR22 and not under 15 minutes for R717.

� Before the initial adjustment of the valve itmust be adjusted to its highest level tomake sure that the superheat is above 10K. Do this by turning the spindle 20 turnsclockwise for R717 and 2.5 turns for R22.The superheat can now be regulated onthe basis of measurements and the curvesin fig. 4.

� The valve for R717 changes the super-heat 0.5 K per rotation of the adjustingscrew. The valve for R22 changes the su-perheat 4 K per rotation. By turning the adjusting screw clockwisethe superheat is increased. By turning thescrew anti-clockwise the superheat isreduced.

� SABROE has adjusted the valve to 10 Ksuperheat.

0178-910-EN 175

2: Intermediate cooling with thermostaticinjection valve type: TEAT (R22)TCMO and TSMC 100/180

Different systems are applied for TCMOand TSMC 100/180 as described below insections A and B.

Fig. 6

�

From receiver

To evaporator

Liquid tank 4L

��

��

Suction filter

��

Oil separator

TEAT

80

Liquid subcooler

A: TCMO

As illustrated in fig. 6 the intermediate gas iscooled by injecting refrigerant into the lowpressure stage pressure chamber in thecompressor. The liquid is thoroughly mixedwith the hot discharge gas by means of thedistributor pos. 83A as may be seen fromfig. 7.

Fig. 7

83A

•

For sub-cooling of liquid to the evaporatorsthe injected liquid first passes a liquidsub-cooler, mounted on the compressor.The liquid injection is controlled by a TEATvalve.

B: TSMC 100/180

From receiver

Mixing chamber

Oil separator

To evaporator

Liquid supply

T

CT

HESI

A

LP HPIPIPLP

LP

Fig. 8��

TEAT

On TSMC 100 and 180 plants, the intermedi-ate cooling system can be designed as illus-trated in fig. 8, in which the intermediate cool-ing is carried out by a thermostatic injectionvalve of the TEAT type, and in which the sub-cooling takes place in a HESI heat exchang-er.

176 0178-910-EN

Adjusting the TEAT valve:

For both systems, A and B, the following applies: The sensor of the TEAT valve is placed in asensor pocket at the discharge branch of thecompressor, and a proper thermal contact isobtained by means of the heat conductingcompound.

The solenoid valve is opened by the KP77thermostat whenever the temperature of thepressure pipe is above 55°C.

It is important to make sure that the interme-diate cooling system functions correctly andthus prevent too much refrigerant from beinginjected into the intermediate pressure gas.

Excess refrigerant may lead to the liquid be-ing unable to evaporate before the intermedi-ate pressure gas is sucked into the HP stageof the compressor and may thus cause liquidstrokes and wear to the moving parts.

When supplied, the TEAT valve is factoryset to the following regulating temperatures:

Refrigerant Regulating temp.

R22

R717 75 C°

75 C°

Before using the valve, the regulating tem-perature must be changed to the same valueas the discharge gas temperature indicatedin the table Anticipated discharge gas tem-peratures in this instruction manual.

Adjustments are made by rotating the regu-lating spindle clockwise, 5 turns for every10K of temperature increase.

Example:

Regulating temperaturefactory setting 75°C

Estimated dischargegas temperature

IT = –10°CCT = 35°C 96°CSuperheat = 20°C

Refrigerant R22

Adjustment

96 – 75 x = 10.5 revolutions510

Under all circumstances, the regulating tem-perature of the valve must be raised at least10K, corresponding to 5 revolutions (clock-wise).

When the plant has stabilized and the com-pressor is working at 100% capacity, the val-ve must be readjusted to the same value asthe discharge temperature with the Antici-pated discharge gas temperature in the table,within -5K to +10K. (In the example, 91°C <96°C < 106°C)

At reduced compressor capacity, the dis-charge gas temperature may rise somewhat;under these circumstances it should bechecked that the discharge gas temperaturedoes not exceed the Set point for the KP98.

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When placing an order for spare parts,please state the following:

1. Shop No.

All compressors are fitted with an identifica-tion plate, which states the type and shop no.of the compressor and indicates what refrig-erant is to be used.

2. Part No.

Spare parts drawings and parts lists insertedin an instruction manual identify spare partswith the following:

a) Spare part no. – which is a referencenumber to facilitate finding a part in thedrawing and cross-referencing in the partslist or vice versa.

b) Designation of the part.

c) Part no. – a 7-digit number which refers toSABROE’s stores.

When you order spare parts, please alwaysadvise at least the designation and part num-

ber. If you are in any doubt, add the sparepart no. too.

3. Forwarding instructions

When ordering spares, please advise the for-warding address, and the address to whichthe invoice should be sent. If appropriate,please state the name of your local bank, theway in which you want the goods transportedand required delivery date.

4. Classification certificate

If you require a certificate from a Classifica-tion authority, please mark the order appropriately, as the inspection and issuingprocedures take extra time and incur extraexpenses.

5. Quotation No.

If a quotation no. has been given during earli-er correspondence, please refer to this whenplacing your order – it will help us to identifyand execute your order quickly.

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On servicing compressor and unit it is alwaysan advantage if you, as our customer, havesome of the most commonly used spareparts at your disposal. This enables you or asummoned SABROE service engineer tocarry out the necessary service work withouthaving to spend extra time on procuring thespare parts needed.

Spare parts are obtainable in sets as men-tioned in the following.By contacting SABROE’s local representa-tive it is possible to receive a list of the sparepart sets recommended by SABROE.

Compressor block

� Standard spare part setContains a suitable selection of O-rings as well as valve ring plates and valvesprings.

� Extended spare part setFurther to the parts included in the stan-dard spare part set this set contains acylinder lining and discharge valve as wellas an extended number and types of gas-kets and fittings.

� Certificate spare part setFurther to the parts from the extendedspare part set this set contains a majornumber of components and wearing partsselected by the classification societies.

� Special spare part setThis is a more compehensive set than theextended spare part set as almost all O-rings and gaskets are included and forthe most wearing parts the number ofparts has been extended.

Spare part set for Basic Unit

� Standard spare part setThis is a set consisting mainly of O-ringsand gaskets for some of the componentsincluded in the unit.

� Certificate spare part setFurther to the parts from the standardspare part set this set contains other com-ponents selected in accordance with therequirements of the classification soci-eties.

Documents

Manual Sabroe SMC_104-106-108_EN.pdf