York SMC 104, SMC-106, SMC-108, TSMC 108 Mk 3 Instruction Manual

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Page 1

Instruction Manual

0178-915-EN Rev. 00.02

SMC 104-106-108/TSMC 108 Mk 3

Reciprocating Compressor

Christian X´s Vej 201, P.O. Box 1810, DK-8270 Højbjerg, Denmark

Phone +45 86 27 12 66 . Fax +45 86 27 44 08

Page 2

00.01

Specifications for SMC 104Ć106Ć108 Mk3 and TSMC 108 Mk3, SĆLĆE

The SMC/TSMC-type piston compressor can be fitted with a range of equipment, depending on the function and requirements it is expected to meet.

Some of these variants are discussed in this

Compressor type Designation

Serial number Refrigerant

Control

Compressor cooling

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

UNISAB II Control- and regulating system Analogue Control System Thermopump Water cooled top and side covers Air cooled top and side covers

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

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

Oil cooling (water-cooled side covers) Oil cooling OSSI/HE8S Coupling

Drive type

Explosion-proof electrical design

Oil pump drive

Equipment for parallel operation SABROE OVUR-type oil separator

V-belts

Pinion drive Chain drive

0178-910-EN

Page 3

Preface

The aim of this instruction manual is to provide the operators with a thorough knowledge of the compressor and the unit, at the same time providing information about:

this instruction manual to ensure reliable and efficient operation of the plant as SABROE is unable to provide a guarantee against damage occurring during the warranty period where this is attributable to incorrect

S the function and maintenance of the

operation.

individual components;

S service schedules; S procedure for dismantling and

reassembling of the compressor.

To prevent accidents during dismantling and assembly of compressors and components, these should only be carried out by authorized personnel.

The instruction manual also draws attention to typical sources of errors which may occur during operations. It states their cause and explains what should be done to rectify them.

The contents of this instruction manual must not be copied or passed on to any unauthorized person without Sabroe’s

It is imperative that the operators familiarize

permission.

themselves thoroughly with the contents of

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

0171-500-EN 96.06

SABROE REFRIGERATION A/S

P.O. Box 1810, DK–8270 Højbjerg

Chr. X’s Vej 201, Århus, Denmark

Phone:

Telefax:

+45 86 27 12 66 +45 86 27 44 74

0171-702-EN

Page 4

List of Contents

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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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 81

Description 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Page 6

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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First Aid for accidents with Ammonia

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

General

Ammonia is not a cumulative poison. It has a distinctive, pungent odour that even at very low, harmless concentrations is detectable by most persons. Since ammonia is self-alarming, it serves at its own warning agent, so that no person will voluntarily remain in concentrations which are hazardous. Since ammonia is lighter than air, adequate ventilation is the best means of preventing an accumulation.

Experience has shown that ammonia is extremely hard to ignite and under normal conditions is a very stable compound. Under extremely high, though limited concentrations, ammonia can form ignitable mixtures with air and oxygen, and should be treated with respect.

Basic rules for first aid

1. Call a doctor immediately.

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

3. A shower bath or water tank should be available near all bulk installations with ammonia.

4. When applying first aid, the persons assisting should be duly protected to avoid further injury.

Inhalation

1. Move affected personnel into fresh air immediately, and loosen clothing restricting breathing.

2. Call a doctor/ambulance with oxygen

equipment immediately

3. Keep the patient still and warmly wrapped in blankets.

4. If mouth and throat are burnt (freeze or acid burn), let the conscious patient drink water, taking small mouthfuls.

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

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

7. If breathing fails, apply artificial respiration.

Eye injuries from liquid splashes or concentrated vapour

1. Force the eyelids open and rinse eyes immediately for at least 30 minutes with the salt water solution just mentioned

2. Call a doctor immediately.

0170-008-EN 96.01

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Page 8

Skin burns from liquid splashes or concentrated vapour

2. Call a doctor immediately.

1. Wash immediately with large quantities of water and continue for at least 15 minutes, removing contaminated clothing carefully while washing.

No plant can ever be said to be too safe.

Safety is a way of life.

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

0178-910-EN

Page 9

First aid for accidents with HFC/HCFC

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

General

HFC/HCFC form colourless and invisible gasses which are heavier than air and smell faintly of chloroform at high concentrations only. They are non-toxic, non-inflammable, non-explosive and non-corrosive under normal operating conditions. When heated to above approx. 300 toxic, acid gas components, which are strongly irritating and aggessive to nose, eyes and skin and generally corrosive. Besides the obvious risk of unnoticeable, heavy gases displacing the atmospheric oxygen, inhalation of larger concentrations may have an accumulating, anaesthetic effect which may not be immediately apparent. 24 hours medical observation is, therefore, recommended.

°C they break down into

Inhalation

1. Move affected person into fresh air immediately. Keep the patient still and warm and loosen clothing restricting breathing.

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

3. Give artificial respiration until a doctor authorizes other treatment.

Eye injuries

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

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

Skin injuries – Freeze burns

Basic rules for first aid

1. When moving affected persons from lowlying or poorly ventilated rooms where high gas concentrations are suspected, the rescuer must be wearing a lifeline, and be under continuous observation from an assistant outside the room.

2. Adrenalin or similar heart stimuli must not be used.

No plant can ever be said to be too safe.

Safety is a way of life.

1. Wash immediately with large quantities of luke warm water to reheat the skin. Continue for at least 15 minutes, removing contaminated clothing carefully while washing.

2. Treat exactly like heat burns and seek medical advice.

3. Avoid direct contact with contaminated oil/ refrigerant mixtures from electrically burntout hermetic compressors.

0178-910-EN

Page 10

Protecting the environment

0170-009-EN 96.01

Increasing industrialisation threatens our environment. It is therefore absolutely imperative that we protect nature against pollution.

To this end, many countries have passed legislation in an effort to reduce pollution and preserve the environment. These laws apply to all fields of industry, including refrigeration, and must be complied with.

Be especially careful with the following substances:

S refrigerants S cooling media (brines etc) S lubricating oils.

Refrigerants usually have a natural boiling point which lies a good deal below 0°C. This means that liquid refrigerants can be extremely harmful if they come into contact with skin or eyes.

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

concentrations of refrigerant vapours are inhaled they attack the human nerve system.

When halogenated gasses come into contact with open flame or hot surfaces (over approx. 300°C) they decompose to produce poisonous chemicals, which have a very pungent odour, warning you of their presence.

In high concentrations, R717 causes respiratory problems, and when ammonia vapour and air mix 15 to 28 vol. %, the combination is explosive and can be ignited by an electric spark or open flame.

Oil vapour in the ammonia vapour increases this risk significantly as the point of ignition falls below that of the mixture ratio stated.

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

The following table shows the values for refrigerant content in air, measured in volume %. Certain countries may, however, have an official limit which differs from those stated.

TWA Time weighted average during a week

Warning smell

0178-910-EN

Unit

vol.%

Halogenated refrigerants

R134a R404A

HFC

R407C

0,1

0,2

R410A

0,1

HCFC

R507 R22

0,10,10,1

0,1

Ammonia

R717

0,005

0,002

Page 11

Further comments on refrigerants:

S If released to the atmosphere, haloge-

nated refrigerants of the type HCFC (e.g. R22) may cause a depletion of the ozone layer in the stratosphere. The ozone layer protects the earth from the ultraviolet rays of the sun. Refrigerants of the types HFC and HCFC are greenhouse gases with contribute to an intensification of the greenhouse effect. They must, therefore, never be released to the atmosphere. Use a separate compressor to draw the refrigerant into the plant condenser/receiver or into separate refrigerant cylinders.

S Most halogenated refrigerants are mis-

cible with oil. Oil drained from a refrigeration plant will often contain significant amounts of refrigerant. Therefore, reduce the pressure in the vessel or compressor as much as possible before draining the oil.

Halogenated refrigerants must never be mixed. Nor must R717 ever be mixed with halogenated refrigerants.

Purging a refrigeration plant

If it is necessary to purge air from a refrigeration plant, make sure you observe the following:

S Refrigerants must not be released to the

atmosphere.

S When purging an R717 plant, use an ap-

proved air purger. The purged air must pass through an open container of water so that any R717 refrigerant remaining can be absorbed. The water mixture must be sent to an authorized incinerating plant.

S Halogenated refrigerants can not be ab-

sorbed by water. An approved air purger must be fitted to the plant. This must be checked regularly using a leak detector.

S 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).

S Even small amounts of ammonia in water

(2-5 mg per litre) are enough to wreak havoc with marine life if allowed to pollute waterways and lakes.

S As ammonia is alkaline it will damage

plant life if released to the atmosphere in large quantities.

Refrigerant evacuated from a refrigerant plant shall be charged into refrigerant cylinders intended for this specific refrigerant.

If the refrigerant is not to be reused, return it to the supplier or to an authorized incinerating plant.

Cooling media

Salt solutions (brines) of calcium chloride (CaCl used.

In recent years alcohol, glycol and halogenated compounds have been used in the brine production.

In general, all brines must be considered as harmful to nature and must be used with caution. Be very careful when charging or purging a refrigeration plant.

Never empty brines down a sewer or into the environment.

The brine must be collected in suitable containers, clearly marked with the contents, and sent to an approved incinerating plant.

) or sodium chloride (NaCl) are often

0178-910-EN

Page 12

Lubricating oils

– alkyl benzene-based synthetic oil

Refrigeration compressors are lubricated by one of the following oil types, depending on the refrigerant, plant type and operating conditions.

– mineral oil

– semi-synthetic oil

Note

This instruction provides only general information. The owner of the refrigeration

plant is responsible for ensuring that all by-laws are complied with.

– polyalphaolefine-based synthetic oil – glycol-based synthetic oil. When you change the oil in the compressor

or drain oil from the refrigeration plant’s vessels, always collect the used oil in containers marked “waste oil” and send them to an approved incinerating plant.

0178-910-EN

Page 13

Description of compressor SMC 104Ć106Ć108 Mk & TSMC 108 Mk 3, SĆLĆE

The SMC 100 and TSMC 100 compressors have 100 mm diameter pistons, as indicated by the first digit in the type designation. The number of cylinders in the compressor block is indicated by the following two digits, where, for example, SMC 108 is an 8-cylinder compressor. SMC 100 is a one-stage compressor which compresses the gas in a single stage.

AARHUS DENMARK

Type Shop no Max. speed

Swept volume Working pressure

Test pressure

SABROE

Refrigerant Year

r.p.m. m3/h

bar bar

0171-481-EN 96.12

In the TSMC 100 two-stage compressors, the gas is compressed in two stages at a ratio of 1:3 between the number of high- and lowpressure cylinders. Thus, a TSMC 108 has 2 high-pressure cylinders and 6 low-pressure cylinders. The SMC 100 and TSMC 100 are available in three versions: an S-type with 80 mm stroke, an L-type with 100 mm stroke, and an E-type with 120 mm stroke. The compressor works on the refrigerants mentioned in the following chapter.

The type can be determined by the nameplate, located on the end face of the compressor, facing away from the coupling/belt drive. The following illustration shows a SABROE nameplate.

T0177093_2

Similarly, the name-plate indicates the compressor’s serial number, which is also stamped into the compressor housing near the suction chambers.

Whenever contacting SABROE about the compressor, its serial number should be stated.

In the compressors the pistons operate in cylinder linings, inserted in the compressor block with two cylinders under each top cover. 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

Page 14

der linings and are kept in position by a powerful safety spring. The safety spring allows the discharge valve unit to rise, providing a greater throughflow aperture in the event of liquid strokes in the cylinder. This prevents

At the axle end, the crankshaft is fitted with a balanced slide-ringtype seal consisting of a cast iron ring with an O-ring which rotates with the crankshaft, and a stationary

spring-loaded carbon ring. any overloading of the connecting rod bearings.

All compressors can be capacity-regulated

by connecting or disconnecting the cylinders The crankshaft is supported in slide bearings

able to assimilate both radial and axial forces. The oil pressure for the bearings and

in pairs. The following diagram shows the

capacity stages at which the compressors

can operate. the capacity regulating system is supplied

from the gearwheel oil pump incorporated in the compressor.

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

SMC 104 x x SMC 106 x x x

Capacity regulation is controlled by means of

solenoid valves mounted on the compressor.

SMC 108 x x x x TSMC 108 x x x

0178-910-EN

Page 15

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

Direction of rotation

In order to reduce the noise level from the electric motors these are often executed with specially shaped fan wings, thus determining a particular direction of rotation.

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

The direction of rotation of the compressor for compressors CMO-TCMO and SMCTSMC is indicated by an arrow cast into the compressor cover, near the shaft seal.

On the BFO compressors the direction of rotation is not indicated by an arrow but is standard as illustrated by the following sketch:

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

During transportation and handling care should be taken not to damage any of the components, pipe or wiring connections.

Areas of application of the reciprocating compressors

Compressor types: BFO 3-4-5 CMO-TCMO, SMC 100-TSMC 100 Mk3, S, L, E SMC 180-TSMC 180, HPO-HPC

In view of preventing an unintended application of the compressor, which could cause injuries to the operating staff or lead to technical damage, the compressors may only be applied for the following purposes:

0170-119-EN 97.12

Seen towards shaft end

Handling of compressor and unit

For lifting of the compressor the large models are equipped with a threaded hole for mounting of the lifting eye. As to the weight of the compressor, see table on compressor data.

Note:

The compressor block alone may be lifted in the lifting eye. The same applies to the motor.

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

The compressor may ONLY be used:

S As a refrigeration compressor with a num-

ber of revolutions and with operating limits as indicated in this manual or according to a written agreement with SABROE.

S With the following refrigerants:

R717 – R22 R410A1 – R5071 – R6001 – R600A1 –

R290

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.

S As a heat pump:

– LPG1

) Exempted are the following compres-

– R134a1 – R404A1 –

0178-910-EN

Page 16

– BFO 3-4-5

CMO - TCMO and SMC - TSMC may be used with a max. discharge pressure of 25 bar.

– HPO – HPC may be used with a max.

discharge pressure of 40 bar.

manual handle, to which there is free access.

S It must be able to stop any dangerous si-

tuation, which may occur, as quickly as possible without this leading to any further danger.

S In an explosion-prone environment, pro-

vided the compressor is fitted with approved explosion-proof equipment.

The compressor must NOT be used:

S For evacuating the refrigeration plant of air

and moisture,

S For putting the refrigeration plant under air

pressure in view of a pressure testing,

S As an air compressor.

Emergency device

The compressor control system must be equipped with an emergency device.

In case the compressor is delivered with a SABROE-control system this emergency device is found as an integrated part of the control.

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

It should only be possible to set back the emergency device by a deliberate act, and this set back must not cause the compressor to start operating. It should only make it possible to restart it.

Combustion motors

If combustion motors are installed in rooms

containing refrigeration machinery or rooms

where there are pipes and components con-

taining refrigerant, you must make sure that

the combustion air for the motor is derived

from an area in which there is no refrigerant

gas, in case of leakage.

Failure to do so will involve a risk of the lubri-

cating oil from the combustion motor mixing

with the refrigerant; at worst, this may give

rise to corrosion and damage the motor.

Explosion-proof electrical execution

If the compressor is delivered in an explo-

sion-proof electrical execution, this is stated

in the table on page 1 of this instruction

manual.

Likewise, the compressor will, besides the

SABROE name plate, be equipped with an

Ex-name plate like the one illustrated below.

