Instruction Manual CMO 24-26-28/TCMO 28 MK 2: Reciprocating Compressor
Instruction Manual CMO 24-26-28/TCMO 28 MK 2: Reciprocating Compressor
Instruction Manual CMO 24-26-28/TCMO 28 MK 2: Reciprocating Compressor
CMO 24-26-28/TCMO 28 Mk 2
Reciprocating Compressor
0171-478-EN Rev. 00.08 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
Instruction manual for
Reciprocating Compressors
97.03
0171-355-EN
CMO 24 - 26 - 28 Mk 2
TCMO 28 Mk 2
99.06
Specifications for
CMO 24Ć26Ć28 Mk2 and TCMOĂ28ĂMk2
The CMO/TCMO-type piston compressor can instruction manual, even if they are not fea-
be fitted with a range of equipment, depend- tured on your particular unit.
ing on the function and requirements it is
The variants featured on the unit are marked
called on to meet.
with an ’x’ in the following diagram, with the
Some of these variants are discussed in this serial number stated below.
Compressor type
Designation
Serial number
0171-370-EN 1
Preface
The aim of this instruction manual is to this instruction manual to ensure reliable and
provide the operators with a thorough efficient operation of the plant as SABROE is
knowledge of the compressor and the unit, at unable to provide a guarantee against
the same time providing information about: damage occurring during the warranty period
where this is attributable to incorrect
S the function and maintenance of the
operation.
individual components;
96.06
to typical sources of errors which may occur
The contents of this instruction manual must
during operations. It states their cause and
not be copied or passed on to any
explains what should be done to rectify them.
0171-500-EN
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 :
2 0171-702-EN
Contents
0171-370-EN 3
General rules for use of lubricating oil in refrigeration compressors . . . . . . . . . . . . . . . 50
Instructions for choosing lubricating oil for refrigeration compressors . . . . . . . . . . . . . 50
Charging refrigeration compressor with lubricating oil . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Changing oil in refrigeration compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Charging the compressor with oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Assessing the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Visual assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Analytical evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
The analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Pressure and temperature settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Expected discharge gas temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Servicing the refrigeration plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Maintenance of reciprocating compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Pump-down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
1. If the compressor is operational . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2. If the compressor is inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Top covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Discharge valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Cylinder lining with suction valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Main bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
By-pass valve pos. 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Suction filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Cleaning of extra suction filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Stop valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Compressor lubricating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Oil pressure valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Capacity regulation and unloaded start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Capacity stages and regulating sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Pilot solenoid valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
The TCMO 28 compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
TCMO with capacity regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
TCMO without capacity regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Cooling of intermediate discharge gas on the TCMO 28 compressor . . . . . . . . . . . . . 90
Heating rods for heating the oil in reciprocating and screw compressors . . . . . . . . . . . . . 91
Stop valves pos. 23 and 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Sundry clearances and check dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Undersize Bearing Diameters for Crankshaft
Reciprocating Compressors with 4 to 8 Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Torque moments for screws and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
4 0171-370-EN
Refrigeration Plant Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Operational reliability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Pumping down the refrigeration plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Dismantling plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Tightness testing and pump-down of refrigeration plant . . . . . . . . . . . . . . . . . . . . . . . . . 98
Trouble-shooting on the Reciprocating Compressor Plant . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Remedying malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Selecting lubricating oil for SABROE compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Data sheet for listed Sabroe oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
List of major oil companies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Alignment of unit, AMR coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Fitting and alignment of AMR-type coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Boring of motor flange for AMR coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
V-belt drive for piston compressor types (T)CMO and (T)SMC . . . . . . . . . . . . . . . . . . . . . . 147
Thermo pump cooling of R717 reciprocating compressors . . . . . . . . . . . . . . . . . . . . . . . . . 149
Principle drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Oil return in parallel operation for
reciprocating compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Refrigerant cooled oil cooler for
CMO reciprocating compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Oil return to the compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Connections on CMO/HPO 24-26-28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Connections on TCMO 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Water cooling of the reciprocating compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Reciprocating compressors used for air conditioning
CMO 24-26-28 and SMC 104-106-108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Cooling of the intermediate gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Ordering Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Spare parts sets for compressors and units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
List of parts for CMO/TCMO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0662-215
Tools for compressor CMO/TCMC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0662-147
Spare Parts drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0662-213/-217
Spare Parts drawing (in detail) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0662-212
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
0171-370-EN 5
Description of compressor
CMO 24Ć26Ć28 & TCMO 28 MkĂ2
T0177142_0 V16
97.03
The CMO 2 is a reciprocating compressor Similarly, the name-plate indicates the com-
with several cylinders in the same block. pressor’s serial number, which is also
0171-351-EN
The first digit in the type number indicates stamped into the compressor housing at the
the stage of development of the compressor. top by the end cover facing away from cou-
The compressor comes in 4-, 6- and 8-cylin- pling/belt drive.
der versions, indicated by the last digit in the
Whenever contacting SABROE about the
type number.
compressor, its serial number should be
stated.
The TCMO 28 is a 8-cylinder version, which
compresses the gas in two stages, with 6 The pistons of the compressor have a diame-
low-pressure cylinders and 2 high-pressure ter of 70 mm and a stroke of 70 mm.
cylinders. The type can be determined by the
The pistons work in replaceable cylinder lin-
compressor’s name-plate which is located at
ings, inserted in the frame and located with
the bottom on one side of the compressor.
two cylinders under each top cover.
6 0171-370-EN
the capacity regulating system is supplied The TCMO 28 compressor is available with
from the gearwheel oil pump built into the either a built-in intermediate cooling system
compressor. or an external intermediate cooling system,
which may be seen from the table on page 1
At the shaft end, the crankshaft is equipped as well as from the description further on in
with a balanced shaft seal of the slide-ring this instruction manual.
type, consisting of a cast-iron ring rotating The compressor can be delivered without
with the crankshaft and a stationary spring– capacity regulating functions but still with the
loaded carbon ring. start unloading function for totally unloaded
start-up.
As standard equipment the compressors
The capacity regulation is controlled by sole-
have a hydraulic capacity unloading system
noid valves, mounted in one of the compres-
that forces the suction valves open, thus pre-
sor side covers.
venting compression. This unloading system
is designed in such a way to ensure that the The following table shows the capacity
compressor always starts totally unloaded. stages at which the compressor can operate.
CMO 24 x x x x
CMO 26 x x x x
CMO 28 x x x x
TCMO 28 x x x x
0171-370-EN 7
Safety Precautions
98.03
safety procedures. when operating parts containing refrigerant.
Safety-toe shoes with slip-proof soles can
Operator and maintenance personnel must help you avoid injury. Keep your protective
0170-123-EN
read and understand these precautions com- equipment in good condition.
pletely before operating, setting up, running,
or performing maintenance on the machine. Never operate or service this equipment if
affected by alcohol, drugs or other sub-
These precautions are to be used as a guide stances or conditions which decrease alert-
to supplement safety precautions and warn- ness or judgement.
ings in the following:
Work area safety
a. All other manuals pertaining to the ma-
Always keep your work area clean. Dirty
chine.
work areas with such hazards as oil, debris,
b. Local, plant, and shop safety rules and or water on the floor may cause someone to
codes. fall to the floor, into the machine, or onto oth-
er objects resulting in serious personal injury.
c. National safety laws and regulations.
Make sure your work area is free of hazard-
General safety instructions and ous obstructions and be aware of protruding
machine members.
considerations
Report unsafe working conditions to your su-
Personal safety
pervisor or safety department.
Machine owners, operators, setup men,
maintenance, and service personnel must be Tool safety
aware of the fact that constant day-to-day Always make sure that the hand tools are in
safety procedures are a vital part of their job. proper working condition.
8 0170-123-EN
Remove hand tooling such as wrenches, Never exceed the safety rated capacity of
measuring equipment, hammers, and other cranes, slings, eyebolts, and other lifting
miscellaneous parts from the machine im- equipment. Follow standards and instructions
mediately after usage. applicable to any lifting equipment you use.
0170-123-EN 9
Never bypass or wire around any safety de-
WARNING vice.
Failure to follow safety instructions Keep all parts of your body off the compres-
on this page may result in serious sor/motor/unit during operation. Never lean
personal injury or death. on or reach over the compressor.
10 0170-123-EN
If any tool is required to remove a guard, cov- disconnect is not locked, tag all start button
er, bracket, or any basic part of this compres- stations with a ”DO NOT START” tag. Ade-
sor, place the Main Disconnect Switch in the quate precautions, such as warning notices,
OFF position, lock it in the OFF position. or other equally effective means must be tak-
If possible, post a sign at the disconnect en to prevent electrical equipment from being
switch indicating that maintenance is being electrically activated when maintenance work
performed. is being performed.
Dismantle main fuses to the unit. When removing electrical equipment, place
number or labeled tags on those wires not
marked. If wiring is replaced, be sure it is of
the same type, length, size, and has the
DANGER: same current carrying capacity.
HIGH VOLTAGE
Close and securely fasten all guards, shields,
Before working on any electrical cir- covers, plates, or doors before power is re-
cuits, turn the machine Main Dis- connected.
connect Device ”OFF” and lock it.