Other demands to the emergency device:

S It must be possible to operate it by means

of an easily recognizable and visible

0178-910-EN

T2516273_0

Page 17

The temperature of tangible surfaces

When a compressor is working, the surfaces that are in contact with the warm discharge gas also get warm. However, the temperature depends on which refrigerants and under which operating conditions the compressor is working. Often, it exceeds 70°C which for metal surfaces may cause your skin to be burnt even at a light touch.

Consequently, the compressors will be equipped with yellow warning signs informing you that pipes, vessels and machine parts

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

0178-910-EN

Page 18

Sound data for reciprocating and screw compressor units - all types of compressors

0170-114--EN 99.06

In the following tables the noise data of the compressors 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 a large number of measurings on various units. The measurings have been carried out in accordance with ISO 9614-2.

The values are further stated as average

sound pressure in a free field above a reflecting plane at a distance of 1 meter from

a fictional frame around the unit. See fig. 1. Normally, the immediate sound pressure

lies between the LW and LP values and can be calculated provided that the acoustic data of the machine room is known.

For screw compressors the average values are indicated in the tables for the following components.

S SAB 81-83-85-87-89, SAB 128, Mk3,

SAB 163 Mk3, SAB 202, SAB 330, SV and FV:

Compressor block + IP23 special motor + oil separator.

S SAB 128 HR and SAB 163 HR:

Compressor block at max. number of revolutions + IP23 special motor + oil separator

S SAB 110:

Compressor block + IP23 standard motor + oil separator

Dimensional tolerances are:

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

As to the reciprocating compressors the

values are stated for the compressor block

only.

The dimensional values are stated for 100%

capacity.

Fig. 1

0178-910-EN

1 meter

Fictional frame

Dimensional plane

Reflecting plane

Page 19

Note the following, however:

S at part load or if the compressor works

with a wrongly set V

the sound level can

sometimes be a little higher than the one indicated in the tables.

S the acoustics is another factor that can

change the sound level in a room. Please note that the sound conditions of the site have not been included in the stated dimensional values.

S additional equipment such as heat ex-

changers, pipes, valves etc. as well as the choice of a different motor type can increase the noise level in the machine room.

S as already mentioned, the stated sound

pressures are only average values above a fictional frame around the noise source. Thus, it is sometimes possible to measure higher values in local areas than the ones stated – for inst. near the compressor and motor.

S by contacting SABROE you can have

sound data calculated for other operating conditions.

The tables have been divided into reciprocating and screw compressors, respectively. The reciprocating compressors are further divided into one- and two-stage compressors as well as in a heat pump. In each table the operating conditions of the compressor during noise measuring have been stated, just as the refrigerant used has been mentioned.

0178-910-EN

Page 20

RECIPROCATING COMPRESSORS One-stage

Evaporating temperature = –15°C Condensing temperature =+35°C Refrigerant = R22/R717 Number of revolutions =1450 rpm.

Two-stage

Evaporating temperature = –35°C

Condensing temperature = +35°C

Refrigerant = R22/R717

Number of revolutions =1450 rpm.

LW LPCompressor block

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°C Condensing temperature = +35°C Refrigerant = R22/R717 Number of revolutions = 900 rpm.

Compressor block LW LP

SMC 186 101 83 SMC 188 102 84

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

Evaporating temperature = –35°C

Condensing temperature = +35°C

Refrigerant = R22/R717

Number of revolutions = 900 rpm.

Compressor block LW LP

TSMC 188 100 82

Heat pump

Evaporating temperature = +20°C

Condensing temperature = +70°C

Refrigerant = R22/R717

Number of revolutions =1450 rpm.

Compressor block LW LP

HPO 24 91 76 HPO 26 93 78 HPO 28 94 79 HPC 104 97 81 HPC 106 98 82 HPC 108 99 84

0178-910-EN

Page 21

SCREW COMPRESSORS

Evaporating temperature = –15°C Condensing temperature = +35°C Refrigerant = R22/R717 Number of revolutions = 2950 rpm.

*Number of revolutions = 6000 rpm.

Compressor block LW LP

Evaporating temperature = –35°C Condensing temperature = –5°C Refrigerant = R22/R717 Number of revolutions = 2950 rpm.

SAB 110 SM 98 81 SAB 1 10 SF 98 81 SAB 1 10 LM 98 81 SAB 1 10 LF 98 81

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

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

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

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

Compressor unit LW LP

SAB 163 BM 106 88 SAB 163 BF 110 92

Evaporating temperature = –15°C Condensing temperature =+35°C Refrigerant = R22/R717 Number of revolutions = 2950 rpm.

Compressor block LW LP

VMY 347 H 97 82 VMY 447 H 100 85 VMY 536 H 104 88

SV 17 100 83 SV 19 101 84

* 101 86

FV 19 SV 24 103 85 FV 24

* 104 86

SV 26 103 85

* 107 85

FV 26 SAB 81 101 86

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

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

Evaporating temperature = 0°C Condensing temperature =+35°C Refrigerant = R22/R717 Number of revolutions = 2950 rpm.

Compressor block LW LP

VMY 347 M 99 84 VMY 447 M 101 86 VMY 536 M 105 89

0178-910-EN

Page 22

Vibration data for compressors Ć all types

0170-115-EN 95.06

Vibration data for SABROE screw compressors comply with the following norm:

ISO 2372 group C

Depending on the laying of the foundation and the size of the motor a screw compres-

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

Ranges of vibration severity

Range

0.28

0.45

0.71

1.12

1.8

2.8

4.5

7.1

11.2 18

28 45

ms-velocity V (in mm/s)

at the range limits

0.28

0.45

0.71

1.12

1.8

2.8

4.5

7.1

11.2 18 28

Class I Class II Class III Class IV

B C

sor unit can - under normal circumstances -

be classified in Class III or IV according to

the following table from ISO 2372. Recip.

compressor units can be classified in class

IV, likewise under normal conditions.

Examples of quality judgement

for separate classes of machines

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

Pay attention to the following, however:

S On placing the unit on the vibration

dampers delivered by SABROE (additional) the vibrations against the foundation are reduced by:

– 85-95% for screw compressor units – 80 % for recip. compressor units

S However, a higher vibration level may oc-

cur if:

0178-910-EN

– Motor and compressor have not been

aligned as described in the Instruction Manual.

– For screw compressors, if the compres-

sor runs at a wrong V

ratio.

– The pipe connections have been

executed in a way that makes them force pull or push powers on the compressor unit or they may transfer vibrations to the unit, caused by natural vibrations or connected machinery.

– The vibrations dampers have not been

fitted or loaded correctly as indicated on the foundation drawing delivered together with the order.

Page 23

Compressor data for reciprocating compressor

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

Operating limits

SABROE prescribes operating limits within which the compressor and any additional equipment must operate. These limits for R717, R22, R134a, R404A, R507 and R407C are shown in the following tables, together with the main data for the compressor.

BoremmStrokemmMax/min

Compressor

type

Number of

cylinders

Speed

RPM

CMO 4 CMO 24 CMO 26 CMO 28 TCMO 28 SMC 104S SMC 106S SMC 108S SMC 112S SMC 116S TSMC 108S TSMC 116S SMC 104L SMC 106L SMC 108L SMC 112L SMC 116L TSMC 108L TSMC 116L SMC 104E SMC 106E SMC 108E SMC 112E SMC 116E TSMC 108E TSMC 116E SMC 186 SMC 188 TSMC 188

✶ 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)

4 65 65 1800/900 93,2 200 4 70 70 1800/900 116 340 6 70 70 1800/900 175 380 8 70 70 1800/900 233 410

2+6 70 70 1800/900 175 410

4 100 80 1500/700 226 580 6 100 80 1500/700 339 675

8 100 80 1500/700 452 740 12 100 80 1500/700 679 1250 16 100 80 1500/700 905 1350

2+6 ♦ 100 80 1500/700 339 775

4+12 ♦ 100 80 1500/700 679 1400

4 100 100 1500/700 283 580

6 100 100 1500/700 424 675

8 100 100 1500/700 565 740 12 100 100 1500/700 848 1250 16 100 100 1500/700 1131 1350

2+6♦ 100 100 1500/700 424 775

4+12♦ 100 100 1500/700 757 1400

4 100 120 1500/700 339 600

6 100 120 1500/700 509 700

8 100 120 1500/700 679 770 12 100 120 1500/700 1018 1300 16 100 120 1500/700 1357 1400

2+6♦ 100 120 1500/700 509 800

4+12♦ 100 120 1500/700 1018 1450

6 180 140 1000/450 1283 2560

8 180 140 1000/450 1710 2840

2+6♦ 180 140 1000/450 1283 2900

Swept

volume

max RPM*

compr. block

Weight

(max.)

0171-476-EN 99.04

0178-910-EN

Page 24

°F

158

140

°C

R717

Operating limits

single stage

122

104

–10

Condensing temperature

–4

–20

–30

–22 –40

–40

–60 –50 –40 –30 –20 –10

–70

–76 –58 –40 –22 –4 14 32 50 68 86 104

–94

T245400_0/2

0 10 20 30 40

Evaporating temperature

compressors

CMO

SMC 100 S-L

SMC 180

°C

°F

Type Area rpm Cooling

max min Booster Single and HP-stage compr.

CMO 20

SMC 100 S-L 3

SMC 180 2-3 1000 450 Water-cooled

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

3-4 1-2 Air-cooled top- and side covers # - or water-cooled

4 1200 1 750

4 900

1800 900

1500

700

Water-cooled Thermopump or water-cooled

# Including refrigerant-cooled oil cooler Thermopump:

Top- and side covers are cooled by refrigerant injection.

Water-cooled:

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

Oil cooling included in the system

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

0178-910-EN

Page 25

°F

158

140

°C

R717

Operating limits

single stage

122

104

–4

–22

–40

–10

–20

–30 –40

–60 –50 –40 –30 –20 –10 0 10 20 30 40

–70

–76 –58 –40 –22 –4 14 32 50 68 86 104

–94

Condensing temperature

T245400_0/2

compressors

SMC 100 E

°C

°F

Evaporating temperature

Type Area rpm Cooling

max min Booster Single and HP-stage compr.

SMC 100E

Thermopump:

Top- and side covers are cooled by refrigerant injection.

1-(1a) 1500

2 1200

700 Water-cooled Thermopump or water

Water-cooled:

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

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

Page 26

°C

°F

158

140

122

104

–10

Condensing temperature

–20

–4

–22

–30

–40

–60 –50 –40 –30 –20 –10 0 10 20 30 40

–70

–76 –58 –40 –22 –4 14 32 50 68 86 104

–94

0177128_0 VIEW 3,1

Evaporating temperature

R717

Operating limits

two-stage

compressors

TCMO

TSMC 100 S-L-E

TSMC 180

°C

°F

Type Area rpm Cooling Note

max min top and side

TCMO 1–2 1800 900 Thermopump or water-cooled

TSMC 100

S-L-E

TSMC 180

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

1 750 2 1000

450 Water-cooled

Oil cooling is always necessary. Thermopump:

Only the HP Stage top covers are cooled by a thermo pump Oil cooling included in the system

Part-load operation:

Depending on the operating conditions and the presure on the compressor a bypass system may be required.

Water-cooled:

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

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

0178-910-EN

Page 27

°F

°C

158

140

122

104

–4

–22

–40

–10

–20

–30

–40

–60 –50 –40 –30 –20 –10 0 10 20 30 40

–70 –94

–76 –58 –40 –22 –4 14 32 50 68 86 104

Condensing temperature

0177128_0 VIEW 4,1

Evaporating temperature

R22

Operating limits

°C

°F

single stage

compressors

CMO

SMC 100 S-L

SMC 180

Type Area rpm Oil-cooling Note

max min required

CMO

SMC 100 S

SMC 100 L

SMC 180

1 2 3 4 1 1000 2 1200 3 1500 4 1200 yes 1 Not applicable 2 1000 3 1200 4 1000 yes

1-2 Not applicable

3 At less than 50% capacity 4

1500

1800

750

900

700

450

Top covers: Air-cooled design only.

When oil cooling is required there is a free choice between A and B - However, for

At less than 50% capacity

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

thermostatic expansion valve.

no no

yes

no no

yes

SMC 180 only A may be selected.

0178-910-EN

Page 28

°F

158

140

122

104

°C

R22

Operating limits

two-stage

compressors

TCMO

–4

–22

–40

–10

–20

–30

–40

–60 –50 –40 –30 –20 –10 0 10 20 30 40

–70

–76 –58 –40 –22 –4 14 32 50 68 86 104

–94

Condensing temperature

0177128_0 VIEW 5,1

Type Area rpm

max min

TCMO

TSMC

100 S

TSMC

100 L

SMC 180

1-2 1500 3-4 1800

1 1000

2-3 1200

4 1500 1

2 1000 3-4 1200 1-2

3-4

750

Evaporating temperature

900 no

700 yes

450

TSMC 100 S-L

TSMC 180

°C

°F

Oil-cooling Note

yes

Not applicable

required

Top covers: Air-cooled design only.

When oil cooling is required there is a free choice between A and B - However, for SMC 180 only A may be selected.

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

thermostatic expansion valve.

0178-910-EN

Part-load operation:

Depending on the operating conditions and the presure on the compressor a bypass system may be required.

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

pressors.

Page 29

°F

°C

R134a

80 176

158

140

122

104

–10

Condensing temperature

–20

–4

–22

–30

Operating limits

single stage

compressors

CMO

SMC 100 S-L

–40

–70 –94

T0177128_ V8,1

Type Area

CMO

SMC 100 S

SMC 100 L

–60 –50 –40 –30 –20 –10 0 10 20 30 40 –76 –58 –40 –22 –4 14 32 50 68 86 104

Evaporating temperature

rpm Oil-cooling Note

no no no

no no

1-2

3 1

2 3

1 2

max min required

1200 1500 1500 1800 At less than 50% capacity 1000 1200 1200 1500 At less than 50% capacity

1000 1000 1200 At less than 50% capacity

900

700

At less than 50% capacity

°C

°F

Not applicable

Top covers: Air-cooled design only.

When oil cooling is required there is a free choice between A and B.

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

thermostatic expansion valve.

0178-910-EN

Page 30

°F

158

140

122

104

°C

R134a

Operating limits

two-stage

compressors

TCMO

–4

–22

–40

Type

TSMC

100 S

TSMC

100 L

–10

–20

–30

–40

–60 –50 –40 –30 –20 –10 0 10 20 30 40

–70

–76 –58 –40 –22 –4 14 32 50 68 86 104

–94

Area rpm

1-2 1500

3 1800

1 1000

2 1200

3 1500

2 1000

3 1200

Condensing temperature

T0177128_0 V8,1

TCMO 28

Evaporating temperature

max min

900

700

TSMC 100 S-L

°C

°F

Oil-cooling Note

required

1) 2)

Not applicable

1) 2)

Oil cooling:

Not required.

Top- and side covers:

Only air-cooled.

0178-910-EN

Part-load operation:

By-pass equipment required to maintain i termediate temperature at minimum load.

Page 31

°F

140

°C

R404A

Operating limits

122

104

Condensing temperature

–10

–20

–4

–30

–22

–70

–60 –50 –40 –30 –20 –10 0 10 20 30 –76 –58 –40 –22 –4 14 32 50 68 86

–94

274263.1 Rev. 0

single stage

compressors

CMO

SMC 100 S-L

°C

°F

Evaporating temperature

Type

Area

rpm Oil-cooling Note

max

1200 1500 1500 1800 At less than 50% capacity 1000 1200 1500 At less than 50% capacity 1000 no

1200

CMO 20

SMC 100 S

SMC 100 L

2 1

Top covers: Air-cooled design only.