Dismantle the main fuses to the An electrial technician must analyse the elec-
compressor unit. trical system to determine the possible use of
Unless expressly stated in applica- power retaining devices such as capacitors.
ble Sabroe Refrigeration documen- Such power retaining devices must be dis-
tation or by appropriate Sabroe Re- connected, discharged, or made safe before
frigeration Field Service Represen- maintenance is performed.
tative, do NOT work with electrical
power ”ON”. If such express state- Working space around electrical equipment
ment or advice exists, working with must be clear of obstructions. Provide ade-
electrical power ”ON” should be quate illumination to allow for proper opera-
performed by a Sabroe Refrigera- tion and maintenance.
tion Field Service Representative.
The customer and subsequent Materials used with this product
transferees must determine that any Always use Sabroe Refrigeration original
other person performing work with spare parts.
electrical power ”ON” is trained and
technically qualified. Please, note the type of refrigerant on which
FAILURE TO FOLLOW THIS the compressor is operating and the precau-
INSTRUCTION MAY RESULT IN tions that you need to pay attention to as de-
DEATH OR SERIOUS PERSONAL scribed in the following sections:
SHOCK INJURY.
0170-123-EN 11
Handling of the compressor, areas of application,
safety equipment and symbols, safety at servicing
sors:
WARNING SMC-TSMC 100 E (only R717)
HPO and HPC (only R717)
The compressor block alone may
All other types of gas may only be
be lifted in the lifting eye.
used following a written approval from
The same applies to the motor.
SABROE.
12 0170-123-EN
S As a heat pump: It should only be possible to set back the
emergency device by a deliberate act, and
– BFO 3-4-5
this set back must not cause the compressor
CMO - TCMO and SMC - TSMC may to start operating. It should only make it pos-
be used with a max. discharge pressure sible to restart it.
of 25 bar.
Other demands to the emergency device:
– HPO – HPC may be used with a max.
S It must be possible to operate it by means
discharge pressure of 40 bar.
of an easily recognizable and visible
S In an explosion-prone environment, pro- manual handle, to which there is free ac-
vided the compressor is fitted with ap- cess.
proved explosion-proof equipment. S It must be able to stop any dangerous si-
tuation, which may occur, as quickly as
possible without this leading to any further
WARNING danger.
Combustion motors
The compressor must NOT be
If combustion motors are installed in rooms
used:
containing refrigeration machinery or rooms
S For evacuating the refrigera-
where there are pipes and components con-
tion plant of air and moisture,
taining refrigerant, you must make sure that
S For putting the refrigeration the combustion air for the motor is derived
plant under air pressure in
from an area in which there is no refrigerant
view of a pressure testing,
gas, in case of leakage.
S As an air compressor.
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.
Safety equipment
0170-123-EN 13
”ON” should be performed by a Sabroe Re-
frigeration Field Service Representative. The
customer and subsequent transferees must
CAUTION determine that any other person performing
work with electrical power ”ON” is trained and
technically qualified.
WARNING
Before handling, installing, operating or
servicing the compressor and unit, read Failure to follow this instruction
the Safety Precautions section in the
may result in death or serious
Instruction Manual.
personal shock injury.
It is the responsibility of the operator or
his employer that the instruction manual
is always available. Explosion-proof electrical execution
This sign must not be removed nor be If the compressor is delivered in an explo-
damaged in any way. sion-proof electrical execution it will, further
to the SABROE name plate, be equipped
Antes de manejer, instalar, poner en mar- with an Ex-name plate like the one illus-
cha o dar servicio al compresor y la uni- trated below.
dad, leer la sección Precauciones de
seguridad en el Libro de Instrucciones.
Es respondabilidad del operarío o de su
patrón, que el libro de instrucciones
permanezca siempre al alcance de la
mano.
Esta señal no debe de ninguna manera
suprimirse o dañarse.
2516-297
T2516273_0
DANGER: The high voltage sign
The temperature of tangible surfaces
DANGER: When a compressor is working, the surfaces
HIGH VOLTAGE that are in contact with the warm discharge
gas also get warm. However, the temperatu-
re depends on which refrigerants and under
Before working on any electrical circuits, turn
which operating conditions the compressor
the machine Main Disconnect Device ”OFF” is working. Often, it exceeds 70°C which for
and lock it. Dismantle the main fuses to the metal surfaces may cause your skin to be
compressor unit. burnt even at a light touch.
Unless expressly stated in applicable Sabroe Consequently, the compressors will be equip-
Refrigeration documentation or by appropri- ped with yellow warning signs informing
ate Sabroe Refrigeration Field Service Rep- you that pipes, vessels and machine parts
resentative, do NOT work with electrical po- close to the warning signs during operation
wer ”ON”. If such express statement or are so hot that your skin may be burnt from 1
advice exists, working with electrical power second’s touch or longer.
14 0170-123-EN
pressor and other parts of the refrigeration
plant.
0170-123-EN 15
First Aid for accidents with Ammonia
Chemical formula: NH3 Ć refrigerant no.: R717)
Inhalation
WARNING 1. Move affected personnel into fresh air im-
mediately, and loosen clothing restricting
No plant can ever be said to be
breathing.
too safe.
Safety is a way of life. 2. Call a doctor/ambulance with oxygen
equipment immediately
General 3. Keep the patient still and warmly wrapped
Ammonia is not a cumulative poison. It has a in blankets.
distinctive, pungent odour that even at very 4. If mouth and throat are burnt (freeze or
low, harmless concentrations is detectable by acid burn), let the conscious patient drink
most persons. Since ammonia is self-alarm- water, taking small mouthfuls.
ing, it serves at its own warning agent, so 5. If conscious and the mouth is not burnt,
that no person will voluntarily remain in con- give hot, sweet tea or coffee (never feed
centrations which are hazardous. Since am- an unconscious person).
monia is lighter than air, adequate ventilation
6. Oxygen may be administered, but only
is the best means of preventing an accu-
when authorized by a doctor.
mulation.
7. If breathing fails, apply artificial respira-
Experience has shown that ammonia is ex- tion.
tremely hard to ignite and under normal
conditions is a very stable compound. Under Eye injuries from liquid splashes or con-
extremely high, though limited concentra- centrated vapour
tions, ammonia can form ignitable mixtures 1. Force the eyelids open and rinse eyes im-
with air and oxygen, and should be treated mediately for at least 30 minutes with the
with respect. salt water solution just mentioned
2. Call a doctor immediately.
Basic rules for first aid
Skin burns from liquid splashes or con-
1. Call a doctor immediately.
centrated vapour
2. Be prepared: Keep an irrigation bottle
1. Wash immediately with large quantities of
available, containing a sterile isotonic
water and continue for at least 15 minutes,
(0.9%) NaCl-solution (salt water).
removing contaminated clothing carefully
3. A shower bath or water tank should be while washing.
available near all bulk installations with 2. Call a doctor immediately.
ammonia.
3. After washing, apply wet compresses
4. When applying first aid, the persons as- (wetted with a sterile isotonic (0.9%)
sisting should be duly protected to avoid NaCl-solution (salt water)) to affected
further injury. areas until medical advice is available.
16 0170-123-EN
First aid for accidents with HFC/HCFC
Refrigerant no.: R134a - R505A Ć R507 Ć R22, etc
0170-123-EN 17
Protecting the operator as well as the environment
To this end, many countries have passed le- In high concentrations, R717 causes respira-
gislation in an effort to reduce pollution and tory problems, and when ammonia vapour
preserve the environment. These laws apply and air mix 15 to 28 vol. %, the combination
to all fields of industry, including refrigeration, is explosive and can be ignited by an electric
and must be complied with. spark or open flame.
Be especially careful with the following sub- Oil vapour in the ammonia vapour increases
stances: this risk significantly as the point of ignition
falls below that of the mixture ratio stated.
S refrigerants
S cooling media (brines etc) Usually the strong smell of ammonia will
give ample warning of its presence before
S lubricating oils.
concentrations become dangerous.
Refrigerants usually have a natural boiling
point which lies a good deal below 0°C. This The following table shows the values for refri-
means that liquid refrigerants can be extre- gerant content in air, measured in volume %.
mely harmful if they come into contact with Certain countries may, however, have an offi-
skin or eyes. cial limit which differs from those stated.
TWA
Time weighted ave- vol.% 0,1 0,1 0,1 0,1 0,005
rage during a week
18 0170-123-EN
Further, it may be said about Halogenated refrigerants must never be
refrigerants: mixed. Nor must R717 ever be mixed with
halogenated refrigerants.
S If halogenated refrigerants are released
directly to the atmosphere they will break
Purging a refrigeration plant
down the ozone stratum in the strato-
If it is necessary to purge air from a refrige-
sphere. The ozone stratum protects the
ration plant, make sure you observe the follo-
earth from the ultraviolet rays of the sun.
wing:
Halogenated refrigerants must, therefore,
never be released to the atmosphere. Use S Refrigerants must not be released to the
a separate compressor to draw the refrig- atmosphere.
erant into the plant’s condenser/receiver
or into separate refrigerant cylinders. S When purging an R717 plant, use an ap-
proved air purger. The purged air must
S Most halogenated refrigerants are mis- pass through an open container of water
cible with oil. Oil drained from a refrigera- so that any R717 refrigerant remaining
tion plant will often contain significant can be absorbed. The water mixture must
amounts of refrigerant. Therefore, reduce be sent to an authorized incinerating plant.
the pressure in the vessel or compressor
as much as possible before draining the S Halogenated refrigerants can not be ab-
oil. sorbed by water. An approved air purger
must be fitted to the plant. This must be
S Ammonia is easily absorbed by water: checked regularly using a leak detector.