When oil cooling is required there is a free choice between A and B.

min

900

700

required

At less than 50% capacity

no no

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

thermostatic expansion valve.

0178-910-EN

Page 32

°F

140

°C

R404A

Operating limits

122

104

–10

–70 –94

–60 –50 –40 –30 –20 –10 0

–76 –58 –40 –22 –414 32

Condensing temperature

274263.3 Rev. 0

Evaporating temperature

°C

°F

two-stage

compressors

TCMO

TSMC 100 S-L

Type

TCMO 28

TSMC

100 S

TSMC

100 L

Oil cooling:

Area rpm

Not required.

Top- and side covers:

Only air-cooled.

max

1800 900 1200

1500 1000 1200

min

700

Oil-cooling

required

Part-load operation:

1) 2)

Note

By-pass equipment required to maintain i termediate temperature at minimum load.

0178-910-EN

Page 33

°F

140

°C

R507

Operating limits

122

104

–4

–22

–40

–10

–20

–30

–40

–60 –50 –40 –30 –20 –10 0 10 20 30

–70

–76 –58 –40 –22 –4 14 32 50 68 86

–94

Condensing temperature

74263.2 Rev. 0

single stage

compressors

CMO

SMC 100 S-L

°C

°F

Evaporating temperature

Type Area

rpm Oil-cooling Note

max

1200 1500 1500 1800 At less than 50% capacity 1200 1200 1500 At less than 50% capacity 1000 no 1200

CMO 20

SMC 100 S

SMC 100 L

1 2

2 3

1 2

3 1 2

Top covers: Air-cooled design only.

When oil cooling is required there is a free choice between A and B.

min

900

700

required

At less than 50% capacity

no no

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

thermostatic expansion valve.

0178-910-EN

Page 34

°F

140

122

°C

R507

Operating limits

two-stage

compressors

104

Condensing temperature

–10

–70 –94

274263.4 Rev. 0

–60 –50 –40 –30 –20 –10 0 –76 –58 –40 –22 –414 32

Area rpm

Type

TCMO 28

TSMC

100 S

TSMC

100 L

1 1200

2 1500

1 1000

2 1200

Evaporating temperature

max min

1800 900

700

TCMO

TSMC 100 S-L

°C

°F

Oil-cooling Note

required

1) 2)

Oil cooling:

Not required.

Top- and side covers:

Only air-cooled.

0178-910-EN

Part-load operation:

By-pass equipment required to maintain i termediate temperature at minimum load.

Page 35

°F

140

122

°C

R407C

Operating Limits

one-Stage

Compressor type

104

CMO & SMC

–4

–10

–20

–30

–60 –50 –40

–70

–76 –58 –40 –22 –4 14 32 50 68 86

–94

–30 –20 –10 0 10 20 30

Evaporating temperature

°C

°F

Condensing temperature

–22

T245411_0 view 2

Type Area rpm Oil-cooling Note

yes

CMO

SMC 100 S

SMC 100 L SMC 100 L

SMC 180

max min required

1 1500 no 2 3 1 1200 2 1500 3 1200 yes 1 1000 2 1200 3 1000 yes 1 NOT APPLICABLE 2 At less than 50% capacity 3

1800

750

900

700

450

At less than 50% capacity

Top covers: Air-cooled design only.

When oil cooling is required there is a free choice between A and B - However, for SMC 180 only A may be selected.

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

thermostatic expansion valve.

0178-910-EN

Page 36

General operating instructions for CMO/TCMO, SMC/TSMC piston compressors

0171-461-EN 96.06

Starting up compressor and plant

S Before the initial start-up of the compres-

sor following a lengthy stand-still period of several months, the compressor must be prelubricated. Hereby, the bearings are lubricated and the oil system filled up with oil before the compressor is set running. Carry out the prelubrication by connecting the oil pump to the prelubricating valve which in the more recent SMCTSMC-HPC compressors is connected to the shaft seal housing pos. 6A and on the CMO-TCMO-HPO to the cover pos. 86H or 87K. As prelubricating pump we recommend SABROE’s hand-operated oil pump part no 3141-155, which is mounted as shown in fig. 1.

Fig. 1

To compressor

Cap

valve for prelubrication

Gasket

Optional handoperated oilpump

For pre-lubrication use a clean new refrigerant machine oil of the same type as the one found in the compressor, and pump as

follows:

Compressor

type

CMO TCMO HPO

SMC 104 106-108 TSMC 108 HPC

SMC 112-1 16 TSMC 116

SMC 186-188 TSMC 188

Pump strokes w.

SABROEs

hand-operated

oil pump

appr. 25

appr. 35

appr. 45

appr. 50

Estimated oil quantity

Liters

2.5

3.5

4.5

5.0

S The heating rod in the crankcase must be

energized at least 6-8 hours before starting up the compressor in order to boil any refrigerant out of the compressor oil. At the same time, the suction check valve must be open.

S Check oil level in crankcase. The oil level

must always be visible in the oil sight glass. See section: Charging the compres- sor with oil.

T0177131_0 V15

0178-910-EN

S Start condenser cooling, brine pumps,

fans at air coolers as well as any compressor cooling device.

S Check correct setting of safety auto-

matics on compressor.

S Open discharge stop valve at compressor. S Set capacity regulator to minimum capa-

city.

Page 37

S In order to avoid excessive pressure re-

duction in the compressor on start–up, the suction stop valve must be opened a few turns, as there is otherwise a risk of oil foaming in the crankcase.

S Open all other stop valves except for the

main valve in the liquid line and possible by-pass valves serving other purposes.

S Check that the time relay 3K13 keeps the

solenoid valve in the oil return line closed for 20-30 mins. after start-up of the compressor.

S Start compressor motor and check suction

and oil pressures.

S Carefully continue opening suction stop

valve to its full open position.

Stopping and starting-up compressor during a short period of standstill

Before stopping the compressor, its capacity must be reduced to the lowest capacity stage for a few minutes, before it stops.

During short periods of standstill, it is not necessary to shut off the suction stop valve and the discharge stop valve. The heating rod must be energized.

If the compressor is cooled by means of cooling water, the water flow must always be stopped during periods of standstill. This is normally done by means of a solenoid valve in the water inlet line to the compressor. Connect the solenoid valve to the start/stop relay of the compressor motor.

S Open main valve in liquid line.

S If the oil in the crankcase foams, or knock-

ing noises are heard from the compressor because droplets of liquid are being fed in with the suction gas, throttle suction stop valve immediately.

S The compressor is now operating.

Increase capacity stepwise, allowing the compressor to adjust to new conditions before switching to next stage. Check carefully whether oil is foaming and whether oil pressure is correct.

S Check whether oil return from oil separa-

tor is working. (Pay attention to any clogging of filter and nozzle.) The pipe should normally be warm.

Compressor start-up must always take place at the lowest capacity stage, after which capacity is increased stepwise at suitable intervals, in order to avoid that a sudden excessive pressure reduction in the evaporation system causes liquid hammering in the compressor and oil foaming in the crankcase.

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

S Shut off liquid supply to evaporators for a

few minutes before stopping the plant.

S Stop compressor and shut off suction and

discharge stop valves. Close valve in oil return.

S Stop condenser cooling, pumps, fans and

any compressor cooling.

S Do not leave plant for first 15 minutes after

start-up and never before it has stabilized.

S Cut off power supply to both master and

control currents.

0178-910-EN

Page 38

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

S Shut off main valve after receiver and

pump down evaporators. If necessary, adjust low-pressure cut-out on unit to a lower pressure during evacuation.

S Allow temperature in evaporators to rise,

then repeat evacuation.

S When suction pressure has been reduced

to slightly over atmospheric, stop compressor. Shut off suction and discharge stop valves and close off stop valve in oil return.

S Shut off condenser cooling. If there is a

risk of freezing, draw off coolant.

S Cut off power supply to master and control

currents.

S Inspect receiver, condenser and pressure

vessels as well as piping connections and apparatus for leakage.

Automatic plants

– correct setting of safety automatics.

Pressure testing refrigeration plant

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

Pressure test the plant with one of the following:

S dry air - pressurized cylinders containing

dry atmospheric air may be used - but never oxygen cylinders;

S air compressor for high pressure; S nitrogen.

Important

The plant compressors must not be used to pressurize the plant.

Water or other fluids must not be used for pressure testing.

If nitrogen is used, it is important to place a reducing valve with a pressure gauge between the nitrogen cylinder and the plant.

S Refrigeration plant should normally be put

into operation as described in the Start-up section.Once started, switch over to automatic operation.

S Special instructions for automatic plant in

question should be followed to the letter.

S 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,

0178-910-EN

During pressure testing, it is important to ensure that pressure transducers and other control equipment are not exposed to the testing pressure. The compressor stop valves must also be closed during pressure testing.

Plant safety valves must normally be blanked off during pressure testing, as their opening pressure is lower than the testing pressure.

Important

During this pressure testing, no person should be allowed to be present in rooms housing plant parts or in the vicinity of the plant outside the rooms.

Page 39

S The entire unit must be pressure tested in

accordance with the local regulations for pressure testing.

S The test pressure must never exceed the

disign pressure.

S If it is required that the compressor should

be pressure tested together with the unit or with the plant, the testing pressure must not exceed: For reciprocating compressors:

HP side: 24 bar LP side: 17.5 bar

S Please observe that manometers, pres-

sure controls, pressure transmitters and other control equipment are not exposed to testing pressure.

S Afterwards, reduce pressure to 10 bar for

a period of 24 hours - as an initial tightness test - as a tightly sealed plant will maintain this pressure throughout the period.

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

S By way of a second tightness test, ex-

amine all welds, flange joints etc. for leakage by applying soapy water, while maintaining the 10 bar pressure.

atmospheric air and moisture. Evacuation must be carried out on all types of refrigeration plant, regardless of the type of refrigerant with which the plant is to be charged.

Observe that HCFC and HFC refrigerants mix only minimally with water, and it is therefore necessary to effect evacuation of such systems with particular care.

The boiling point of a fluid is defined as the temperature at which the steam pressure equals atmospheric pressure. For water, the boiling point is 100°C. Lowering the pressure also lowers the boiling point of the water.

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

Boiling point of

water °C

5 10 15 20

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

At pressure

mm HG

6,63

9,14 12,73 17,80

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

S date of pressure testing, S person carrying out the test, S comments.

Pumping down refrigeration plant

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

The vacuum pump must be able to lower the pressure to approx. 0.1 mm Hg (mercury column) and must be fitted with a gas ballast valve. This valve should be used wherever possible to prevent water vapours condensing in the vacuum pump.

Important

Never use the refrigeration compressor to evacuate the plant.

0178-910-EN

Page 40

For a satisfactorily performed evacuation, the final pressure must be lower than 5 mm Hg. Attention is drawn to the fact that there may be a risk of any water left in the refrigeration plant freezing if ambient temperatures are lower than 10°C. In such instances, it will be necessary to supply heat to the component surroundings, as ice evaporates with difficulty.

It is recommended to carry out evacuation as follows:

S Evacuate to a pressure lower than 5 mm

Hg.

S Blow dry air or nitrogen into system to a

pressure corresponding to atmospheric.

Never use OXYGEN cylinders.

S Repeat evacuation to reduce pressure to

less than 5 mm Hg.

S Shut the vacuum pump off from refrigera-

tion plant and check that the pressure does not rise for the next couple of hours. If the system still contains water, this will evaporate and cause the pressure to rise, thereby indicating unsatisfactory evacuation and necessitating a repetition of the procedure.

0178-910-EN

Page 41

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 regular intervals, thus providing important information about the cause of any undesired changes in the operating state. (See following page)

Observation Measuring point Measurement unit

Date and timeTime

Suction pressure

Discharge pressure

Oil pressure

Oil temperature Suction gas temp.

Discharge gas temp.

Oil level in compressor

• Compressor pressure gauge

• UNISAB II Control

• Compressor pressure gauge

• UNISAB II Control

• Compressor pressure gauge

• UNISAB II Control

• Thermometer in suction pipe

immediately

before compressor

• UNISAB II Control

• Thermometer in discharge pipe

immediately after compressor but before oil separator

• UNISAB II Control

• Oil level sight glass

in compressor

°C or bar

bar

°C

Must be visible in oil

sight glass

Recharding of oil on compressor

Compressor motor’s consumption in amps.

At the same time, attention should be paid to the following: (tick these off in the log, if you wish)

S whether the compressor’s cooling system is functioning correctly, S whether any unusual noise is coming from the compressor, S whether there are unusual vibrations in the compressor.

• See section on oil

charging

• Electrical panel

• UNISAB II (additional)

Number of litres

Amps

0178-910-EN

Page 42

Servicing the piston compressor

0171-462-EN 99.03

In order to ensure problem-free operation, it is advisable to carry out regular servicing to the refrigeration plant. In this section, SABROE indicates some periodic services fixed on the basis of the number of operating hours from the first start-up or after over hand of the compressor.

The servicing schedules also depend on the speed of the compressor. If the compressor is running at less than 1200 rpm, SABROE permits extended service intervals. However, the compressor must always operate within the speed recommended by SABROE. See Description of compressor. Providing the compressor operates within the specified pressures and temperatures and the prescribed periodic services are performed, the compressor will have a long and efficient service life.

S The following must therefore be checked

daily:

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

The actual operating conditions should be entered in an operating log daily. See the Operating log section.

S Immediately after stopping compressor,

read off pressure on discharge and suction side of compressor.

S Close discharge stop valve quickly and,

from moment of closure, time how long it takes for pressure to drop on high pressure side of compressor. Normally, the pressure drop should not be more than 3 bar over a period of 5 minutes or so.

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

S where pressure valve ring plates are in

bad contact with their seats (Pos. 20C

against 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. Cylinder

lining is thus resting on rocker arms, Pos.

15A; (not CMO). S on safety valve, because valve cone does

not fit tightly against seat, or outer O-ring

Pos. 24B or inner O-ring Pos. 24C is de-

fective. (See Safety valve section.) During pressure drop testing, pay attention to

any piping connections to the discharge side of the compressor, which may have an influence on the test result.

Pressure drop test:

Using the pressure drop test, it is possible to check the internal tightness of the compressor from discharge to suction side. The pressure drop test is performed with the compressor at standstill, as described below:

0178-910-EN

Removing refrigerant from compressor

Before the compressor can be dismantled, the refrigerant must be removed from the compressor, which can be done in the following ways:

Page 43

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 piping connections to compressor.

4. On HFC and HCFC compressors, remove remaining refrigerant gas using a pumpdown compressor connected to purge valve Pos. 42.

Evacuating pump

R22

Water

R717

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

The water will absorb the refrigerant, which can then be dispatched for proper destruction. The moment the pressure is equalized, the valve must be reclosed in order to prevent water being sucked back into the compressor.

Note:

The following instructions apply to the compressor only. Servicing of the refrigeration plant is described in a separate section. Service the compressor motor according to your own instructions. For the various scheduled services, SABROE can supply ready-made spare-part sets, which it would be an advantage to have before carrying out the scheduled service.

S On the R717 compressor, adopt the fol-

lowing method:

In the event that the compressor cannot operate, start evacuation as described under pt. 3, and remember also to close the suction stop valve.

0178-910-EN

Page 44

Scheduled services

No.

Operating

hours

< 1200 rpm

75 50

300 200

Operating

hours

> 1200 rpm

Activity

1.1 Remove and discard filter bag in suction filter. Clean suction filter. Following major repair work or in event of severe soiling of filter bag, it is recommended that a new filter bag be fitted for another period of 50 operating hours.