At 15°C, 1 litre of water can
absorb approx. 0,5 kg liquid Cooling media
ammonia (or approx. 700 litres Salt solutions (brines) of calcium chloride
ammonia vapour). (CaCl2) or sodium chloride (NaCl) are often
used.
S Even small amounts of ammonia in water
(2-5 mg per litre) are enough to wreak In recent years alcohol, glycol and halogena-
havoc with marine life if allowed to pollute ted compounds have been used in the brine
waterways and lakes. production.
If the refrigerant is not to be reused, return it The brine must be collected in suitable con-
to the supplier or to an authorized incinerat- tainers, clearly marked with the contents, and
ing plant. sent to an approved incinerating plant.
0170-123-EN 19
Lubricating oils – alkyl benzene-based synthetic oil
NOTE
This instruction provides only general information. The owner of the refrigeration plant is
responsible for ensuring that all codes, regulations and industry standards are complied
with.
20 0170-123-EN
Sound data for reciprocating and screw
compressor units - all types of compressors
In the following tables the noise data of the S SAB 81-83-85-87-89, SAB 128, Mk3,
compressors is stated in: SAB 163 Mk3, SAB 202, SAB 330, SV
and FV:
– A-weighted sound power level LW
Compressor block + IP23 special motor +
(Sound Power Level)
oil separator.
– A-weighted sound pressure level LP
S SAB 128 HR and SAB 163 HR:
(Sound Pressure level)
Compressor block at max. number of
The values for LW constitute an average of a revolutions + IP23 special motor + oil
large number of measurings on various units. separator
The measurings have been carried out in ac-
cordance with ISO 9614-2. S SAB 110:
Compressor block + IP23 standard motor
The values are further stated as average + oil separator
99.06
pressors
Normally, the immediate sound pressure
±5 dB for VMY screw compressors
lies between the LW and LP values and can
be calculated provided that the acoustic data As to the reciprocating compressors the
of the machine room is known. values are stated for the compressor block
only.
For screw compressors the average values
are indicated in the tables for the following The dimensional values are stated for 100%
components. capacity.
Fig. 1
Fictional frame
Dimensional plane
0170-114-EN 21
Note the following, however: S the acoustics is another factor that can
change the sound level in a room. Please
S at part load or if the compressor works
note that the sound conditions of the site
with a wrongly set Vi the sound level can
have not been included in the stated
sometimes be a little higher than the one
dimensional values.
indicated in the tables.
S additional equipment such as heat ex- S by contacting SABROE you can have
changers, pipes, valves etc. as well as the sound data calculated for other operating
choice of a different motor type can in- conditions.
crease the noise level in the machine
room.
The tables have been divided into reciprocat-
S as already mentioned, the stated sound ing and screw compressors, respectively.
pressures are only average values above The reciprocating compressors are further
a fictional frame around the noise source. divided into one- and two-stage compressors
Thus, it is sometimes possible to measure as well as in a heat pump. In each table the
higher values in local areas than the ones operating conditions of the compressor dur-
stated – for inst. near the compressor and ing noise measuring have been stated, just
motor. as the refrigerant used has been mentioned.
22 0170-114-EN
RECIPROCATING COMPRESSORS Two-stage
One-stage Evaporating temperature = –35°C
Evaporating temperature = –15°C Condensing temperature = +35°C
Condensing temperature =+35°C Refrigerant = R22/R717
Refrigerant = R22/R717 Number of revolutions =1450 rpm.
Number of revolutions =1450 rpm.
Compressor block LW LP
SMC 112 S 99 82
SMC 116 S 100 83
Evaporating temperature = –35°C
Condensing temperature = +35°C
SMC 104 L 96 80
Refrigerant = R22/R717
SMC 106 L 97 81
Number of revolutions = 900 rpm.
SMC 108 L 98 82
SMC 112 L 100 83 Compressor block LW LP
SMC 116 L 101 84
TSMC 188 100 82
SMC 104 E 96 80
SMC 106 E 97 81
SMC 108 E 98 82 Heat pump
SMC 112 E 100 83 Evaporating temperature = +20°C
SMC 116 E 101 84 Condensing temperature = +70°C
Refrigerant = R22/R717
Number of revolutions =1450 rpm.
Evaporating temperature = –15°C
Condensing temperature = +35°C
Compressor block LW LP
Refrigerant = R22/R717
Number of revolutions = 900 rpm. HPO 24 91 76
HPO 26 93 78
0170-114-EN 23
SCREW COMPRESSORS
Evaporating temperature = –15°C Evaporating temperature = –35°C
Condensing temperature = +35°C Condensing temperature = –5°C
Refrigerant = R22/R717 Refrigerant = R22/R717
Number of revolutions = 2950 rpm.
Number of revolutions = 2950 rpm.
*Number of revolutions = 6000 rpm.
Compressor block LW LP
24 0170-114-EN
Vibration data for compressors Ć all types
Vibration data for SABROE screw compres- sor unit can - under normal circumstances -
sors comply with the following norm: be classified in Class III or IV according to
ISO 2372 group C the following table from ISO 2372. Recip.
compressor units can be classified in class
Depending on the laying of the foundation
IV, likewise under normal conditions.
and the size of the motor a screw compres-
Vibration severity ranges and examples of their application to small machines (Class I) medium size ma-
chines (Class II), large machines (Class III) and turbo machines (Class IV)
0.28
0.28
0.45
0.45 A
0170-115-EN
0.71
0.71 A
1.12
1.8
1.12 B A
1.8 B A
2.8
2.8 C B
4.5
4.5 C B
7.1
7.1 D C
11.2
11.2 D C
18 18
28
D
28 D
45
45
71
SABROE screw compressor unit: – Motor and compressor have not been
Group C, class III or IV aligned as described in the Instruction
SABROE recip. compressor unit: Manual.
Group C, class IV. – For screw compressors, if the compres-
sor runs at a wrong Vi ratio.
Pay attention to the following, however:
– The pipe connections have been
S On placing the unit on the vibration executed in a way that makes them force
dampers delivered by SABROE pull or push powers on the compressor
(additional) the vibrations against the unit or they may transfer vibrations to the
foundation are reduced by: unit, caused by natural vibrations or con-
nected machinery.
– 85-95% for screw compressor units
– The vibrations dampers have not been
– 80 % for recip. compressor units
fitted or loaded correctly as indicated on
S However, a higher vibration level may oc- the foundation drawing delivered
cur if: together with the order.
0178-250-EN 25
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.
Bore Stroke Max/min Swept Weight
Compressor Number of Speed volume (max.)
type cylinders max RPM* compr. block
mm mm RPM m3/h kg
CMO 4 4 65 65 1800/900 93,2 200
CMO 24 4 70 70 1800/900 116 340
CMO 26 6 70 70 1800/900 175 380
CMO 28 8 70 70 1800/900 233 410
TCMO 28 2+6 70 70 1800/900 175 410
99.04
SMC 104S 4 100 80 1500/700 226 580
SMC 106S 6 100 80 1500/700 339 675
SMC 108S 8 100 80 1500/700 452 740
0171-476-EN
SMC 112S 12 100 80 1500/700 679 1250
SMC 116S 16 100 80 1500/700 905 1350
TSMC 108S 2+6 ♦ 100 80 1500/700 339 775
TSMC 116S 4+12 ♦ 100 80 1500/700 679 1400
SMC 104L 4 100 100 1500/700 283 580
SMC 106L 6 100 100 1500/700 424 675
SMC 108L 8 100 100 1500/700 565 740
SMC 112L 12 100 100 1500/700 848 1250
SMC 116L 16 100 100 1500/700 1131 1350
TSMC 108L 2+6♦ 100 100 1500/700 424 775
TSMC 116L 4+12♦ 100 100 1500/700 757 1400
SMC 104E 4 100 120 1500/700 339 600
SMC 106E 6 100 120 1500/700 509 700
SMC 108E 8 100 120 1500/700 679 770
SMC 112E 12 100 120 1500/700 1018 1300
SMC 116E 16 100 120 1500/700 1357 1400
TSMC 108E 2+6♦ 100 120 1500/700 509 800
TSMC 116E 4+12♦ 100 120 1500/700 1018 1450
SMC 186 6 180 140 1000/450 1283 2560
SMC 188 8 180 140 1000/450 1710 2840
TSMC 188 2+6♦ 180 140 1000/450 1283 2900
✶ The maximum speed permitted can be lower than stated here depending on operating
conditions and refrigerant; please see the following diagrams.
♦ Two - stage compressors (High Stage cylinders and Low Stage cylinders)
26 0171-370-EN
TC
°F °C R717
158 70 Operating limits
140 60 single stage
122 50 compressors
1 CMO
104 40 4
Condensing temperature
50 10
32 0 3
14 –10
–4 –20
–22 –30
–40 –40
–70 –60 –50 –40 –30 –20 –10 0 10 20 30 40 °C
T245400_0/2
TE
–94 –76 –58 –40 –22 –4 14 32 50 68 86 104 °F
Evaporating temperature
NB: At part load the discharge gas temp. must not exceed 150°C/302°F
0171-370-EN 27
°F
TC
°C 1a R717
158 70 Operating limits
140 60 single stage
122 50 compressors
SMC 100 E
104 40 2
Condensing temperature
86 30
68 20 1
50 10
32 0
14 –10
–4 –20
–22 –30
–40 –40
–70 –60 –50 –40 –30 –20 –10 0 10 20 30 40 °C
TE
104 °F
T245400_0/2
Evaporating temperature
Thermopump: Water-cooled:
Top- and side covers are cooled Top- and side covers.
by refrigerant injection. 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%.
28 0171-370-EN
TC
°F °C R717
158 70
Operating limits
140 60
two-stage
122 50
compressors
104 40 1 TCMO
Condensing temperature
32 0
14 –10
–4 –20
–22 –30
0177128_0 VIEW 3,1
–40 –40
–70 –60 –50 –40 –30 –20 –10 0 10 20 30 40 °C
TE
–94 –76 –58 –40 –22 –4 14 32 50 68 86 104 °F
Evaporating temperature
0171-370-EN 29
TC
°F
158
°C
70
R22
Operating limits
140 60
single stage
122 50
1
4 2 compressors
104 40
CMO
Condensing temperature
32 0
14 –10
–4 –20
–22 –30
0177128_0 VIEW 4,1
–40 –40
–70 –60 –50 –40 –30 –20 –10 0 10 20 30 40 °C
TE
–94 –76 –58 –40 –22 –4 14 32 50 68 86 104 °F
Evaporating temperature
Type Area rpm Oil-cooling Note
max min required 1)
1 no
1500
2 no
CMO 900
3 At less than 50% capacity
1800
4 yes
1 1000 no
2 1200 no
SMC 100 S 700
3 1500 At less than 50% capacity
4 1200 yes
1 Not applicable
2 1000 no
SMC 100 L
3 1200 700 At less than 50% capacity
4 1000 yes
1-2 Not applicable
SMC 180 3 At less than 50% capacity
750 450
4 yes
30 0171-370-EN
°F
TC
°C R22
158 70
Operating limits
140 60
two-stage
122 50 compressors
3 1
104 40 2 TCMO
Condensing temperature
86 30
TSMC 100 S-L
4
68 20
TSMC 180
50 10
32 0
14 –10
–4 –20
–22 –30
–40 –40
40 °C
0177128_0 VIEW 5,1
Evaporating temperature
0171-370-EN 31
TC
°F °C R134a
176 80 Operating limits
158 70
1
single stage
140 60
2 compressors
122 50
CMO
SMC 100 S-L
104 40
3
Condensing temperature
86 30
68 20
50 10
32 0
14 –10
–4 –20
–22 –30
–40 –40
40 °C
T0177128_ V8,1
1200 no
1-2
1500 At less than 50% capacity
CMO 900
1500 no
3
1800 At less than 50% capacity
1 1000 no
2 1200 no
SMC 100 S 700
1200 no
3
1500 At less than 50% capacity
1 Not applicable
2 1000 no
SMC 100 L
1000 700 no
3
1200 At less than 50% capacity
32 0171-370-EN
TC
°F
158
°C
70
R134a
Operating limits
140 60 1
2 two-stage
122 50 compressors
104 40 3 TCMO
Condensing temperature
50 10
32 0
14 –10
–4 –20
–22 –30
–40 –40
–70 –60 –50 –40 –30 –20 –10 0 10 20 30 40 °C
TE
T0177128_0 V8,1
Evaporating temperature
0171-370-EN 33
TC
°F °C R404A
140 60 Operating limits
122 50 single stage
1
compressors
104 40
CMO
Condensing temperature
32 0
14 –10
–4 –20
–22 –30
–70 –60 –50 –40 –30 –20 –10 0 10 20 30 °C
TE
274263.1 Rev. 0
Evaporating temperature
34 0171-370-EN
TC
°F °C
R404A
140 60 Operating limits
two-stage
122 50
compressors
TCMO
Condensing temperature
104 40
1 TSMC 100 S-L
86 30
2
68 20
50 10
32 0
14 –10
–70 –60 –50 –40 –30 –20 –10 0 °C
TE
32 °F
274263.3 Rev. 0
Evaporating temperature
0171-370-EN 35
TC
°F °C R507
140 60 Operating limits
122 50 single stage
1
104 40
compressors
CMO
Condensing temperature
86 30
SMC 100 S-L
68 20
2
50 10
32 0
14 –10
–4 –20
–22 –30
–40 –40
–70 –60 –50 –40 –30 –20 –10 0 10 20 30 °C
TE
–94 –76 –58 –40 –22 –4 14 32 50 68 86 °F
74263.2 Rev. 0
Evaporating temperature
36 0171-370-EN
TC
°F °C
R507
140 60 Operating limits
two-stage
122 50
compressors
TCMO
Condensing temperature
104 40
1 TSMC 100 S-L
86 30
2
68 20
50 10
32 0
14 –10
–70 –60 –50 –40 –30 –20 –10 0 °C
TE
32 °F
274263.4 Rev. 0
Evaporating temperature
0171-370-EN 37
TC
R407C
°F °C Operating Limits
140 60
one-Stage
122 50
Compressor type
104 40 1 CMO & SMC
Condensing temperature
86 30
2
68 20
3
50 10
32 0
14 –10
–4 –20
–22 –30
–70 –60 –50 –40 –30 –20 –10 0 10 20 30 °C
TE
–94 –76 –58 –40 –22 –4 14 32 50 68 86 °F
Evaporating temperature
T245411_0 view 2
38 0171-370-EN
General operating instructions
for CMO/TCMO, SMC/TSMC piston compressors
Starting up compressor and plant For pre-lubrication use a clean new refriger-
ant machine oil of the same type as the
S Before the initial start-up of the compres-
one found in the compressor, and pump as
sor following a lengthy stand-still period of
follows:
several months, the compressor must be
prelubricated. Hereby, the bearings are Pump strokes w. Estimated
lubricated and the oil system filled up Compressor SABROEs oil quantity
type hand-operated
with oil before the compressor is set run- oil pump Liters
ning.
CMO
Carry out the prelubrication by connect- TCMO appr. 25 2.5
ing the oil pump to the prelubricating HPO
SMC 104
valve which in the more recent SMC- 106-108 appr. 35 3.5
TSMC-HPC compressors is connected to TSMC 108
96.06
HPC
the shaft seal housing pos. 8A and on the
CMO-TCMO-HPO to the cover pos. 86H SMC 112-116
appr. 45 4.5
TSMC 116
0171-461-EN
0178-900-EN 39
S In order to avoid excessive pressure re- Stopping and starting-up com-
duction in the compressor on start–up, the pressor during a short period of
suction stop valve must be opened a few
standstill
turns, as there is otherwise a risk of oil
foaming in the crankcase. Before stopping the compressor, its capacity
must be reduced to the lowest capacity stage
S Open all other stop valves except for the for a few minutes, before it stops.
main valve in the liquid line and possible
During short periods of standstill, it is not
by-pass valves serving other purposes.
necessary to shut off the suction stop valve
and the discharge stop valve. The heating
S Check that the time relay 3K13 keeps the
rod must be energized.
solenoid valve in the oil return line closed
for 20-30 mins. after start-up of the com- If the compressor is cooled by means of cool-
pressor. ing water, the water flow must always be
stopped during periods of standstill.
S Start compressor motor and check suction This is normally done by means of a solenoid
and oil pressures. valve in the water inlet line to the compres-
sor.
S Carefully continue opening suction stop Connect the solenoid valve to the start/stop
valve to its full open position. relay of the compressor motor.
S Open main valve in liquid line. Compressor start-up must always take place
at the lowest capacity stage, after which ca-
S If the oil in the crankcase foams, or knock- pacity is increased stepwise at suitable inter-
ing noises are heard from the compressor vals, in order to avoid that a sudden exces-
because droplets of liquid are being fed in sive pressure reduction in the evaporation
with the suction gas, throttle suction stop system causes liquid hammering in the com-
valve immediately. pressor and oil foaming in the crankcase.
S Do not leave plant for first 15 minutes after S Cut off power supply to both master and
start-up and never before it has stabilized. control currents.
40 0178-900-EN
Stopping plant for lengthy periods – correct setting of safety automatics.
(more than 2-3 days)
S Shut off main valve after receiver and Pressure testing refrigeration plant
pump down evaporators. If necessary, ad- Before charging the plant with refrigerant, it
just low-pressure cut-out on unit to a lower must be pressure tested and pumped down.
pressure during evacuation.
Pressure test the plant with one of the follow-
S Allow temperature in evaporators to rise, ing:
then repeat evacuation.
S dry air - pressurized cylinders containing
S When suction pressure has been reduced dry atmospheric air may be used - but
to slightly over atmospheric, stop com- never oxygen cylinders;
pressor. Shut off suction and discharge
S air compressor for high pressure;
stop valves and close off stop valve in oil
return. S nitrogen.
0178-900-EN 41
S The entire unit must be pressure tested in atmospheric air and moisture. Evacuation
accordance with the local regulations for must be carried out on all types of refrigera-
pressure testing. tion plant, regardless of the type of refriger-
ant with which the plant is to be charged.
S The test pressure must never exceed the
disign pressure.