1.2 Check tension of driving belts.

2.1 Check or change oil. When changing oil, change oil filter cartridge, too. See following section:

Assessing the oil.

2.2 Clean suction filter.

2.3 Check that following function correctly: Solenoid valves Compressor cooling Thermopump Safety automatics Heating rod V-belt drive.

2.4 Retighten external piping connections.

2.5 Check oil return system from oil separator.

2.6 Retighten coupling.

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

Assessing the oil.

3.2 Clean suction filter.

3.3 Check that following function correctly: Solenoid valves Compressor cooling Thermopump Safety automaitcs

7500 50003

Heating rod V-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 bearings Piston and oil scraper rings.

0178-910-EN

Change suction and discharge valve ring plates.

3.5 Finish off with a pressure drop test.

Page 45

No.

Operating

hours

< 1200 rpm

15000 10000

Operating

> 1200 rpm

hours

Activity

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

the oil.

4.2 Clean suction filter.

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

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

4.5 Finish off with a pressure drop test.

5.1 Check V-belt drive

5.2 For heat pump operation, inspect:

Valve seats

22500 15000

Cylinder linings Pistons, gudgeon pins and gudgeon pin bearings Piston and oil scraper rings.

Change: Suction and discharge valve ring plates.

0178-910-EN

Page 46

No.

Operating

Hours

< 1200 rpm

30000 20000

Operating

> 1200 rpm

Hours

Activity

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

6.2 Clean suction filter.

6.3 Check following: Solenoid valves Oil cooling system Water cooling system for any deposits and clogging Thermopump Safety automatics Heating rod V-belt drive Coupling and alignment Valve seats Cylinder linings Pistons, gudgeon pins and gudgeon pin bearings Piston 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)

6.5 Finish off with a pressure drop test.

7 8

37500 25000 As for service no. 5 45000 30000 As for service no. 4

52500 35000 As for service no. 3 60000 40000 Major overhaul; contact SABROE Refrigeration

Then repeat scheduled services from no. 3 inclusive.

0178-910-EN

Page 47

Lubricating oil

Lubricating oil requirements

Above all, the refrigerator oil must provide satisfactory lubrication of the compressor, even at the relatively high temperatures occurring during compression. It must be incapable of coking at such high temperatures and must not precipitate solid constituents such as paraffin or wax at the lowest occurring temperatures. The oil must not have any corrosive effect, whether alone or mixed with refrigerant. According to the oil companies the oils mentioned in the Oil Recommendation in this instruction manual comply with these conditions. See section on Choice of

lubricating oils.

General rules for use of lubricating oil in refrigeration compressors

S The refrigeration oil must be free of mois-

ture, which may give rise to operating malfunctions and attacks of corrosion.

The oil should therefore be purchased in containers corresponding to the quantity to be used for a single, or at most, two top-ups. The oil containers must be kept carefully sealed. If all the oil in a container is not used in one go, the container should be tightly sealed and stored in a warm place to prevent the absorption of moisture.

Note:

It is inadvisable to reuse oil which has been drawn from a compressor or plant. This oil will have absorbed moisture from the air and may cause operating problems. Always switch off the power to the heating rod before drawing off the oil.

S Only fresh, clean refrigeration machine oil

may be charged. Oil tapped from the

evaporator system in an ammonia plant must not be reused in the compressor.

S Use grade of oil originally prescribed for

compressor.

S As far as possible, avoid mixing different

types of oil. Mixed oil is generally inferior to the two original oils. Mixing various types of oil may give rise to formation of sludge, which will lodge in valves and filters.

S If necessary to switch to another brand of

oil, this must be done at the same time as completely changing the oil in the compressor and tapping off all oil from the refrigeration plant.

If, after reading the above, any doubt exists as to the type of oil which has been used on your compressor, you are recommended to contact SABROE, rather than risk charging with unsuitable oil.

Instructions for choosing lubricating oil for refrigeration compressors

The instructions in Choice of lubricating oils offer more detailed guidelines for choosing the lubricating oil best suited to each individual case on the basis of the anticipated operating conditions.

Charging refrigeration compressor with lubricating oil

Since all SABROE piston compressors are supplied with a special oil-charging valve on

0178-910-EN

Page 48

the crankcase, refrigeration oil may be topped up while the compressor is in operation.

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

Note:

When charging for the first time, use the oil pump; it goes without saying that the compressor must not be started unless already charged with oil.

S Reduce pressure in crankcase, e.g. by

throttling suction stop valve, until suction pressure gauge shows pressure slightly below atmospheric.

S Fill pipe connected to oil charging valve

with refrigerator oil and insert free end of pipe down into a receptacle containing fresh refrigerator oil.

S Open oil charging valve carefully, thereby

causing external air pressure to force oil into crankcase.

therefore, it is necessary to refill with refrigeration oil after starting up for the first time and after charging with fresh refrigerant.

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

Changing oil in refrigeration compressor

S Cut off power to heating rod. S Close compressor stop valves and valve

in oil return line from oil separator.

S Reduce pressure in compressor crank-

case to slightly above atmospheric by throttling suction stop valve while compressor is running at its lowest capacity stage. Alternatively, raise to slightly above atmospheric pressure by stopping compressor and closing suction stop valve. Pressure in crankcase will then rise gradually.

S Avoid getting air or other impurities

sucked into compressor.

Note:

In order to achieve pressure below atmospheric, it will sometimes be necessary to reset the low-pressure cut-out so that the compressor can aspirate down to this pressure. Remember to reset the pressure cut-out to its normal setting after charging with oil.

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

Note:

Since halocarbon refrigerants such as R22 mix with refrigeration oils, there will always be a good portion of oil blended with the refrigerant in the plant. Often,

S Oil in the crankcase can then be forced

out through drain valve Pos. 23 when compressor is at a standstill.

S Equalize pressure in compressor to atmo-

spheric through purge valve pos. 42. See

section on Environmental protection. S Dismantle side covers. S Replace oil filter cartridge with a new one. S Clean crankcase thoroughly, wiping with a

clean, dry linen cloth (not cotton waste). S Reassemble side covers. S Charge to correct level with fresh, clean

refrigerator oil according to SABROE’s oil

recommendations. S Connect heating cartridge.

0178-910-EN

Page 49

S Connect vacuum pump to compressor and

pump down to 5-7 mm Hg; close off connection.

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

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

S Open discharge stop valve and valve in oil

return line; compressor is then ready for start-up as described in section

General operating instructions.

0178-910-EN

Page 50

Charging the compressor with oil

Compressor

Type Size

BFO

CMO

TCMO

SMC 100

TSMC 100

Mk 3 S-L-E

SMC 180

TSMC 180

Volume of oil

in crankcase

Litres

3 4 5

24 26 28

413

104 106 108

112 116

186 188

1,5

4 5

14 16 18

26 28 30 47 50

80 90

The oil level must be checked with extreme care, particularly when starting and charging with refrigerant.

The oil level must always be visible in the oil level sight glass. The below diagram illustrates, how many litres of oil a drop in the oil level of 10 mm is approximately equal to.

T0177162_0

The volume of oil stated in the table is the amount which must always be present in the crankcase.

As a rule, the compressor should be charged with oil after the plant is started for the first time, as some of the oil – especially on an HCFC installation – will be absorbed by the refrigerant in the plant.

The following determinants decide the total volume of oil a refrigeration plant should contain:

S type of refrigerant

S refrigerant charge (volume)

S size of plant

Compressor

type size

CMO/ TCMO

SMC / TSMC 100 S-L-E

SMC / TSMC

24 26 28

104 106 108

112 116

186 188

10 millimeter

difference in

oil levels equals

~1 litre of oil

~2 litres of oil

~6 litres of oil

180

Assessing the oil

Refrigeration machine oil is a vital part of the compressor, as it not only lubricates and cools the movable parts of the compressor, it also prevents abrasive particles from entering the bearings.

S temperature range in which refrigeration

plant is to operate.

0178-910-EN

An analysis of the oil can give important information on how the compressor is running.

Page 51

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

An oil sample must be drawn off while the compressor is in operation, which gives a representative sample. Before taking the sample, clean the drain valve and tap a little oil off, to prevent any impurities which may have accumulated in the valve or the piping from mixing with the sample.

As a special offer to our customers SABROE has developed an analytical concept, in cooperation with Mobil Oil, which is able to analyse all oil makes. This will mean a uniform reporting of the results.

The analysis allows the following to be determined:

S Whether or not the oil is still usable, if nec-

essary after filtering.

Visual assessment

If you pour the sample into a clean, transparent glass bottle or a test-tube and hold it up to a clear light source, it will be easy to assess the quality. You can also compare the sample with the fresh oil of the same make and grade.

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

S be clear and shiny S not contain any visible particles S feel viscous, smooth and greasy when a

drop is rubbed between two fingers.

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

Warning

If the oil sample is poured into a glass bottle, this must not be hermetically sealed until all the refrigerant in the oil sample has evaporated. Refrigerant in the oil may produce excess pressure in the bottle with subsequent risks of explosion. Never fill a bottle up completely. Do not send glass bottles through the postal service – use purpose-made plastic bottles. Please see below.

S Whether solid particles possibly present in

the oil originate from the bearings or other components exposed to wear and tear in which case the compressor must be inspected.

S Each report will include the corresponding

measuring results from the previous 3 oil analyses. In this way you will be able to follow up on the state of both the oil and the compressor from one analysis to the next.

Procedure

S A form set with a plastic sampling bottle

and a dispatching envelope can be requested from the local Sabroe Refrigeration representation.

S The oil sample must be drained from the

cleaned oil drain valve into the sample bottle. Screw the lid loosely on and let the bottle stand for a few hours to enable refrigerant contained in the oil sample to evaporate before sending it to the laboratory.

Analytical evaluation

Naturally, the oil sample can be analysed by the oil company which supplies the oil.

S Please follow the Sampling and Shipping

Instructions enclosed in the form set in

which the addresses of the laboratory in Holland are also mentioned.

0178-910-EN

Page 52

The analysis

The following section states some average values that can be applied in practice. However, you should be on the alert whenever the results of the analyses approach these values. In some cases the water content of 100 ppm in HCFC plants may be too much and thus lead to Cu–plating in the shaft seal. Similarly, a rise in the oil viscosity of max. 65% normally does not cause any operating problems as the refrigerant reduces the oil viscosity in the plant.

Wear particles expressed im ppm, are measured for:

Lead max. 10

Copper max. 10

Silicon max. 25

Iron max. 100

Chrome max. 5

Nickel max. 5

Aluminium max. 10

Tin max. 10 A report is drawn up for every sample re-

ceived. This report indicates:

Kinematic viscocity at +40°C.

Max. indication from the specified value at +40°C stated in the tables of Selecting

lubricating oil for SABROE compressors

–15%

S Acid number (TAN). max.0.1 S Oxidation. max.7 S Water content (ppm). max.100 (HCFC) S Water content (ppm). max.600 (R717) S pH value. min.4 (HCFC) S pH value. min.5 (R717) S Strong acids (SAN). max.0 S The oil is filtered through two filters

(1,2 micron and 5 micron).

specified value +65%

Whether the oil can still be used – without

taking any further action. Whether the oil can be used after it has

been filtered through a very fine filter.

If this is necessary, the oil must be

pumped directly from the compressor unit

through a 3 micron filter and back to the

unit. The system must be completely

closed, to prevent the oil being affected by

moisture in the air. Whether the oil is no longer fit for use. The report will always be sent to the address

stated on the sample label included in the form set. A copy will be sent to SABROE Refrigeration, so that we are in a position to advise you, if required.

0178-910-EN

Page 53

Pressure and temperature settings for SABROE compressor types SMCĆTSMC and CMOĆTCMO

Refrigerant

R22

R134a

R404A

R507

R717

24 bar (standard)

22 bar (special)

12 bar

Safety valve on the compressor

xxx x

High and intermediate cut-out

Low-pressure cut-out

Oil pressure cut-out

Safety equipmentControl equipment

Discharge pipe thermostat

Oil thermostat Thermostat for

compressor cooling Thermo valve for

compressor cooling

Injection valve for intermediate cooling

By-pass valve

KP 5

(KP15)

KP 1

(KP15)

MP 55

KP 98

T(E) X T(E) Y

T(E) F

TEAT

T(E) X TEA

PMC + CVC

Set so that the compressor stops at a pressure 2 bar lower than the

safety valve setting.

Set to a pressure with saturation temp.

x x

C lower than the lowest evaporating5

temperature.

C 80

C 55KP 77

° °

C 45

C-15

x x

Normally set at 4 Change to min. 10 superheat

Factory set.

Factory set. Adjust to min 10°C superheat

Adjust to min 10°C superheat

3,5 bar

* 120 * 150

-25

superheat.

See below.

C 75

0170-012-EN 96.04

Oil pressure regulating valve

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 achieved 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

1) 2)

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

3.5 bar

SMC - TSMC - CMO2 - TCMO2 CMO4

4.5 bar

1.3 bar

0178-910-EN

Page 54

0170-105-EN 96.02

0178-910-EN

Suction gas superheat

Condensing temp. °C

Evaporating temperature

intermediate temperature

barCondensing pressure

°C

20 25

25 30

30 35

35 40

40 45

45 20

20 25

25 30

30 35

35 40

40 45

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

5.7

6.6

7.7

8.8

10.1

11.5

5.7

6.6

7.7

8.8

10.1

11.5

HFC - HCFC

Condensing pressure

R134a R22 R404A/R507 R717

41 45 50 54 59 63

51 55 60 64 69 73

Evaporating temperature

48 57

57 65

65 74

74 82

82 90

90 59

59 68

68 76

76 84

84 92

92 98

°C

61 69

69 77

77 85

85 94

100

72 80

80 88

88 96

103

109

76 84

84 92

92 99

106

112

88 95

102

102 109

109

115

121

101

101 108

108

115

120

120 126

126 103

103

110

110 117

117

123

123 128

128 133

133

intermediate temperature

43 48 53 58 63 67

53 58 63 68 73 77

°C

48 52 58 64 69 74

58 62 68 74 79 84

55 59 66 74 79 82

65 69 76 84 89 92

bar

8.2 9

9.5

11.

11.1

12.7 14

14.5

16.5 8

8.2 9

9.5

11.1

12.7

14.5

16.5

37 47

47 55

55 68

68 72

72 81

81 48

48 57

57 65

65 73

73 82

82 90

Evaporating temperature

intermediate temperature

bar

40 44 49 54 59 65

50 54

64 69 75

42 47 52 57 62 67

52 57 62 67 72 77

11.0

12.5

14.3

16.2

18.2

20.5

11.0

12.5

14.3

16.2

18.2

20.5

46 51 56 61 66 71

56 61 66 71 76 81

°C

Evaporating temperature

intermediate temperature

83 95

106

117

126

83 95

106

116

127

127 136

136

°C

102

113

123

123 133

133 143

143 103

103

114

125

125 134

134 144

144 154

154

bar

53 71 91 110 131

7.6 53 71 91 110 131

9.1

10.7

12.6

14.6

101

16.9

110

7.6

9.1

10.7

12.6

100

14.6

111

16.9

121

121 133

133 141

141 151

151 161

161 122

122 132

132 142

142 152

152 162

162 171

171

142

142 151

151 160

160 170

170

–

143

143 153

153 162

162

–

– –

–

Expected discharge gas temperatures

20 25

25 30

30 35

35 40

40 45

5.7

6.6

7.7

8.8

10.1

11.5

58 64 69 73

61 65 70 74 79 83

63 68 73 78 83 87

68 72 78 84 89 94

75 79 86 94 99

102

8.2 9

9.5

11.1

12.7

14.5

16.5

11.0

12.5

14.3

16.2

18.2

20.5

60 64 69 74

62 67 72 76 82 87

66 71 76 81 86 91

78 86

86 95

101

101 108

108

91 98

106

111

117

69 75

75 84

84 92

92 99

Discharge gas temp. Discharge gas temp.