Observe that HCFC and HFC refrigerants
S If it is required that the compressor should mix only minimally with water, and it is there-
be pressure tested together with the unit fore necessary to effect evacuation of such
or with the plant, the testing pressure must systems with particular care.
not exceed:
For reciprocating compressors: The boiling point of a fluid is defined as the
HP side: 24 bar temperature at which the steam pressure
LP side: 17.5 bar equals atmospheric pressure. For water, the
boiling point is 100°C. Lowering the pressure
S Please observe that manometers, pres- also lowers the boiling point of the water.
sure controls, pressure transmitters and
other control equipment are not exposed The table sets out the boiling point of water
to testing pressure. at very low pressures:
S Afterwards, reduce pressure to 10 bar for
a period of 24 hours - as an initial tight-
Boiling point of At pressure
ness test - as a tightly sealed plant will water °C mm HG
maintain this pressure throughout the peri-
od. 5 6,63
10 9,14
During the tightness test, it is permitted to
15 12,73
enter the room and approach the plant.
20 17,80
S By way of a second tightness test, ex-
amine all welds, flange joints etc. for leak-
age by applying soapy water, while main- For evacuation, use a vacuum pump which
taining the 10 bar pressure. bleeds the plant of air and steam.
When pressure testing, compile a pressure The vacuum pump must be able to lower the
test report containing the following: pressure to approx. 0.1 mm Hg (mercury col-
S date of pressure testing, umn) and must be fitted with a gas ballast
valve. This valve should be used wherever
S person carrying out the test, possible to prevent water vapours condens-
ing in the vacuum pump.
S comments.
Important
Pumping down refrigeration plant
Never use the refrigeration compressor
Following pressure testing, the refrigeration to evacuate the plant.
plant must be evacuated in order to eliminate
42 0178-900-EN
For a satisfactorily performed evacuation, the S Blow dry air or nitrogen into system to a
final pressure must be lower than 5 mm Hg. pressure corresponding to atmospheric.
Attention is drawn to the fact that there may Never use OXYGEN cylinders.
be a risk of any water left in the refrigeration
S Repeat evacuation to reduce pressure to
plant freezing if ambient temperatures are
less than 5 mm Hg.
lower than 10°C. In such instances, it will be
necessary to supply heat to the component S Shut the vacuum pump off from refrigera-
surroundings, as ice evaporates with difficul- tion plant and check that the pressure
ty. does not rise for the next couple of hours.
If the system still contains water, this will
It is recommended to carry out evacuation as
evaporate and cause the pressure to rise,
follows:
thereby indicating unsatisfactory evacua-
S Evacuate to a pressure lower than 5 mm tion and necessitating a repetition of the
Hg. procedure.
0178-900-EN 43
Operating log This operating log should be kept at regular
intervals, thus providing important informa-
In order to keep tabs on the operating state tion about the cause of any undesired
of the refrigeration plant, it is recommended changes in the operating state.
that an operating log be kept. (See following page)
44 0178-900-EN
Servicing the reciprocating compressor
Reciprocating compressors CMO/TCMO, SMC/TSMC
100 and SMC/TSMC 180
In order to ensure problem-free operation, it sure drop test is performed with the compres-
is advisable to carry out regular servicing to sor at standstill, as described below:
the refrigeration plant. In this section,
SABROE indicates some periodic services S Immediately after stopping compressor,
fixed on the basis of the number of operating read off pressure on discharge and suc-
hours from the first start-up or after over tion side of compressor.
hand of the compressor. S Close discharge stop valve quickly and,
from moment of closure, time how long it
The servicing schedules also depend on the
takes for pressure to drop on high pres-
speed of the compressor. If the compressor
sure side of compressor. Normally, the
is running at less than 1200 rpm, SABROE
pressure drop should not be more than 3
permits extended service intervals. However,
bar over a period of 5 minutes or so.
the compressor must always operate within
the speed recommended by SABROE. See If the pressure falls more quickly, this is
Description of compressor. Providing the due to internal leakage, which may occur:
99.05
S The following must therefore be checked S with defective seal Pos. 19K;
daily:
Operating pressure, S because cylinder lining and top cover
Operating temperatures, have been tightened without long mount-
Oil level and pressure, ing stopper having been fitted. Cylinder
Abnormal noise and vibrations. lining is thus resting on rocker arms, Pos.
15A; (not CMO).
The actual operating conditions should be
S on safety valve, because valve cone does
entered in an operating log daily. See the Op-
not fit tightly against seat, or outer O-ring
erating log section.
Pos. 24B or inner O-ring Pos. 24C is de-
fective. (See Safety valve section.)
Pressure drop test: During pressure drop testing, pay attention to
Using the pressure drop test, it is possible to any piping connections to the discharge side
check the internal tightness of the compres- of the compressor, which may have an influ-
sor from discharge to suction side. The pres- ence on the test result.
0171-462-EN 45
Removing refrigerant from
compressor 42
Before the compressor can be dismantled,
the refrigerant must be removed from the
compressor, which can be done in the follow- Water
ing ways:
R717
1. Run compressor at lowest capacity stage
and throttle suction stop valve slowly until
Connect the purge valve Pos. 42 to a sealed,
completely closed.
empty vessel which in turn is connected to an
2. The compressor will then stop on the low open tank containing water.
pressure cut-out. This can be adjusted to The water will absorb the refrigerant, which
stop compressor at a pressure lower than can then be dispatched for proper destruc-
normal. tion. The moment the pressure is equalized,
the valve must be reclosed in order to pre-
3. Close discharge stop valve and other pip-
vent water being sucked back into the com-
ing connections to compressor.
pressor.
4. On HFC and HCFC compressors, remove
Note:
remaining refrigerant gas using a pump-
The following instructions apply to the
down compressor connected to purge val-
compressor only. Servicing of the refrig-
ve Pos. 42.
eration plant is described in a separate
section. Service the compressor motor ac-
42 cording 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
Evacuating pump carrying out the scheduled service.
46 0171-462-EN
Scheduled services
0171-462-EN 47
Operating Operating
No. hours hours Activity
< 1200 rpm > 1200 rpm
48 0171-462-EN
Operating Operating
No. Hours Hours Activity
< 1200 rpm > 1200 rpm
0171-462-EN 49
Lubricating oil
50 0171-462-EN
the crankcase, refrigeration oil may be therefore, it is necessary to refill with re-
topped up while the compressor is in opera- frigeration oil after starting up for the first
tion. time and after charging with fresh refriger-
ant.
For this purpose, use a manual oil pump or
adopt the following procedure: For a while after the plant is started for the
first time, keep an extra sharp eye on the oil
Note: level in the compressor, therefore.
When charging for the first time, use the
oil pump; it goes without saying that the
Changing oil in refrigeration com-
compressor must not be started unless
already charged with oil. pressor
S Cut off power to heating rod.
S Reduce pressure in crankcase, e.g. by
throttling suction stop valve, until suction S Close compressor stop valves and valve
pressure gauge shows pressure slightly in oil return line from oil separator.
below atmospheric.
S Reduce pressure in compressor crank-
S Fill pipe connected to oil charging valve case to slightly above atmospheric by
with refrigerator oil and insert free end of throttling suction stop valve while com-
pipe down into a receptacle containing pressor is running at its lowest capacity
fresh refrigerator oil. stage. Alternatively, raise to slightly above
atmospheric pressure by stopping com-
S Open oil charging valve carefully, thereby pressor and closing suction stop valve.
causing external air pressure to force oil Pressure in crankcase will then rise gradu-
into crankcase. ally.
S Avoid getting air or other impurities S Oil in the crankcase can then be forced
sucked into compressor. out through drain valve Pos. 23 when
compressor is at a standstill.
Note:
In order to achieve pressure below atmo- S Equalize pressure in compressor to atmo-
spheric, it will sometimes be necessary to spheric through purge valve pos. 42. See
reset the low-pressure cut-out so that the section on Environmental protection.
compressor can aspirate down to this
S Dismantle side covers.
pressure. Remember to reset the pressure
cut-out to its normal setting after charging S Replace oil filter cartridge with a new one.
with oil.
S Clean crankcase thoroughly, wiping with a
When in operation, the compressor may be clean, dry linen cloth (not cotton waste).
refilled with oil using the manual oil pump.
S Reassemble side covers.
Note:
S Charge to correct level with fresh, clean
Since halocarbon refrigerants such as
refrigerator oil according to SABROE’s oil
R22 mix with refrigeration oils, there will
recommendations.
always be a good portion of oil blended
with the refrigerant in the plant. Often, S Connect heating cartridge.
0171-462-EN 51
S Connect vacuum pump to compressor and 42 is open. See section on Environmental
pump down to 5-7 mm Hg; close off con- protection, however. When smelling R717,
nection. close purge valve.
52 0171-462-EN
Charging the compressor with oil
Compressor Volume of oil The oil level must be checked with extreme
in crankcase care, particularly when starting and charging
Type Size
Litres with refrigerant.
3 1,5 The oil level must always be visible in the
BFO 4 4
oil level sight glass. The below table illus-
5 5
trates, how many litres of oil a drop in the
24 14 oil level of 10 mm is approximately equal
CMO 26 16 to.
TCMO 28 18
4 13
104 26
SMC 100 106 28
TSMC 100 108 30
Mk 3 112 47
S-L-E
116 50
0171-462-EN 53
We would, therefore, advise that the oil anal- As a special offer to our customers
yses be carried out at the intervals prescri- SABROE has developed an analytical con-
bed. cept, which is able to analyse all oil makes.
This will mean a uniform reporting of the re-
An oil sample must be drawn off while the
sults.
compressor is in operation, which gives a
representative sample. Before taking the
The analysis allows the following to be deter-
sample, clean the drain valve and tap a little
mined:
oil off, to prevent any impurities which may
have accumulated in the valve or the piping S Whether or not the oil is still usable, if nec-
from mixing with the sample. essary after filtering.
If you don’t feel that you can approve the oil S A form set with a plastic sampling bottle
by visual assessment, charge with new oil or and a dispatching envelope can be re-
send a sample to a laboratory for analysis. quested from the local Sabroe Refrigera-
tion representation.
Warning
If the oil sample is poured into a glass bottle, S The oil sample must be drained from the
this must not be hermetically sealed until all cleaned oil drain valve into the sample
the refrigerant in the oil sample has evapora-
bottle. Screw the lid loosely on and let the
ted. Refrigerant in the oil may produce ex-
cess pressure in the bottle with subsequent bottle stand for a few hours to enable re-
risks of explosion. Never fill a bottle up com- frigerant contained in the oil sample to
pletely. Do not send glass bottles through evaporate before sending it to the labora-
the postal service – use purpose-made plas-
tic bottles. Please see below. tory.
54 0171-462-EN
The analysis the results of the analyses approach these
The following table states some average values. In some cases the water content of
values that can be applied in practice. How- 100 ppm in HCFC plants may be too much
ever, you should be on the alert whenever and thus lead to Cu–plating in the shaft seal.
Limiting values
Sabroe Oil PAO 68 Sabroe Oil AP 68 Sabroe Oil A 100
Parameter Unit Method Target Target Target
Spec. Max. Min. Spec. Max. Min. Spec. Max. Min.
Viscosity @ 40°C cSt ASTM D 445 66 76 53 64 74 51 100 115 80
TAN *1) mg KOH/g ASTM D 664 0.03 0.2 – 0.01 0.2 – 0.05 0.2 –
SAN * 2) mg KOH/g ASTM D 665 – 0 – – 0 – – 0 –
Water ppm Karl Fisher – 100 – – 100 – – 100 –
Appearance – – report report report
Colour – ASTM D report report report
1500
Pentane Insolubles W% MM 490 – 0.05 – 0.05 – – 0.05 –
(5mm)
Oxidation abs/cm IR,1700-1720 – 5 – – 5 – – 5 –
/cm
Nitration abs/cm IR,1627-1637 – 5 – – 5 – – 5 –
/cm
Nitro Compounds abs/cm IR,1547-1557 – 0.5 – – 0.5 – – 0.5 –
/cm
1): TAN (Total Acid Number) is only reported for non-ammonia- 2): SAN (Strong Acid Number) is only reported for non-ammo-
applications nia-applications
0171-462-EN 55
A report is drawn up for every sample re- through a 3 micron filter and back to the
ceived. This report indicates: unit. The system must be completely
closed, to prevent the oil being affected by
S Whether the oil can still be used – without moisture in the air.
taking any further action.
S Whether the oil is no longer fit for use.
S Whether the oil can be used after it has
been filtered through a very fine filter. The report will always be sent to the address
stated on the sample label included in the
If this is necessary, the oil must be form set. A copy will be sent to SABROE Re-
pumped directly from the compressor unit frigeration, so that we are in a position to ad-
vise you, if required.
56 0171-462-EN
Pressure and temperature settings for SABROE
compressor types SMC ĆTSMC and CMO Ć TCMO
Refrigerant
R404A
R134a
R507
R717
R22
24 bar (standard)
HP x x x x x
Safety valve 22 bar (special)
on the compressor
IP x x x x x 12 bar
Safety equipment
1)
Oil pressure cut-out MP 55 x x x x x 3,5 bar
KP 98
thermostat x * 150 ° C
Oil thermostat KP 98 x x x x x 80 ° C
Thermostat for KP 77 x x x x x 55 ° C
compressor cooling
Thermo valve for T(E) X Normally set at 4 ° C superheat.
compressor cooling T(E) Y x x x x Change to min. 10° C superheat
T(E) F
Control equipment
PMC + x x x x -25 ° C
By-pass valve CVC x -15 ° C
Oil pressure x x x x x 4.5 bar 2)
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 achie-
ved at 100% compressor capacity.
Increase the opening temperature 10°C by turning the spindle 5 turns clockwise.
NB: Factory setting must always be increased by min. 10°C.
Adjustment of the TEAT valve must be carried out with the thermopump
out of operation
1) SMC - TSMC - CMO2 - TCMO2 3.5 bar 2) SMC - TSMC - CMO2 - TCMO2 4.5 bar
CMO4 0.8-1.2 bar CMO4 1.3 bar
0171-370-EN 57
58
20 5.7 38 41 43 48 55 8
8.2 37 48 61 76 91 11.0 40 42 46 53 62 7.6 53 71 91 110 131
25 6.6 44 45 48 52 59 9
9.5 47 57 69 84 101 12.5 44 47 51 58 67 9.1 65 83 102 121 142
30 7.7 49 50 53 58 11. 55
66 11.1 65 77 92 108 14.3 49 52 56 63 71 10.7 77 95 113 133 151
10 35 8.8 53 54 58 64 74 12.7 68 74 85 99 115 16.2 54 57 61 67 75 12.6 89 106 123 141 160
40 10.1 57 59 63 69 14
79 14.5 72 82 94 106 120 18.2 59 62 66 72 79 14.6 101 117 133 151 170
45 11.5 61 63 67 74 82 16.5 81 90 100 112 126 20.5 65 67 71 77 83 16.9 110 126 143 161 –
20 5.7 48 51 53 58 65 8
8.2 48 59 72 88 103 11.0 50 52 56 63 72 7.6 65 83 103 122 143
25 6.6 54 55 58 62 69 9
9.5 57 68 80 95 110 12.5 54 57 61 68 77 9.1 77 95 114 132 153
20 30 7.7 59 60 63 68 11
76 11.1 65 76 88 102 117 14.3 59 62 66 73 81 10.7 89 106 125 142 162
35 8.8 63 64 68 74 12
84 12.7 73 84 96 109 123 16.2 64 67 71 77 85 12.6 100 116 134 152 –
40 10.1 67 69 73 79 14
89 14.5 82 92 103 115 128 18.2 69 72 76 82 89 14.6 111 127 144 162 –
45 11.5 71 73 77 84 16
92 16.5 90 98 109 121 133 20.5 75 77 81 87 93 16.9 121 136 154 171 –
20 5.7 58 61 63 68 75 8
8.2 59 70 83 97 113 11.0 60 62 66 73 82 7.6 78 96 115 134 153
25 6.6 64 65 68 72 79 9
9.5 69 78 91 105 120 12.5 64 67 71 78 87 9.1 90 106 126 144 163
30 7.7 69 70 73 78 11
86 11.1 75 86 98 111 125 14.3 69 72 76 83 91 10.7 102 118 136 154 –
30
35 8.8 73 74 78 84 12
94 12.7 84 95 106 118 131 16.2 74 76 81 87 95 12.6 112 128 146 163 –
0172-133-EN
40 10.1 77 79 83 89 14
99 14.5 92 101 111 123 135 18.2 79 82 86 92 99 14.6 123 138 155 – –
45 11.5 81 83 87 94 102 16.5
16 99 108 117 128 139 20.5 85 87 91 97 103 16.9 132 148 165 – –
Discharge gas temp.° C Discharge gas temp.° C Discharge gas temp.° C Discharge gas temp.° C
0170-105-EN 96.02
Servicing the refrigeration plant
During both start-up and operation it must be S the condenser pressure is not excessively
made sure that the plant is working correctly. high, and
0178-250-EN 59
Check Interval Activity
60 0178-250-EN
Maintenance of reciprocating compressor
CMO 24Ć26Ć28 Mk2, TCMO 28 Mk2
and ammonia. All O-rings are made of neo- compressor is ready for opening.
prene rubber.
S Remove all fuses, if any.
Pump-down
2. If the compressor is inoperative
Before opening up the compressor for in-
S Leave heating rod in crankcase connected
spection, the pressure inside must be low-
for a couple of hours before compressor
ered to slightly above atmospheric. This can
is due to be opened in order to heat up oil.
be done in the following way, depending on
whether the compressor is operational or de- Warm oil does not contain as much refrig-
fective. erant.
S Suction stop valve must be open while
1. If the compressor is operational heating rod is connected.
Run the compressor at minimum capacity at S Keep discharge stop valve closed.
normal operating temperature. S Close suction stop valve and disconnect
Adjust the low-pressure cut-out so that the heating rod.
compressor stops at a suction pressure of S Equalize pressure in compressor through
approx. 0.1 bar. purge valve Pos. 42.
Throttle the suction stop valve very slowly. S Once pressure has been equalized to at-
Keep an eye on the suction pressure gauge. mospheric, compressor is ready for
opening. Remember to make sure that
The suction pressure must be lowered slowly
enough to give the refrigerant dissolved in power cannot be inadvertently connected,
the oil time to escape without the oil foaming. thereby starting the motor.
This is of great importance in compressors S Remove all fuses, if any.