105

111

118

123

123 128

128

120

120 125

125 131

131 135

135 139

139

°CDischarge gas temp.°C

°C

113

73 78 83 87 92 97

103

°C

82 87 91 95 99

7.6

9.1

10.7

12.6

14.6

16.9

115

106

126

102

118

136

112

128

146

123

138

155

132

148

165

Discharge gas temp.

134

134 144

144 154

154 163

163

–

– –

–

153

153 163

163

°C

–

– –

–

Page 55

Servicing the refrigeration plant

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

Compressor and condenser must be able to work satisfactorily, safety devices must be intact and the evaporator must function under load - that is to say:

S the desired temperatures are observed, S the oil pressure and discharge pipe

temperature on the compressor are correct,

Check Interval Activity

Condensing pressure Excessively high pressure may be

Pressure and temp.

S the condenser pressure is not excessively

high, and

S the plant otherwise works as it is sup-

posed to.

The service instructions outline some general guidelines for servicing the refrigeration plant, with some references to the instruction manual. The service instructions should therefore be read and followed carefully.

due to:

• reduced cooling effect

• air in the condenser.

Daily

Too low condenser pressure implies a risk of restricting the refrigerant supply to the evaporator.

0171-470-EN 97.07

Filters

Dehumidifier

Discharge pipe temperature

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

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

Clean when needed

When needed

Normal discharge pipe temperature acc. to instructions.

Accumulated dirt causes reduced refrigerant supply to the evaporator.

If a filter has a hot inflow and cold discharge, this may be due to clogging of the component.

Some installations are provided with a sight-glass featuring moisture indicator; if the indicator colour switches from green to yellow, there is moisture in the refrigerant.

Change the drying filter regularly.

0178-910-EN

Page 56

Refrigerant

Check Interval Activity

Refrigerant charge Inadequate charge results in re-

duced plant capacity and often leads to an excessively high discharge pipe temperature.

Leak detection

Periodically

The plant must be searched regularly for leaks. Flanges and joints settle during the plant’s initial operation period. They must therefore be tightened and checked.

Automatic controls

Electric motor

Condenser

Safety pressure controls Automatic operating controls Alarms

Lubrication of electric motors

Alignment of coupling V-belt drive

Corrosion Marine condensers are normally

Periodically

Periodically – normally min. 4 times a year

Adjust operating point and check the function. Replace switch system if sticking.

Clean and lubricate according to supplier’s instructions. At temperatures lower than -25°C, use special lubricant.

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

protected against galvanic corrosion by the mounting of corrosion plugs in the condenser covers.

Metallic contact between corrosion plug and cover is essential to proper functioning.

Evaporator

0178-910-EN

Frosting-up Problem-free operation is condi-

When needed

Oil draining (ammonia plant) Check evaporator, intermediate

Periodically

tional on the evaporator being kept free of ice. Defrost as and when required.

cooler, receiver, etc. for oil accumulation. Exercise caution; use a gas mask.

Page 57

Maintenance of reciprocating compressor

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

General

When the compressor requires maintenance, it is important to follow the instructions given below. In order to make sure that the compressor is working correctly, the gauge measurements and screw torques must be strictly adhered to. Before opening the compressor, it is expedient to ensure that you have spares of those seals and gaskets to be stripped down or dismantled. An O-ring which has been exposed to oil and heat for any length of time may have expanded so much as to prevent it being refitted. All seals and gaskets used are resistant to oil, HFC/HCFC and ammonia. All O-rings are made of neoprene rubber.

Pump-down

Before opening up the compressor for inspection, the pressure inside must be lowered to slightly above atmospheric. This can be done in the following way, depending on whether the compressor is operational or defective.

1. If the compressor is operational

Run the compressor at minimum capacity at normal operating temperature.

Adjust the low-pressure cut-out so that the compressor stops at a suction pressure of approx. 0.1 bar.

the oil time to escape without the oil foaming. This is of great importance in compressors running on HFC/HCFC. An ammonia compressor can stand having the pressure reduced somewhat more quickly without the oil foaming.

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

S Close suction stop valve. S Cut off power to compressor motor. S Close discharge stop valve. S Draw off last remains of refrigerant gas

through purge valve Pos. 42.

S Having ensured that power to compressor

motor cannot be inadvertently connected, the compressor is ready for opening.

S Remove all fuses, if any.

2. If the compressor is inoperative

S Leave heating rod in crankcase connected

for a couple of hours before compressor is due to be opened in order to heat up oil. Warm oil does not contain as much refrigerant.

S Suction stop valve must be open while

heating rod is connected.

S Keep discharge stop valve closed.

0171-468–EN 00.01

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

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

S Close suction stop valve and disconnect

heating rod.

S Equalize pressure in compressor through

purge valve Pos. 42.

0178-910-EN

Page 58

S Once pressure has been equalized to at-

mospheric, compressor is ready for opening. Remember to make sure that power cannot be inadvertently connected, thereby starting the motor.

S Remove all fuses, if any.

Dismantling and assembly

The following sections describe the individual components. When dismantling and assembling, parts should generally be fitted in the same position from which they were taken, and should therefore be marked as they are removed. Further they should be thoroughly cleaned, checked and lubricated prior to being reassembled.

Top covers

Dismantling top cover

Before dismantling the top cover, the relief mechanism must be deactivated; this is done by dismantling the short plug Pos. 12D and mounting the long plug from the tool kit instead. This moves the piston Pos. 12B to the opposite end of the relief cylinder.

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

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

Fitting top cover

Before fitting the top cover, the long plug must be fitted into the relief cylinder. Check, in addition, that the gasket Pos. 2C is intact and, if necessary, check that the clearance volume and lifting reserve have been adjusted as described later on in these instructions.

If the gasket Pos. 2C needs to be replaced at all, the graphitized side must face the compressor frame. After placing the top cover loosely on top of the springs Pos. 21, it is recommended that all screws be mounted by hand, as they will jointly guide the top cover into position. Now tighten the top cover firmly with the two screws mentioned above, then with the remaining ones.

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

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

0178-910-EN

713 5

842 6

13 14

Once the top cover has been fitted, remove the long plug and insert the short plug. The top covers must be mounted as shown on the following chart.

Page 59

Mounting top and water covers

SMC 112 SMC 116 TSMC 116

SABROE

SMC 104 SMC 106

SABROE

Shaft end

SABROE

SMC 108 TSMC 108

SABROE

Shaft endShaft end

SABROE

Control end

Shaft end

Water covers

Right top covers

SABROE

Left top covers

SABROE

Shaft end

Side covers

T0177092_0

0178-910-EN

Page 60

Discharge valve

20E

20D

Pos. 20

20B 20A 20C 20G

As shown on the above drawing, the function of the discharge valve Pos. 20 is partly to allow the compressed gas to pass from the compression chamber of the cylinder to the discharge chamber beneath the top covers and partly to create a seal from the discharge chamber to the cylinder.

Furthermore, the discharge valve acts as a safety device in the event of liquid refrigerant passing the valve together with the discharge gas, also called liquid stroke. Such stroke should normally not occur, as liquid cannot pass the valve as quickly as the compressed gas. This produces a violent increase in pressure in the compression chamber.

In order to avoid pressure of such intensity that it may damage the bearings in the compressor, the discharge valve is retained in position by the safety spring Pos. 21, which allows it to lift a little under the strain of increased pressure.

Liquid strokes are heard as a distinct hammering in the compressor; the cause must be found immediately and the malfunction rectified.

20F

Discharge valve types:

Depending on the refrigerant and operating conditions under which the compressor operates, various discharge valves need to be used to achieve an optimal function. The discharge valves are selected as shown in the diagram below on the basis of the condensating or intermediate pressure temperature.

Refri-

gerant

R717

HFC/

HCFC

15°C v TC <

TC w

Marking

All pressure valves supplied from SABROE today are marked as described below and shown on the sketch.

Refrigerant R717 : All discharge valves are marked with one

groove.

Conditions Valve

TC w 15°C

45°C R404A-R507 50°C R22 70°C R134a

type

LPTC t 15°C HP LPTC t 15°C

VHP

0178-910-EN

Page 61

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

S Tighten bottom nut Pos. 20E to torque of

10.2 Kpm ≅ 100 Nm. If need be, exert counterpressure with 5 mm Allen key on bolt head.

Marked with LP-HP or VHP

Marked with one groove for R717

two grooves for HFC/HCFC

Dismantling

S When top cover has been removed, spring

Pos. 21 and discharge valve Pos. 20 can be lifted out by hand. See dismantling of top cover.

S Tighten discharge valve in a soft-jawed

vice, then dismantle two nuts Pos. 20E together with spring guide Pos. 20F.

S Fit spring guide Pos. 20F and tighten top

nut to same torque: 10.2 Kpm ≅ 100 Nm.

Tightness testing of discharge valve

This is done by means of the pressure drop test as described elsewhere in this instruction manual.

Service life of discharge and suction valves

In order to ensure that the compressor always works perfectly, it is advisable - at suitable intervals - to replace the suction and discharge valve ring plates.

It is difficult to give altogether precise times for such replacements, as the durability of the valve ring plates depends on the following factors:

S Screw Pos. 20D, discharge valve seat

Pos. 20A and ring plate Pos. 20C can now be disassembled by hand.

S Remove valve springs Pos. 20G by hand.

Assembly

Before assembling the discharge valve, you must make sure that the valve springs Pos. 20G are in good order and fixed firmly in their apertures.

Assemble the discharge valve in reverse sequence to that described above. Note the following, however:

S If the compressor is exposed to liquid

stroke or moist refrigerant gas, the service life is reduced.

S Speed of the compressor:

At 900 rpm, the service life of the valve ring plates is considerably longer than at 1500 rpm.

S The compressor ratio at which the com-

pressor operates: At high compression ratios, the load on valve ring plates and springs is appreciably larger than at low compression ratios. When the valve ring plates are changed, the valve springs should also be replaced.

0178-910-EN

Page 62

Cylinder lining with suction valve

Marking of suction valve stop:

Marking of suction valve

Dismantling suction valve

Dismantling the screws Pos. 19N makes it possible for the guide ring Pos. 19J, suction valve stop Pos. 19H and ring plate Pos. 19F to be removed from the cylinder lining. The paper gasket Pos. 19T can be expected to disintegrate during dismantling and require replacement.

Mounting suction valve

one groove for R717 two grooves for

HFC/HCFC

T0177131_0 v3

The cylinder lining and suction valve form an integral unit which can be dismantled by removing the screws 19N.

In order to gain access to the cylinder lining or suction valve, the top cover, spring Pos. 21, and discharge valve Pos. 20 need to be disassembled.

Extracting cylinder lining

S Rotate crankshaft to position relevant pis-

ton at top dead centre.

S Fit the two T-shape extractors no. 3 from

tool kit into threaded holes in guide ring Pos. 19J.

Before reassembling the suction valve, you must ensure that the valve springs Pos. 19G are in good order and fixed firmly in their apertures.

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

S Change paper gasket. S Before tightening screws 19N, ensure suc-

tion valve plate can be moved freely in its guide. Tighten screws Pos. 19N to torque of 1.4 Kpm ≅ 14 Nm.

Inserting cylinder lining

S Rotate crankshaft to position piston at top

dead centre.

S Check that long plug from tool kit is

screwed into relief cylinder; see Top cov-

ers section.

S Check that gasket Pos. 19K is in position

on frame.

S Carefully pull out cylinder lining with suc-

tion valve, checking that gasket Pos. 19K remains in frame.

S Insert protective plate no. 5 (from tool kit)

between piston and frame so the piston can rest on it. This will enable piston and piston rings to slide onto the protective plate without being damaged when the crankshaft is turned.

0178-910-EN

S Lubricate piston, piston rings and cylinder

face with clean refrigeration machine oil. Likewise, grease O-ring Pos. 19M on HP cylinder of TSMC compressor with clean refrigeration oil.

S Rotate piston rings on piston in order to

stagger ring gaps at 120° to each other. Press cylinder lining down over piston carefully. The chamfering on the cylinder

Page 63

interior will catch the piston rings and squeeze them to the diameter of the cylinder. If possible, fit cylinder in same place from which it was taken.

S Press cylinder lining down manually, and

with no rotary movements, until it makes contact with gasket Pos. 19K.

S Check clearance volume, which is de-

scribed in section Control measurements

for insertion of new cylinder lining.

S Discharge valve Pos. 20 and safety head

spring Pos. 21 can then be fitted.

S Fit gasket and top cover.

S Once top cover is in position - see Top

covers section - remove long threaded plug and screw in short plug, having first checked aluminium gasket Pos. 12E and found it fit for use.

Connecting rod

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

Procedure for removing piston and connecting rod

S Bleed compressor of oil and refrigerant

and safeguard against any unintended start-up.

S Disconnect any water hoses and other

piping connections to top and side covers.

S Dismantle top and side covers.

S Remove spring Pos. 21, discharge valve

and cylinder liner.

S Remove nuts Pos. 17D; following this, the

bottom part of the connecting rod can be taken out by hand.

S Piston and connecting rod can then be

lifted out through the top cover opening on the frame.

The connecting rod Pos. 17 is equipped with independent bearings at both ends. The big end is fitted with two bearing half bushes Pos. 17A, consisting of a half-cylindrical steel plate internally coated with white metal. These bearing half bushes are secured in the connecting rod, partly through their fit in the connecting rod bore and partly by a spring which fits into a milled groove in the connecting rod. The opposite end of the connecting rod is fitted with the gudgeon pin bearing Pos. 17B, of which the following two types are found: See spare-parts drawing.

S The bearing bushing Pos. 17B-1 is made

of special bronze and is also used in R717 compressors. The bearing bushing is used in all SMC compressors and in the low pressure stage on TSMC compressors.

S The needle bearing Pos. 17B-2 is 2 mm

greater in outside diameter than the above bearing bush and must therefore be fitted in a piston rod bored to the diameter of this bearing. The needle bearing has no inner ring but fits the diameter of the gudgeon pin directly.

S If the bearings in the connecting rod are

worn so that the clearance is greater than that prescribed in the table entitled Vari-

ous clearances and adjustment measurements, they must be replaced with new

bearings. In this connection, note that undersized half sections of bearing can be supplied for use in the crankshaft where the journals have been ground to a corre-

0178-910-EN

Page 64

sponding undersize. See table in section on Diameters for undersized bearings.

Fitting bearings

S The bearing bushing or needle bearing

can be squeezed into or out of the connecting rod in a vice or hydraulic press. Use softjaws in the vice and use tools which do not damage any components. The bearing bushing must be fitted as shown on the sketch, with the lubricating ducts facing sideways.

Fig. 1

Note:

Sleeve to be fitted with lubricating ducts positioned as shown on drawing.

T0177131_0 v2,a

S Introduce connecting rod down through

top cover opening in frame and guide into position on crankshaft manually. Take care so that connecting rod bolts do not leave marks in crankshaft journals.

S Position connecting rod interior through

lateral opening on frame, and fit nuts.

Note:

The two parts of the connecting rod are numbered with the same number; this is only of importance when assembling. Parts with different numbers must not be assembled and it is important that the numbers are fitted in the same direction as shown in Fig. 2.

Fig. 2

Note:

Stamped number on the same side on assembly

Fitting connecting rod

Before fitting the connecting rod in the compressor stand, piston and piston rings must be fitted onto the connecting rod. See the following sections. In addition, the two connecting rod bolts Pos. 17C must be fitted as shown on the spare parts drawing.

S Fit bearing bushes into both parts of con-

necting rod.

916 916

T0177131_0 v2,b

S Tighten nuts Pos. 17D alternately with in-

creasing torque and finish off with torque wrench. Torque: 4.4 Kpm ≅ 43 Nm.

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Page 65

Piston

The piston is made of aluminium and fitted with two piston rings, nearest the piston top, and an oil scraper ring.

Fig. 3

For compressors with: 80mm stroke lengths, type S, 100mm stroke lengths, type L, and with 120mm stroke lengths, type E. The difference is clearly seen from fig. 3.

Piston

Type S

120

Piston

Type L

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

Fitting piston rings in piston

Before mounting the piston rings in the piston, their fit in the cylinder lining should be checked by measuring the ring gap. See section entitled Various clearances and adjust- ment measurements.

Piston

Type E

110

T0177131_0 v1

S Fit one of the circlips pos. 18D into bore

reserved for piston pin.

S Heat piston to 70°C in oil or on hotplate. S After inserting bearing bush or needle

bearing, guide connecting rod into place in heated piston. The piston pin can now be positioned without the use of tools. It is sometimes possible to fit the piston rod by hand without a preliminary heating of the piston.

100

Assembling and stripping down piston and connecting rod

Adopt the following procedure when assembling piston and connecting rod:

S Fit last Seeger ring To strip, reverse sequence; however, do not

heat piston, but press piston pin out using a punch or mandrel.

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Shaft seal

10F 10D 10E 10H

10J 10A

5.5 mm 8C

2 mm

8A 8F

10G 10B

8G 8B

3126-176-R

The purpose of the shaft seal is to create a tight seal along the crankshaft between the inside of the compressor and the atmosphere.

It comprises a slide ring Pos. 10E, manufactured from special-purpose cast iron, which is secured to the crankshaft by means of the locking ring Pos. 10H, tightening flange Pos. 10A and the four screws Pos. 10J with spring washers Pos. 10K.

The carbon slide ring Pos. 10F is pressed against the flat-machined, lapped slide ring at the end of Pos. 10E by a series of springs Pos. 10B. The carbon slide ring is prevented from rotating by means of the retention pin Pos. 8H.

T0177131_0 V13

It is recommended to exercise great care with the lapped slide surfaces. Even the slightest scratch or other damage to the slide surfaces will result in leaks.

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

When the shaft seal is operating, a tiny amount of oil drifts out between the slide faces to lubricate them. An oil throw ring Pos. 8F has therefore been fitted to prevent this oil migrating along the axle to the transmission linkage.

The spring pressure, combined with the flat-lapped faces of the two slide rings, ensures an optimal seal between the faces, either when rotating or stationary.

0178-910-EN

The thrower ejects the oil into the groove in the shaft seal cover Pos. 8A and the oil is piped via the plastic hose to a plastic bottle positioned under the compressor.

Page 67

1. Dismantling and stripping down shaft

seal

1.1.Once the gas pressure in the compressor has been eliminated and the motor safeguarded against inadvertent start-up, dismantle coupling or V-belt disk.

Fig. 3

10G 8A8G 10F

•

Note:

On units featuring coupling, there is no need to move the motor, as the coupling and the shaft seal can be taken out between the two shaft ends.

1.2.Dismantle shaft seal cover Pos. 8A by alternately loosening bolts Pos. 8C so as to displace shaft seal cover outwards without jiggling. This will avoid damage to internal parts of the shaft seal.

1.3.Once the spring force is equalized and the bolts removed, the shaft seal cover can be taken off the shaft end by hand. Take care so that no damage is done to the carbon slide ring Pos. 10F which comes out with it.

1.4.The carbon slide ring Pos. 10F can be extracted by dismounting circlip pos. 8G as follows:

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

•

1.5.Dismantle slide ring 10E by turning the four Allen screws 10J a max. of 2-3 turns; the entire unit can then be taken out with the fingers or using two screwdrivers inserted into the external groove on the slide ring Pos. 10E and moved in the direction of the arrow as illustrated in fig. 4.

Fig. 4

10A

Take care not to tighten screw A too much as this could damage the carbon ring.

Circlip pos. 8G is now easily extracted by means of a screw driver without damaging the slide surface of the carbon slide ring.

After removing tool no. 2, the carbon slide ring pos. 10F, O-ring pos. 10G and springs pos. 10B (see fig. 2) can now be dismantled.

•

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 and free of scratches, blows and wear marks. Then oil the crankshaft and the shaft seal components thoroughly with the same type of oil as used in the compressor.

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2. Unit with slide ring, Pos. 10E

2.1.Before fitting slide ring Pos. 10E, tighten screws Pos. 10J until there is approx. 2 mm spacing and parallelism between the two flanges. Check also that locking ring Pos. 10H is mounted as shown in the drawing and that O-ring Pos. 10D is in position.

2.2.Position slide ring Pos. 10E on shaft and ensure tightening flange makes contact with shaft shoulder.

2.3.Crosswise, tighten screws Pos. 10J alternately with Allen wrench from tool kit. The torque is specified in the instruction manual.

2.4.Check axial position of shaft seal by measuring distance from frame sealing face to slide face on Pos. 10E. This must measure approx. 5.5 mm, as shown in the drawing.

3. Unit with shaft seal cover Pos. 8A

3.1.Mount O-ring Pos. 10G and the ten spiral springs 10B in shaft seal cover Pos. 8A, then position carbon slide ring Pos. 10F carefully. Rotate carbon slide ring so slot fits in over retention pin Pos. 8H.

3.2.With tool no. 2 fitted as shown in fig. 3 press carbon slide ring pos. 10F against spring pos. 10B. Locking ring Pos. 8G can now be fitted. Observe closely that the carbon slide ring is not overloaded by misbalanced pressure and that its slide face is not damaged.

3.3.Give complete shaft seal cover an extra oiling on slide face of carbon slide ring and guide it in over shaft together with gasket Pos. 8B.

3.4.Gently pressing shaft seal cover and carbon ring in against slide ring Pos. 10E without compressing springs Pos. 10B,

measure distance from gasket Pos. 8B to sealing face of shaft seal cover. This distance must be about 3 mm. Make sure the hose branch Pos. 8D faces down.

3.5.Mount screws Pos. 8C and tighten evenly, crosswise. This will avoid damaging the carbon slide ring. Tighten screws Pos. 8C to prescribed torque according to table in instruction manual.

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

3.7.After mounting coupling half or V-belt disk, it must be possible to turn the crankshaft easily by hand.

Crankshaft

The crankshaft is made of heat-treated SG cast iron with fine strength and glide properties. The bearing journals are superfinished and oil channels are bored for all lubricating points.

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

When fitting the crankshaft, it should be checked that the plugs are mounted and tightened. By way of bores in the counterweights, the crankshaft is dynamically balanced with regard to 1st and 2nd order forces.

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 E stamped into the connecting end.

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Page 69

Dismantling crankshaft

Inspection

Dismantle the crankshaft through the pump end of the frame in the following way:

S Bleed compressor of oil and refrigerant

and safeguard against inadvertent start-up.

S Dismantle top and side covers. S Dismantle all cylinder linings. S Extract all pistons and connecting rods. S Pull off V-belt pulley or coupling half . S Dismantle shaft seal cover and shaft seal. S Dismantle cut-outs and pipes to manome-

ters, or piping connections to UNISAB.

S Dismantle end cover, Pos. 4A. S Dismantle oil filter.

Check bearing journals on connecting rods for wear and tear and, if necessary, measure diameter of journals. The maximum wear on the bearings is shown in the section Various clearances and adjustment measurements. In most instances, the permissible play in the bearing can be obtained by replacing the bearing half bushes. The bearing journals on the main bearings are normally subject to very little wear, but should be check measured during main overhauls. If wear and tear exceeds the play stated, the crankshaft can normally be ground to 0.5 mm undersize. For the ground crankshaft, main bearings and connecting rod bearings with an undersize of

0.5 mm can be supplied as stated in the parts list.

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

S Dismantle oil pump drive and oil pump. S On SMC/TSMC 112-116 loosen the

middle bearing by dismantling the plugs pos. 49H as well as gasket pos. 49J in both sides of the compressor. Next, dismantle screws pos. 49F and locking plates pos. 49G.

S Rotate crankshaft to place connecting rod

journals on horizontal level.

S Dismantle bearing cover at pump end and

support the crankshaft by means of a board inserted through the side openings.

S After this the crankshaft can be drawn out

of the framne. The crankshaft must still be supported.

S The middle bearing on SMC/TSMC

112-116 can be dismantled by removing

screws pos. 49B and shims pos. 49C as well as guide pins pos. 49D.

Note:

After grinding the crankshaft, all lubricating channels must be thoroughly cleaned with an approved cleansing fluid and blasted with compressed air. Remember to refit the blind plugs.

S Check sealing face for O-ring seal, Pos.

10D, on shaft seal. The surface must be bright and free of scratches and marks.

Refitting crankshaft

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

S After the crankshaft has been inserted into

the housing, mount main bearing cover Pos. 5A using gasket Pos. 5D as a shim.

S Check end play on crankshaft by pressing

shaft up against pressure bearing Pos. 6C and measure clearance in the other bearing, using a feeler gauge.

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Page 70

The permissible end play is indicated in the section Various clearances and adjust-

ment measurements.

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

The gasket can be supplied in the following thicknesses, see the spare parts list:

0.25mm 0.50mm 0.75mm 1.0mm

Main bearings

The main bearings pos. 5C and 6C are mounted on the main bearing covers and their purpose is to guide the crankshaft both radially and axially.

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

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

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

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

Fig. 1

Mounting of bearing bushing pos. 6C

12 o’clock

4 o’clock

Cover pos. 6A seen from the inside of the compressor

T0177167_0

The bearing bushings can be delivered with crankshafts ground to undersize. See Spare Parts List.

The crankshaft for the SMC 112 and 116, and for the TSMC 116, is fitted with a centre bearing. This is fitted with four sets of bearing half bushes of the same type as used in the connecting rods. The centre bearing housing is made up of two half parts which must be clamped around the crankshaft before this is inserted into the compressor stand.

The half parts are assembled by means of four screws and guided together with the aid of cylindrical guide pins. The bearing housing is prevented from rotating by two screws Pos. 49F. These screws are accessible only when the threaded plug Pos. 49H has been removed. The screws can be removed using a box wrench NV 17 and crank from the tool set.

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Compressor lubricating system

19D 15D

19B 15A 15B

The oil pump pos. 11 sucks oil from the crankcase, 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. The pump forces the oil through an internal pipe, pos. 38A, until it reaches the shaft seal housing.

The filter element Pos. 33A is a disposable filter which cannot be cleaned. See description of oil filter.

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

38A

33A

33J/K

T0177131_0 V10

Excess oil is returned through a bored channel to the crankcase.

From the shaft seal housing, the oil is distributed as follows:

S Through the bored channels in the crank-

shaft to lubricate main and connecting rod bearings. Lubrication of piston pin bearings is done by splash lubrication through a countersunk hole in the top of the connecting rod.

S To the differential oil pressure cut-out and

the pressure gauge. The effective oil pressure can be read straight off the manometer (the suction pressure gauge of the compressor).

S Through external oil pipes, on to the regu-

lating cylinders Pos. 12 for unloaded start and capacity regulation.

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Page 72

Oil pump

11H 11Q

11R 11G

11T11M 11J

11L 11N

•

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

It is therefore important to ensure that the direction of rotation of the crankshaft is as indicated by the arrow on the bearing cover Pos. 6A.

If the crankshaft is to turn in the opposite direction of rotation, the oil pump can be fitted with a chain drive. See next section.

•

11P 11S

S When the four M6 screws pos. 11M secur-

ing the oil pump to the bearing cover have been removed, it can be taken out by hand.

Note:

The oil pump normally has a very long service life. Therefore, it is not worthwhile repairing it. Rather replace it with a new one.

Dismantling the oil pump

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

S Dismantle end cover Pos. 4A and side

covers Pos. 3.

S Dismantle internal oil pipes and nipples

screwed into pump.

S Dismantle nut Pos. 11J and extract gear-

wheel pos. 11G.

0178-910-EN

Mounting the oil pump

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

The play between the two teeth when engaged must be 0.05-0.08mm measured with a feeler gauge. Repeat the measurement six times, turning the crankshaft 60° between each measurement, and adjust until the smallest play is measured to be as started above.

Page 73

Chain-driven oil pump with inverse direction of rotation

If the SMC 100 compressor is to run in the opposite direction of rotation to that shown by the arrow on the bearing cover Pos. 6A, the gearwheel drive on the oil pump must be replaced with a chain drive.

To this end, use a set of replacement parts,

5 3 1

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 all screws needed.

In case the compressor is driven by an electric motor, attention should be paid to the prescribed direction of rotation of the motor. See section: Direction of rotation of the com-

pressor.

7 8

4 2

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 all types of SMC/TSMC compressor. On older compressors, however, a little adjustment may be necessary, as detailed below:

S Dismantle the two gear wheels by remov-

ing screws Pos. 11Q and nut Pos. 11J.

S On older compressors, the oil pump is

linked to the principal bearing cover Pos. 5A by 2 guide pins and retained by four M6 screws. Remove two guide pins here and bore the free holes for screws up to a diameter of 8 mm. This should be done after the oil pump has been dismantled. On more recent compressors, the free

0178-910-EN

Page 74

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

S Mount lubricating oil baffle as shown on

drawing. Drill two M6 threaded holes and tap, using baffle as template; position so that the baffle is at a tangent to the external diameter of the bearing bush D = 92 mm.

D92

T0177085_0

Adjusting the chain drive:

S Tighten chain by shifting oil pump. The

correct tension of the chain is shown on the sketch.

3.5 – 5.5mm

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

S Slightly tighten four screws securing oil

pump to bearing cover.

S Place chain wheel with hub Pos. 4 and 2

on pump shaft. The retainer nut can be tightened once the entire chain drive has been mounted.

S Place the assembled chain, hub and chain

wheel, Pos. 5, 1 and 3, in position; tighten wheel firmly with screws Pos. 11Q from gearwheel drive.

T0177085_0

Finally, when the proper centre distance has been established, secure oil pump tightly.

S Tighten chain wheel on oil pump.

Marking direction of rotation

The arrow on the end cover of the compressor should be cancelled out and replaced by one painted on the indicate the new direction of rotation.

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Page 75

Oil pressure valve

The oil pressure valve pos. 22 regulates the oil pressure in the compressor. Mounted in the cover Pos. 6A, it connects directly with the oil pressure chamber in the shaft seal housing.

The oil pressure is regulated by a spring loaded cone, the spring pressure being adjusted by turning an adjusting screw at the valve end. Use a screwdriver for this purpose.

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

Adjustment

Oil pressure: 4.5 bar. The oil pressure can be read off the suction

pressure gauge or on UNISAB II.

On more recent compressor models the adjusting screw may be locked by means of an M6 pointed screw, fig. 1, which must be loosened before adjustment can take place.

Service

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

Fig. 1

locking screw

In the event of a malfunction, the complete valve should be replaced.

22A

22B

T0177083_0

0178-910-EN

Page 76

By-pass valve pos. 24

The compressor is equipped with a built-in mechanical by-pass valve, fig. 1, which safeguards it against any inadvertent excess pressure if the electrical safety equipment fails. The by-pass valve safeguards against any excess pressure between the discharge and suction sides of the compressor.