0171-370-EN 61
Dismantling and assembly ted. Pay attention to the powerful spring
The following sections describe the individual pressure under the top cover. After disman-
components. When dismantling and assem- tling of the two screws – unscrew alternately
bling, parts should generally be fitted in the – the top cover can be removed.
same position from which they were taken,
Mounting of top cover
and should therefore be marked as they are
removed. Further, they should be thoroughly Check that gasket pos. 2B is intact and – if
cleaned, checked and lubricated prior to be- necessary – check that the clearance vol-
ing reassembled. ume has been adjusted as described later in
this instruction.
7 1 3 5
T0177142_0 V9 11 9
12 10
8 4 2 6
Loosen these screws approx. 1 mm and
check that the cover lifts off the gasket.
But if the cover remains fastened to the gas-
ket, loosen it by a blow on the side with a soft
T0177142_0 V9
hammer while keeping the two screws fit-
62 0171-370-EN
Discharge valve
Pos. 20
21
20F
20E
20D
20H
20C
20A
T0177142_0 V2
As shown in the drawing, the function of the Liquid strokes are heard as a distinct
discharge valve Pos. 20 is partly to allow the hammering in the compressor; the cause
compressed gas to pass from the compres- must be found immediately and the mal-
sion chamber of the cylinder to the discharge function corrected.
chamber beneath the top covers and partly to
create a seal from the discharge chamber to Discharge valve types:
the cylinder. Depending on which refrigerant the compres-
sor is operating on, various discharge valves
Furthermore, the discharge valve acts as a must be used in order to achieve optimum
safety device in the event of liquid refrigerant function.
passing the valve together with the discharge
gas, also called liquid stroke. Such strokes Marking
should normally not occur, as liquid cannot
All pressure valves supplied from SABROE
pass the valve as quickly as the compression
today are marked as described below and
gas. This produces a violent increase in pres-
shown in the sketch.
sure in the compression chamber.
Refrigerant R717:
In order to avoid pressure of such intensity All discharge valves are marked with one
as to damage the bearings in the compres- groove.
sor, the discharge valve is retained in posi-
tion by the safety spring Pos. 21, which al- Refrigerants HFC/HCFC:
lows it to lift a little bit under the strain of in- All discharge valves are marked with two
creased pressure. grooves.
0171-370-EN 63
If necessary, exert counterpressure with 3
mm Allen key on bolt head.
S Fit spring guide Pos. 20F and tighten top
nut to same torque: 3,2 Kpm ≅ 31 Nm.
S Tighten bottom nut Pos. 20E to torque of When the valve ring plates are changed, the
3,2 Kpm ≅ 31 Nm. valve springs should also be replaced.
64 0171-370-EN
Cylinder lining with suction valve Pos. 19F to be removed from the cylinder
lining.
Marking of suction valve stop
T0177142_0 v1
S Before tightening screws 19J, ensure suc-
tion valve plate can be moved freely in its
In order to gain access to the cylinder lining guide. Tighten screws Pos. 19J to a
or suction valve, the top cover, spring Pos. torque of 7.6 Nm.
21, and discharge valve Pos. 20 need to be
Inserting cylinder lining
dismantled.
S Rotate crankshaft to position piston at top
The cylinder lining and suction valve form an dead centre.
integral unit and can be dismantled by re-
S Check that gasket Pos. 19K is in position
moving screws Pos. 19J.
on frame.
0171-370-EN 65
S In order to be able to check the size of the Connecting rod
clearance volume. However, it is neces-
Connecting rod Pos. 17 consists of a light
sary to press cylinder lining down against metal alloy which, besides its excellent
gasket Pos. 19K, using of 2 tightening strength properties, is also well-suited as
bars no. 1 to be mounted diagonally bearing material.
above the cylinder lining. To be used as
shown on the following drawing. Thus, the bearing surfaces of the connecting
rod work directly on the crankshaft and the
bearing surfaces of the gudgeon pin.
Next, mount discharge valve Pos. 20, spring S Position connecting rod interior through
Pos. 21, and top cover. Before this, check lateral opening on frame, and fit nuts Pos.
gasket Pos. 2B. 17H.
66 0171-370-EN
Note: Assembling and stripping down piston
The two parts of the connecting rod are and connecting rod
numbered with the same number; this is
Adopt the following procedure when assem-
only of importance when assembling.
bling piston and connecting rod:
Parts with different numbers must not be
assembled and it is important that the
S Fit one of the circlips pos. 18E into bore
numbers are fitted in the same direction
reserved for piston pin.
as shown in Fig. 1.
S Heat piston to 70°C in oil or on hotplate.
T0177131_0 v2,b
Fitting piston rings in piston S Remove spring Pos. 21, discharge valve
Before mounting the piston rings in the pis- and cylinder lining.
ton, their fit in the cylinder lining should be
checked by measuring the ring gap. See sec- S Remove nuts Pos. 17H; following this, the
tion entitled Various clearances and adjust- bottom part of the connecting rod can be
ment measurements. taken out by hand.
Note:
At the ring opening the oil scraper ring is S Piston and connecting rod can then be
marked TOP. This mark must face the pis- lifted out through the top cover opening on
ton top. the frame.
0171-370-EN 67
Shaft seal
Fig. 2
10H 10F 10C 10A 8E 8A 8H 8B 10D 8D 8C 16G
68 0171-370-EN
The spring pressure, combined with the 1.2. Dismantle shaft seal cover Pos. 8A by
flat-lapped faces of the two slide rings, ensur- alternately loosening bolts 8C so as to
es an optimal seal between the faces, displace shaft seal cover outwards wit-
both when rotating or stationary. hout jiggling. This will avoid damage to
internal parts of the shaft seal.
1.3. Once the spring force is equalized and
It is recommended to exercise great care the bolts removed, the shaft seal cover
with the lapped slide surfaces. Even the can be taken off the shaft end by hand.
slightest scratch or other damage to the Take care so that no damage is done to
slide surfaces will result in leakage. the carbon slide ring Pos. 10B which
comes out with it.
1.4. The carbon slide ring Pos. 10B can be
The O-ring Pos. 10C creates a seal between
extracted by dismounting circlip pos. 8E
the slide ring Pos. 10A and the crankshaft.
as follows:
The O-ring Pos. 10D seals between the car-
Mount tool no. 2 as illustrated in fig. 3
bon slide ring Pos. 10B and the shaft seal
and tighten screw A so that the carbon
cover Pos. 8A.
slide ring does not touch the locking
ring.
When the shaft seal is operating, a tiny
Take care not to tighten screw A too
amount of oil drifts out between the slide
much as this could damage the car-
faces to lubricate them. An oil throw ring Pos.
bon ring.
16G has therefore been fitted to prevent this
oil migrating along the axle to the transmis- Circlip pos. 8E is now easily extracted
sion linkage. by means of a screw driver without
damaging the slide surface of the car-
bon slide ring.
The oil splash ring ejects the oil into the
groove in the shaft seal cover Pos. 8A. Via After removing tool no. 2, the carbon
internal channels, the oil comes out under slide ring pos. 10B, O-ring pos. 10D
the shaft seal and through a plastic hose, it is and springs pos. 10K (see fig. 2) can
collected in a plastic bottle. now be dismantled.
Fig. 3
1. Dismantling and stripping down shaft
seal 8E 10B 10D 8A 8C
0171-370-EN 69
1.5. Dismantle slide ring 10A by turning the The torque is specified in the instruction
four Allen screws 10G a max. of 2-3 manual.
turns; the entire unit can then be taken
3. Unit with shaft seal cover Pos. 8A
out with the fingers or using two
screwdrivers inserted into the external 3.1. Mount O-ring 10D and the ten spiral
groove on the slide ring Pos. 10A and springs 10K in shaft seal cover 8A,
moved in the direction of the arrow as then position carbon slide ring 10B
illustrated in fig. 4. carefully. Rotate carbon slide ring so
slot fits in over retention pin 8H.
70 0171-370-EN
In case the movement is bigger, check S Extract all pistons and connecting rods.
whether the tightening flange Pos. 10F S Pull off V-belt pulley or coupling half .
has been pushed completely up against
the crankshaft shoulder as described in S Dismantle shaft seal cover and shaft seal.
sections 2.2 and 2.3. S Dismantle pressure cut-outs and pipes to
manometers, or piping connections to
3.5. Make sure that the screws Pos. 8C are
UNISAB.
evenly tightened cross-wise. Hereby da-
mage of the carbon slide ring is avoi- S Dismantle oil filter as well as its bracket
ded. Tighten screws Pos. 8C to prescri- Pos. 59A.
bed torque, acc. to table in instruction S Dismantle end cover, pos. 4A.
manual.
S Dismantle bearing cover with oil pump
3.6. Mount oil throw ring Pos. 16G, as
Pos. 5A at screws Pos. 5C, then pull out
shown in drawing.
bearing cover. It is not necessary to dis-
3.7. After mounting coupling half or V-belt mantle oil pump Pos. 11 from bearing cov-
disk, it must be possible to turn the er. it is also normally not necessary to
crankshaft easily by hand.
support the crankshaft.
Now pull out crank from the frame, sup-
Crankshaft
porting it by hand through one of the side
The crankshaft is made of heat-treated SG openings.
cast iron with fine strength and glide proper-
ties. The bearing journals are superfinished Inspection
and oil channels are bored for all lubricating
S Check bearing journals at connecting rods
points.
of wear and tear and, if necessary, mea-
At the centre and end of the crankshaft, the sure diameter of journals. Max. wear of
oil channels are blanked off with 3 blind the journals appear from section Various
plugs. clearances and adjustment measure-
ments.