If the by-pass valve goes into action, the compressor must be immediately stopped and the cause established.

The by-pass valve is supplied ready-set and sealed in accordance with the adjustment pressures indicated in the table Pressure and temperature settings. The actual set pressure is stamped on the rating plate, pos. A.

Thus, watch out that hole pos. B does not get covered or clogged.

In case the pressure on the discharge side exceeds the set pressure so that the by-pass valve opens, the valve will remain open until the pressure on the discharge side has fallen to approx. half the set pressure. The valve then closes automatically. However, at great differential pressures across the compressor the valve may remain open. In that case, stop the compressor and close the discharge stop valve entirely. The equalization of pressure in the compressor will then close the safety valve and the compressor can be restarted.

The by-pass valve is supplied factory-set and sealed and need normally not be disassembled and readjusted.

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

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

Fig. 1

•

If necessary, control of function and set pressure must be made in accordance with local regulations for safety valves.

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

24C 24B

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T3137T02I_1

Page 77

Oil filter

All oil to the lubricating system of the compressor is filtered through a oil filter installed in the crankcase. The filtration element is a filter cartridge (Pos. 33A on the drawing) which is non-cleanable and must be replaced with a new one when the filter capacity is used up.

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

Filter cartridge

As shown in fig. 1 the filter cartridge pos. 33A is a single unit consisting of a 60 m primary filter, a magnetic filter and a shield which covers half of the filter.

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

Changing filter cartridge

The filter cartridge should be replaced at regular intervals. See the section entitled Servic- ing compressors on this point. In particular, it should be remembered that the filter cartridge must often be replaced after a relatively short operation time following initial startup.

This is due to small particles of dirt originating from the plant during the initial operating period.

Fig. 1

33L

33F 33M

Before changing the oil filter cartridge all preparations in connection with the opening of the compressor must be carried out in accordance with the instruction manual.

33A33B

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

Proceed as follows:

S Dismount the lock nut pos. 33M and

washer pos. 33L and remove manually the

S Let the bracket pos. 33F stay mounted in

the compressor.

0178-910-EN

Page 78

S When mounting the new oil filter cartridge

as illustrated in Fig. 1, first place the gasket pos. 33B on the bracket pos. 33F.

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

S Then place the oil filter cartridge pos. 33A

on the bracket pos. 3Fand turn it so that

S Tighten the nut pos. 33M to a torque of

4.5 Nm.

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Page 79

Suction filters

The purpose of the filters is to collect impurities conveyed from the plant to the compressor with the suction gas and thus prevent them from penetrating into the compressor.

The suction filters therefore have a very fine mesh and as an additional precaution have a filter bag insert, which should normally be used for 50 operating hours from the initial start-up of the compressor. The filter bag is then removed and disposed of.

If the filter bag is badly soiled after the 50 operating hours mentioned, it is recommended that a new bag be fitted for an additional 50 operating hours. Similarly, a filter bag ought to be fitted for a period of 50 operating hours after any major repair work to the refrigeration plant.

Note:

Do not forget to remove the filter cartridge after 50 operating hours, as a blocked filter bag may cause the suction filter to burst and thus contaminate the compressor to an extreme degree.

There are always two suction filters in the compressor and these are removed through the flanged opening in the bottom end of the filter housing. Attention is drawn to the fact that there are two types of suction filter, as detailed below:

On SMC compressors, the two suction filters are identical and should only be fitted with an O-ring in the end facing up towards the suction stop valve. The filters are open at both ends.

TSMC 108

LP HP

On TSMC compressors, the suction filter

located on the lefthand side opposite the lowpressure 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.

TSMC 116

LP HP

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.

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Page 80

Stop valves

AK AC A AJ

D C

H Y

POS. 25

ZAGQGN

The suction and discharge stop valves are used to isolate the compressor from the refrigeration plant.

They are closed completely by manual tightening and it is therefore advisable not to use any tool to close the valve, as this will simply overload the valve parts.

The valve seat is sealed with a teflon ring Pos. 25H which, if necessary, can be replaced as follows:

Dismantling of valve:

S Once the pressure on the inlet and dis-

charge sides of the valve has been equalized to atmospheric, dismantle screws Pos. 25AJ. The valve throat Pos. 25B, and with it the entire valve insert, can then be removed.

S Turn spindle clockwise until cone and

threaded piece Pos. 25G can be removed by hand.

T0177131_0 V14

S Mount threaded piece Pos. 25G in a

soft-jawed vice and dismantle screw Pos. 25E.

Note:

The screw has a lefthand thread, and it is therefore inadvisable to leave the threaded piece in the valve holder while dismantling the screw, as the guide pin Pos. 25N will be overloaded.

S The front and rear pieces Pos. 25C and

25D can now be separated and the Teflon ring Pos. 25H removed. The Teflon ring will be flattened on one outer edge, which is normally of no importance to its sealing ability providing it is free of scratches and marks.

S If required, the Teflon ring can be reversed

when reassembling so that the other outer edge seals towards the valve seat in the housing.

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Page 81

Reassembly of valve:

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

S Before mounting the complete valve in-

sert, the valve cone with threaded piece Pos. 25G must be screwed right into the valve neck Pos. 25B.

S The O-ring Pos. 25J may have expanded

under the influence of the oil in the plant and will normally have to be replaced with a new one.

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

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

Adopt the following procedure:

S Using handwheel, open valve completely

to achieve a seal between valve cone and valve throat. The gasket Pos. 25Q acts as a sealing element.

S The packing screw joint Pos. 25M can

then be screwed out for inspection or replacement of the O-ring Pos. 25R and 25P. Thoroughly lubricate all parts with oil before reassembling.

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Page 82

Unloaded start and capacity regulation on SMC

0171-907-EN 96.02

and TSMC 100 and 180 compressors

SMC and TSMC compressors are equipped with an automatic unloader system to provide full relief to the compressor during the start-up phase. This reduces the starting torque of the compressor considerably.

Fig. 1

19D 15D 19B

15A

15B

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

The following schematic outline shows the lubrication and hydraulics system on the compressors together with unloader mechanism.

12J

Description of unloader mechanism and capacity regulation

No-load starting and capacity regulation are achieved by keeping the suction valve ring plate in the open position; the refrigerant gas thus aspired into the cylinder is not compressed but thrust back out through the suction valve.

T0177131_0 V10

See the blue spare parts drawing of the cylinder linings at the end of this manual.

Around each pair of cylinder linings a frame Pos. 13 is fitted, controlling two sets of rocker arms Pos. 15A. The frame is connected by means of a piston rod to the regulating piston in the unloading cylinder pos. 12.

0178-910-EN

Page 83

When the regulating piston is unaffected by the oil pressure - i.e. when the connected solenoid valve is de-energized or when the compressor is at standstill - the regulating piston and the entire frame are shifted to the right by the pressure from the springs Pos. 12J (see fig. 1) .

The tension springs Pos. 15D will thus raise the rocker arms Pos. 15A into the vertical position, as these rotate in the ball sockets Pos. 15B.

This movement lifts the relief ring and the pins Pos. 19B, opening the suction valve by force.

If oil pressure is placed on the relief cylinder during operation, the unloader system is shifted to the left (see sketch). This lowers the rocker arms Pos. 15A, and the relief ring with pins Pos. 19B is moved away from the suction valve ring plate, allowing this to oper-

ate freely and close during the compression phase.

During operation, the unloader system can therefore regulate the capacity of the compressor by causing the solenoid valve - which is linked to the relief cylinder - to open or close for oil pressure to the relief cylinders, controlled by an electrical regulation system.

On TSMC compressors, attention is drawn to the two types of relief cylinder - for the LP and HP stage, respectively, as shown on the spare parts drawing.

Note:

Adjust the oil pressure on the regulating valve Pos. 22 to 4.5 bar. At an oil pressure lower than 3.5 bar (the breaking pressure for the safety automatices), there is a risk of the unloader system not being moved effectively and thus being damaged.

0178-910-EN

Page 84

Pilot solenoid valves

The pilot solenoid valve is an electromagnetic three-way valve which with a dead coil connects the unloading cylinder to the crankcase (the path for the oil flow from pipe 2 to pipe 3 is open). See fig. 1. If the coil is energized, the valve switches so that the path for the oil flow from pipe 1 to pipe 2 is open and

The solenoid valves are integrated in blocks (fig. 2) with 1,2,3, or 4 solenoid valves in each block. In these blocks the solenoid valves have a collective supply of pressure oil (pipe 1) and a collective connection to the crankcase (pipe 3). Each individual solenoid valve has its own oil connection to the relevant unloading cylinder (pipe 2).

the connection to pipe 3 is closed off.

Sectional drawing of capacity regulating valve

Fig. 2

Danfoss 034F9034_1

0178-910-EN

Page 85

Schematic outlines

The following schematic outlines shows the oil pipe connections and the wiring diagram with cut-out functions.

The schematic outlines also indicate the percentual capacity at which the compressor operates at the various capacity stages.

The lowest capacity percentage indicated on schematic outlines 1 corresponds to the lowest permissible capacity step at which the compressor may work by continous operation.

In special instances, e.g. where the start-up phase is lengthy, it may prove necessary to relieve the compressor altogether until the motor has achieved a sufficient torque. In such cases, an extra solenoid valve marked ’S’ can be mounted as shown on schematic outlines 2.

The S-valve is connected to the regulating cylinder(s) not involved in capacity regulation.

The valve is designed to prevent fast rising oil pressure actuating the compressor cylinders before the motor starter has changed over to the delta position, or a gas or diesel motor has reached full rotation speed.

TSMC compressors are always equipped with S-valves and thus feature totally unloaded start as standard.

Note:

Please note that the solenoid valve S must not be wired so as to form part of the capacity regulation. The compressor may operate totally unloaded for no more than 5 minutes, as its operating temperature will otherwise become too high.

0178-910-EN

Page 86

Standard unloaded start and capacity regulation

The SMC and TSMC compressors always start totally unloaded and in their standard design will activate a number of cylinders corresponding to the lowest capacity stage once the oil pump has built up the necessary oil pressure.

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

It is recommended that solenoid valves be wired so as not to receive the opening signal until the drive motor has achieved full torque.

Regulating sequence

The unloading is effected for two cylinders at a time by cutting off the voltage to the accompanying solenoid valve.

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

Note:

TSMC 116 must always have valves 3 and 4 connected simultaneously, as this capacity stage includes both low- and high-pressure cylinders.

The regulating sequence may be seen from the schematic drawings.

Schematic drawings 1

SMC/HPC 104

100

SMC/HPC 106 SMC 186

100

67 33

SMC/HPC 108 SMC 188

100

75 50

SMC 112

TSMC 108 TSMC 188

1 2

100

50 33

SMC 116

1 3

2 4

100

87 75

1 2 3

37 25

1 3 5

2 4 6

100

S 1 2

S21

TSMC 116

100

1 2 5 S

S 3 4

T1534070_1 rev.3

0178-910-EN

Page 87

Totally unloaded start and capacity regulation

Futher to the standard equipment, as shown on the previous page, the compressor may feature an extra solenoid valve marked S. TSMC compressors, however, are invariably equipped with this S-valve.

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

S Where total unloading is required until the

motor has achieved max. torque.

The ’S’ solenoid valve makes total unloading of the compressor possible, i.e. 0% capacity over a shorter period during operation. However, the ’S’ solenoid valve must never be involved in normal capacity regulation, as there is a risk of the compressor overheating if operated for some length of time at 0% ca-

Schematic drawings 2

SMC/HPC 104

100

SMC/HPC 106 SMC 186

100

67 33

SMC/HPC 108

100

75 50

S 1

1 2 3

Compressor seen from the shaft end

SMC 112

100

S 1 3

S 2 4

S Where a refrigeration plant is occasionally

subject to brief operating stops and compressor stop is not desirable. The compressor may then be allowed to run for a maximum of 5 minutes at 0% capacity.

The regulating sequence may be seen from the schematic drawings:

SMC 188

T1534070_2 rev.3

Relief cylinder

Oil return Oil pressure

100

75 50

S 1 2 3

SMC 116

100

87 75

37 25

S 1 3 5

2 4

0178-910-EN

Page 88

Service

It will normally not be necessary to service the solenoid valves, and it is therefore recommended not to strip them down. Should it be considered necessary to replace the solenoid valve, however, unscrew it from the block and replace by a new one. See the spare parts list.

Regulating sequence

The schematic outlines show that disconnection of a cylinder pair is done by cutting off the current to the relevant magnetic coil. Disconnection must be done by numerically ascending sequence, while connection should be done by numerically descending sequence.

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

rent to the number of solenoid valves needed to supply the compressor with the capacity required.

Note:

When starting a compressor this must be done at the lowest capacity stage and it should be allowed to run for a few minutes (e.g. 3 to 5 minutes) before its capacity is increased. This will prevent the oil in the compressor from heavy foaming and the refrigerant from being sucked into the compressor from the evaporating system; something which can lead to liquid strokes. For the same reasons the compressor should always, when a new stage has been loaded, be allowed to run for 3 to 5 minutes at this stage before the next higher capacity stage is loaded. Unloading of capacity on the compressor can usually take place more quickly.

Automatic capacity regulation

Where there is an automatic capacity regulating facility, solenoid valve control can be effected in the following ways:

- using pressure cut-outs

- using thermostats

- using microelectronics such as e.g. the UNISAB II.

Piston rod

Pos.

Dimensions

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

12-1 12-2

12-3 12-4 12-5 12-7

12-1 12-2

12-3 12-4 184 257 3135-022

21.5

46.5

71.5

96.5

24.5

49.5 49 94

139

100 125 150

107 122 167

212

Relief

Cylinder

3135-149 3135-150

3135-151 3135-152 3135-161 3135-154

3135-019 3135-020

3135-021

11122 1 1111

Relief cylinders

The relief cylinders vary in type, depending on the position they have on the compressor. The chart below shows the number and dimensions of the relief cylinders for the individual compressor types.

Number in each compressor

SMC 100 TSMC 100

222 1 1

SMC 180

186 188

1 1

TSMC 180

1 1 1

188

1 1

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

0178-910-EN

Page 89

Heating rods, pos. 30

In order to keep the lubricating oil in the compressor warm during a period of standstill, the oil reservoir has one or two heating rods built in. Before start-up, the heating rod (s) must have been activated for 6-8 hours in order to ensure that there is only a minimum of refrigerant in the oil. When containing much refrigerant, the oil will lose its lubricating property and the following operational interruptions may occur:

In reciprocating compressors there is a serious danger of vigorous oil foaming when the compressor starts as a result of a falling suction pressure.

For screw compressors starting with much refrigerant dissolved in the oil, there is a risk of the compressor being stopped by the Flow Switch as the oil will be foaming owing to the fall in pressure through oil pipe and oil filter.

As illustrated on the drawing the heating rod consists of an electric heating element, incorporated in a dia. 30 mm pipe. The entire heating cartridge is screwed on tight at the

/4” thread.

G 1

Note:

The heating rod must not be energized if the oil level in the reservoir is below the minimum mark in the sight glass, and it should generally be switched off during compressor operation. Remember to turn off the heating rod whenever the crankcase of the reciprocating compressor is opened for inspection.

The following table indicates which heating rods are used for the various compressor types. In the spare parts lists for compressor or unit you will find the current part numbers.

0170-017-EN 98.05

Power

Watt

270 270 270

460 460 460

Heating rods

Voltage

250 230

115*

250 230

115*

NV 50

G 1 1/4”

158 175

Marking: Prod. nr.

Watt Volt Manu. date

Ø 30

L1 L2

Used for:

CMO - TCMO - SMC 100 - TSMC 100

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

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

0178-910-EN

Page 90

Stop valves pos. 23 and 42

23G

0171-463-EN 95.03

Fig. 1

Fig. 2

23A 23D

Danv

42A 42H

42G 42F 42E 42C

23F

23C 23B 23E

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

The valves are safeguarded against inadvertent opening by means of a red cap.

The red cap can further be used for opening or closing the valve by unscrewing it and turning it upside down. The square hole in the top of the cap fits the square in the valve spindle.

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

42D

42B

T0177156_0

trating the valves whenever they are not used.

S If the valve is used as an oil charging

valve it is fitted with a nut pos. 23C and threaded nipple pos. 23B as shown by fig. 1.

S If the valve is used as a purge valve it is

fitted with a screwed connection as illustrated by fig. 2.

The purge valve is fitted either directly on the top cover or by means of an intermediate connection in the cast pressure channels in the frame.

0178-910-EN

Page 91

Monitoring cylinder lining insertion

When reassembling the slide linings, it is important to check the clearance volume as described in section 1 below.

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

1. Checking clearance volume

After each cylinder lining assembly, it is recommended that the clearance volume be checked. Adjustment of the clearance volume is done by means of gasket pos. 19K which, in addition to its sealing function, is also used as an adjusting element. Consequently, the gaskets come in two sizes and may sometimes be used at the same time under the same cylinder lining.

Gasket

thickness

19K

0.5mm

0.8mm

HPC

SMC 100

part no.

2356-111

2356-233

SMC 180

part no.

2356-116

2356-249

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

Fig. 1

S-L for SMC 100 type S

•

pos. 19K

E for SMC 100 type E

S Turn crankshaft until piston is in top posi-

tion.

S Using a depth or slide gauge, measure ”X”

as shown in fig. 2

Fig. 2

Cylinder lining

0171-467-EN 98.01

Adjustment is made as follows:

S The rocker arm system is lowered by fit-

ting the long plug no. 4 from the tools kit in the unloading cylinder pos. 12 instead of screw pos. 12D.

S Insert an 0.5mm gasket pos. 19K and

mount cylinder lining.

S Press cylinder lining against gasket pos.

19K by means of two locking devices –

Piston

T0177131_0 v6

S ”X” must lie between the below mentioned

limits and may, as mentioned earlier, be adjusted by the use of gasket pos. 19K.

0178-910-EN

Page 92

Clearance

volume

”X” HPC

SMC 100

Mk1, Mk 2, Mk 3

SMC 180

Mk1, Mk 2

min. max.

mm mm

0.6

0.9

1.0

1.5

The rocker arms must be in their vertical position i.e. with the short screw pos. 12D and gasket 12E fitted. The measured distances ”Y1 and Y2” may not vary more than max. 0.25mm.

S Adjustment of the lifting reserve can now

be performed if necessary. See point 2.

2. Checking lifting reserve

When fitting a new cylinder, or if the com- pressor is to be changed from running on R717 to some other refrigerant, or vice versa, or in the event of any major overhaul to the compressor, the lifting reserve must be checked.

Note:

The lifting reserve must not be checked until the clearance volume has been adjusted. Start by checking that the mutual height of the rocker arms is the same as described in the following:

Having removed the cylinder lining, measure distance ”Y” from the contact face of the cylinder lining in the frame to the top of the two rocker arms which interact on either side of the cylinder lining. See fig. 3.

In case this difference is greater, a shim Pos. 15E must be placed under the lowest rocker arm bearing pos. 15B or a shim removed from the highest bearing. Normally, there is no shim or max. 2 shims under the rocker arm bearing.

Check lifting reserve:

S 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 making them unable to be lowered again when the cylinder is put into service. Perform the adjustment as follows:

Fig. 3

0178-910-EN

Block

Rocker arms

T0177131_0 v4

S Position cylinder lining incl. the correct

gasket pos. 19K in the compressor block and press down against rocker arms by hand.

S 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.

Page 93

Fig. 4

S The difference in the two measurements

of ”Z” must be within the limits stipulated in the following table.

•

pos. 19K

T0177131_0 v5

S Measure distance ”Z” as shown in fig. 4.

Note down the ”Z” measure.

S Replace normal plug pos. 12D with the

long plug no. 4 from the tools kit, lowering rocker arms in the process.

S Press cylinder lining down against gasket

pos. 19K using the two locking devices no. 1 as shown in fig. 1, and repeat measurement ”Z”.

Lifting reserve

”Z”

HPC SMC 100

Mk 1, Mk 2, Mk 3

SMC 180

Mk 1, Mk 2

Min.

0,6

0,8

Max.

1,0

1,5

S If the difference between the two mea-

surements does not fall within the parameters stated, it must be regulated by inserting or removing shims pos. 15E under the rocker arm bearings.

S It is important that the long threaded plug

is fitted while the top cover is being mounted.

Note:

Remember to put the normal plug in once the top cover has been tightened.

0178-910-EN

Page 94

Pressure gauges

0170-161-EN 95.06

The analog instrumentation on the compressor includes two pressure gauges: one that measures the discharge pressure on the compressor and one combined suction and oil pressure gauge. These pressure gauges are filled with glycerine, which both attenuates the deflections of the indicators and lubricates the gauge works.

However, a fluctuating ambient temperature has an influence on the volume of the glycerine (warm glycerine takes up more space than cold glycerine), which can affect the measuring accuracy of the gauge. Furthermore, it is essential that no excess pressure can possibly occur in the gauge housing, as this involves a risk of explosion of the housing.

Both these considerations have been effectively solved in the gauges by a combination of internal temperature compensation and the so-called blow-out safety device which is fitted in the back plate of the pressure gauge housing.

Adjustment to other temperature ranges:

A balancing screw on the rear of the instrument is firmly tightened at a temperature of 20°C – the normal ambient temperature.

temperature under which the instrument will be functioning.

Example:

If the mid–compensation range is to be moved from 20°C to 10°C, equalization must be performed at 10°C. When the screw is then retightened, the middle of the compensation range will have been moved down to 10°C. The total stretch of the compensation range remains unchanged.

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

°C

-10°C

°C

+10

°C

50°C

°C

T0177086_0

Cleaning and refilling glycerinefilled gauges

S Remove blow-out disk and temperature

compensator from back of housing.

S Wash gauge interior with warm water and

allow to dry carefully.

S Fill gauge housing with fresh glycerine un-

til it flows out of bleeder hole.

If ambient temperatures change considerably thus requiring a general shift in the compensation range, slacken the balancing screw for approx. 1 minute, then retighten. This must be done at the average operating

0178-910-EN

Note:The glycerine must be absolutely wa-

terfree.

S Refit compensator and blow-out disk in

gauge housing and cover centrehole in blow-out disk with a piece of tape.

Page 95

Note:

Glycerine should be refilled at a room temperature of 20°C; when mounted, and the compensator must be its normal shape as shown at the top of the following drawing.

S Clean gauge exterior with warm water. S Remove tape from centrehole. S Refit gauge.

T0177086_0

Balancing screw

Compensator

Blow-out

+20

-10

+60

°C

0178-910-EN

Page 96

Undersize Bearing Diameters for Crankshaft Reciprocating Compressors with 4 to 8 Cylinders

0171-904-EN 96.05

Compressor

CMO 2

SMC/TSMC

type

HPO

HPC,

100 S

100 L

100 E

R=2.5

Main bearing

First

grinding

–0.060 –0.070

–0.070

79.5 –0.080

59.5

79.5

Super

finish

Final

grinding

–0.060 –0.090

–0.070 –0.090

=0.35

45°

R=d

Connecting rod bearing

First

grinding

–0.030

54.5 54.5 –0.049

0.000

79.5 –0.010

Super

finish

Final

grinding

–0.035 –0.050

=0,20Ra=0,20

0.000

79.5 –0.020

=0.35

R=2.5

3559.5

mm mm mm mm mmmmmm mm mm

0.0

–0.1

0.0

–0.1

0.0

–0.1

0.0

–0.1

T0177137_0

abcd

0.0

1.0

0.2

–0.3

2.5

3.5

SMC/TSMC

180

–0.110

134.0 –0.120

134.0

–0.110 –0.140

=0,63

0.000

134.0 –0.010

Undersize bearings: See SABROE spare parts list.

0178-910-EN

–0.015

134.0 70 –0.040

=0,63

0.0

–0.1

0.16

1.15

Page 97

Sundry clearances and check dimensions

Bearing clearance

CMO 1 CMO 2 SMC 65 CMP 1 TCMO1 CMO4 HPO HPC

Main bearings Connecting rod

bearings Piston pin

bearings

Parallel to piston pin

At right angles

PistonNewGround down

to piston pin

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

manufactured max.

0.08

0.20

0.08

0.15

0.04

0.10

0.18 –

0.11

0.30

TCMO 2 TSMC 65

0.08

0.20

0.08

0.15

0.04

0.10

0.18 –

0.11

0.30

0.08

0.20

0.08

0.15

0.04

0.10

0.18 –

0.11

0.30

All measurements stated are in mm

SMC 100 TSMC 100 4–10 cyl.

0.08

0.20

0.10

0.20

0.04

0.10

0.20 –

0.15

0.40

Crankshaft end-play

min. max.

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.

0.30 0.30 0.30 0.40 0.75 0.95

0.55 0.55 0.55 0.64 1.00 1.20

SMC 100 SMC180 TSMC 100 12–16 cyl.

0.08

0.20

0.10

0.20

0.04

0.10

0.20 –

0.15

0.40

TSMC 180 Mk1 & Mk2

0.14

0.35

0.14

0.30

0.09

0.20

0.25 –

0.35

0.90

0171-901-EN 91.04

Piston ring gap

min. max.

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

0.25 0.25 0.25 0.33 0.33 0.66

1.00 1.00 1.00 1.30 1.30 2.50

Dimensions of crankshaft bearing journal

Main bearing journals

Connecting rod bearing journals

Intermediate journals

Main bearing journals

Connecting rod bearing 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

54.5

49.5

–0.09 –0.025

–0.040

–0.06 –0.09

–0.025 –0.040

–0.09 –0.09 –0.09 –0.09 –0.14

–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

59.5 –0.09 –0.09 –0.09 –0.09 –0.14

–0.025 0 0 0 –0.015

54.5 54.5 79.5 79.5 134 –0.040 –0.02 –0.02 –0.02 –0.040

55 80 80 135

54.5 79.5 79.5 134

79.5

–0.010 –0.029

–0.010

–0.029

0178-910-EN

Page 98

Torque moments for screws and bolts

Metric thread (ISO 8.8)

M 4 5 6 810 121416 18202224 27

0171-465-EN 94.12

Kpm ft.lbf. Nm

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

108

15 110 147

23 170 225

30 220 295

38 270 375

52 370 510

Metric thread (ISO 12.9)

M 4 5 6 810 121416 18202224 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

Connecting rods with UNF thread

HPO/CMO HPC/SMC 100 SMC 180

68 490 670

100 720 980

0178-910-EN

T0177082_0

UNF Kpm ft.lbf. Nm

5/16”

2.1 15 20

3/8”

4.4 32 43

5/8”

17 130 167

Page 99

Bolt on discharge valve

HPO/CMO HPC/SMC 100 SMC 180

AMR

NORMEX

Kpm ft.lbf. Nm

Compressor type

HPO/CMO/TCMO

104-108

HPC/ SMC/ TSMC

SAB

112-116

186-188 128 163 128

3.2 23 32

Coupling

type

AMR225 AMR312S

AMR350S

AMR450S

H148 H168

225

Thread

5/16” 7/16”

1/2”

11/16”

M8 M8

5/16”

10.2 75

101

Torque (A)

Kpm. ft.lbf. Nm

3.5

5.6

2.2

3.5

255 344

25 40

200

16 16 25

34 55

128

275

22 22 34

Series 52

VMY

163 202

depending on the motor size

262

Series 52

200

225

262

312

Series 52 NORMEX

350

375

425

450

3/8” 7/16”

5/16”

3/8”

7/16”

1/2”

9/16”

5/8”

11/16”

4.2

3.5

4.2

5.6

130

175

200

55405.6312

128

177

245

275

0178-910-EN

Page 100

Refrigeration Plant Maintenance

0171-464-EN 94.05

Operational reliability

The prime causes of operating malfunctions to the plant are:

1. Incorrect control of liquid supply to the evaporator.

2. Moisture in the plant.

3. Air in the plant.

4. Anti-freezing liquid is missing.

5. Congestion due to metal shavings and dirt.

6. Congestion due to iron oxides.

7. Congestion due to copper oxides.

8. Inadequate refrigerant charge.

Below, some information is given about ways of keeping contaminants out of the refrigerating system and at the same time facilitating day-to-day supervision of the refrigeration plant.

Pumping down the refrigeration plant

Before dismantling any parts of the refrigeration plant for inspection or repair, pump-down must be carried out.

1. Open suction and discharge stop valves on compressor.

bled of refrigerant. Adjust any constantpressure valves to bring evaporator pressure down to atmospheric.

3. Start up the compressor. Adjust regulating system to lower suction pressure.

4. Keep a close eye on the suction pres- sure gauge! When the suction pressure is equal to atmospheric, stop the compressor and quickly shut off the discharge stop valve. Shut off any stop valve in the oil return line.

If the receiver has an extra stop valve in the feed line, this can be closed; practically the entire refrigerant charge will then remain shut off in the receiver.

Note:

The receiver must not be overfilled! There should be a minimum gas volume of 5%.

5. A slight overpressure should normally remain in the piping system - this safeguards the system against the penetration of air and moisture.

6. Before dismantling parts, the operator

should put a gas mask on.

Dismantling plant

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

2. Close liquid stop valve after condenser or receiver so that liquid refrigerant can be collected in the tank. Any solenoid valves in the liquid line should be opened by force, adjusting the thermostat to its lowest position so that the liquid line can be

0178-910-EN

1. No component should be opened unnecessarily.

2. When dismantling the system, the pressure in the system should be a little higher than atmospheric.

York SMC 104, SMC-106, SMC-108, TSMC 108 Mk 3 Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Instruction Manual

Preface

Purging a refrigeration plant

Cooling media

Lubricating oils

Operating limits

Starting up compressor and plant

Automatic plants

Pressure testing refrigeration plant

Pumping down refrigeration plant

Operating log

Removing refrigerant from compressor

Scheduled services

Lubricating oil

General rules for use of lubricating oil in refrigeration compressors

Instructions for choosing lubricating oil for refrigeration compressors

Charging the compressor with oil

Assessing the oil

Visual assessment

Procedure

Analytical evaluation

The analysis

Expected discharge gas temperatures

Servicing the refrigeration plant

Pump-down

Dismantling and assembly

Top covers

Mounting top and water covers

Discharge valve

Tightness testing of discharge valve

Service life of discharge and suction valves

Cylinder lining with suction valve

Connecting rod

Piston

Shaft seal

Crankshaft

Main bearings

Compressor lubricating system

Oil pump

Chain-driven oil pump with inverse direction of rotation

Oil pressure valve

By-pass valve pos. 24

Oil filter

Suction filters

Stop valves

Pilot solenoid valves

Schematic outlines

Standard unloaded start and capacity regulation

Totally unloaded start and capacity regulation

Service

Stop valves pos. 23 and 42

Monitoring cylinder lining insertion

Pressure gauges

Sundry clearances and check dimensions

Torque moments for screws and bolts

Refrigeration Plant Maintenance

Operational reliability

Pumping down the refrigeration plant