When fitting the crankshaft, it should be
checked that the plugs are mounted and In most instances, the permissible play in
tightened. By way of bores in the counter- the bearing can be obtained by replacing
weights, the crankshaft is dynamically bal- the connecting rods.
anced with regard to 1st and 2nd order
Normally, the journals are only slightly
forces.
worn at main bearings, but during com-
Dismantling crankshaft plete overhauls they should be measured.
Dismantle the crankshaft through the pump By wear and tear beyond the plays stated,
end of the frame in the following way: the crankshaft can normally be ground to
S Bleed compressor of oil and refrigerant 0.5 mm undersize.
and safeguard against inadvertent
Main bearings and new connecting rods
start-up.
with a 0.5 mm undersize can be supplied
S Dismantle top and side covers. to the ground down crank, as stated in the
S Dismantle all cylinder linings. parts list.
0171-370-EN 71
Drawing for grinding of crankshaft to un- Main bearings
dersize can be requested from SABROE.
Main bearings Pos. 5E and 6E consist of a
After grinding the crankshaft, all lubricat- steel bushing with collar, coated with a thin
ing channels must be thoroughly cleaned layer of white metal inside the bushing and
with an approved cleansing fluid and on the collar.
blasted with compressed air. Remember
The bushings can be squeezed out and re-
to refit the blind plugs.
placed by new ones and require no finishing
once assembled.
S Check sealing face for O-ring seal, Pos.
10D, on shaft seal. The surface must be When pressing in new bushings, the in- and
bright and free of scratches and marks. outlets of the lubricating duct for bushing at
shaft seal end, pos. 6E, should be positioned
Refitting crankshaft
as illustrated on the drawing. The cover is
Refit the crankshaft in the reverse order to shown from the inside and as fitted on the
that for dismantling. compressor.
Note the following, however:
The bushing at the oil pump end of the com-
S After positioning the crankshaft in the pressor, pos. 5E, must be placed so that the
frame, mount main bearing cover Pos. 5A in- and outlets of the lubricating duct are fa-
with a gasket Pos. 5B as a shim. cing upwards.
S Before refitting bearing cover, position and Main bearing bushings can be supplied for
rotate oil pump coupling on pump shaft so ground down crankshaft.
that the retaining pins on the crankshaft See spare parts list.
engage the two nylon bushings.
72 0171-370-EN
By-pass valve pos. 24
The compressor is equipped with a built-in In case the pressure on the discharge side
mechanical by-pass valve, fig. 1, which safe- exceeds the set pressure so that the by-pass
guards it against any inadvertent excess valve opens, the valve will remain open until
pressure if the electrical safety equipment the pressure on the discharge side has fallen
fails. The by-pass valve safeguards against to approx. half the set pressure. The valve
any excess pressure between the discharge then closes automatically. However, at great
and suction sides of the compressor. differential pressures across the compressor
the valve may remain open. In that case,
If the by-pass valve goes into action, the
stop the compressor and close the discharge
compressor must be immediately stopped
stop valve entirely. The equalization of pres-
and the cause established.
sure in the compressor will then close the
The by-pass valve is supplied ready-set and safety valve and the compressor can be re-
sealed in accordance with the adjustment started.
pressures indicated in the table Pressure and
The by-pass valve is supplied factory-set and
temperature settings. The actual set pressure
sealed and need normally not be disassem-
is stamped on the rating plate, pos. A.
bled and readjusted.
The by-pass valve is of the high-lift type
which makes it very sturdy and durable. If necessary, control of function and set pres-
sure must be made in accordance with local
Further, the by-pass valve is independent of regulations for safety valves.
the pressure on the compressor suction side.
Consequently, it only opens when the pres- On the outside the by-pass valve is sealed
sure on the discharge side exceeds the set with two O-rings, pos. 24B and 24C.
pressure in relation to atmospheric. Fasten it to the compressor housing by
Thus, watch out that hole pos. B does not means of screws pos. 24D and washers pos.
get covered or clogged. 24E.
A B T3137T02I_1
0171-370-EN 73
Suction filter
On the inside of the end cover Pos. 7A the normally clean plants it may then be removed
compressor is equipped with a plate shaped together with the supporting spring.
suction filter Pos. 7G with a very large filter-
ing area. By non contaminated refrigeration In case the filter is badly soiled after the
plants it is therefore not necessary to clean 50 operating hours mentioned, it is rec-
suction filters between main overhauls. ommended to fit a new filter bag for
another 50 operating hours. Similarly, a
If the plant is not completely clean, the com- filter bag should be fitted for a period of
pressor will normally be equipped with an ex- 50 hours after major repair works on the
tra suction filter as described below. refrigeration plant.
74 0171-370-EN
Stop valves
A Z AJ
AK
AC
AD S
E T
Y U
POS. 25
AG F C H D Q G N B J L P R M K
T0177142_0 V5
The suction and discharge stop valves Pos. S Mount threaded piece Pos. 25G in a
25 are used to isolate the compressor from soft-jawed vice and dismantle screw
the refrigeration plant. Pos. 25E.
0171-370-EN 75
Reassembling of valve Pos. 25M to be serviced even when there
Reassembly is done in reverse order to that is excess pressure in the valve housing.
above. Note the following, however:
S Before mounting the complete valve in- Adopt the following procedure:
sert, the valve cone with threaded piece S Using handwheel, open valve completely
Pos. 25G must be screwed right into the to achieve a seal between valve cone and
valve neck Pos. 25B. valve throat. The gasket Pos. 25Q acts as
a sealing element.
S The O-ring Pos. 25J may have expanded
under the influence of the oil in the plant
S The packing screw joint Pos. 25M can
and will normally have to be replaced by a
now be unscrewed for inspection or re-
new one.
placement of O-rings Pos. 25R and 25P.
The stop valve has a so-called retroseal, Lubricate all parts thoroughly with oil be-
which enables the packing screw joint fore reassembling.
76 0171-370-EN
Compressor lubricating system
To oil pressure
regulating valve Pos. 22
To capacitiy
regulating system
11 9A
60
T0177131_0 V12
The oil system has two functions: The oil lu- Clockwise rotation incrases the pressure;
bricates and cools all movable parts in the anticlockwise rotation lowers the pressure.
compressor and it works as a hydraulic sys-
Excess oil is returned to the crankcase.
tem for regulation of the compressor pum-
ping capacity. A description follows later. From the shaft seal housing, the oil is distrib-
uted as follows:
The oil pump pos. 11M sucks oil from the
crankcase, through filter element Pos. 60, S Through the hollow-bored chrankshaft to
past the magnetic filter located inside the lubricate main and connection rod bear-
filter element. The pump forces the oil ings. Lubrication of piston pin bearings is
through an internal pipe Pos. 9A an on to done by splash lubrication through a coun-
the shaft seal housing. tersunk hole in the top of the connecting
rod.
The filter element Pos. 60 is a disposable fil- S To the oil differential pressure cut-out and
ter which cannot be cleaned. See description pressure gauge. The effective oil pressure
of Oil filter. can be read straight off the pressure
gauge (the suction pressure gauge of the
The shaft seal housing acts as a distribution
compressor). In case the compressor is
chamber for the oil. The oil pressure in the
fitted with UNISAB, the oil pressure is tak-
shaft seal housing is adjusted by means of
en through external pipe connections to
the oil pressure regulating valve Pos. 22,
the control box.
which is mounted on the one side cover.
S Through internal oil pipes the oil is taken
The regulation valve can be adjusted from to the regulating cylinders, Pos.12, for un-
the outside by means of a screwdriver. loaded start and capacity regulation.
0171-370-EN 77
Oil filter The filtered oil also passes a magnetic filter
Pos. 60J-K, where any small iron particles
All oil to the lubricating system of the com- are caught, before the oil flows to the oil
pressor is filtered through an oil filter, fitted in pump.
the crankcase.
Changing filter cartridge
The filtration element is a filter cartridge, pos. The filter cartridge should be replaced at reg-
60 A on Fig. 1, which cannot be cleaned and ular intervals. See the section entitled Servic-
therefore must be replaced by a new one ing compressors on this point. In particular, it
once the filter capacity is used up. should be remembered that the filter car-
tridge must often be replaced after a relative-
ly short operating time following initial start-
It is important therefore, to keep a spare
up.
filter cartridge in store at all times. It is
also recommendable to have gaskets, This is due to small particles of dirt originat-
pos. 59C and pos. 60B, available before ing from the plant during the initial operating
replacement of filter cartridge. period.
60B 60P 60N 60M 60J 60K 60A 60L 60H 60P-1
59D
78 0171-370-EN
The easiest method of dismantling the oil fil- Filter Cartridge, pos. 60A, cannot be
ter is via the left–hand side cover opening cleaned and must therefore be replaced
(the end of the compressor on which the ma- by a new unused one.
nometers/UNISAB are mounted). Dismantle
Mount the oil filter in the following order:
the oil filter by removing the screws, pos.
59B. Mind the gasket, pos. 59C. S Mount the gasket, pos. 60B
If a refrigerant–cooled oil cooler is mounted S Mount the filter cartridge, pos. 60A, the
in the compressor, this should be dismantled washer, pos. 60H and the self–locking nut,
together with the oil filter. Cf. the section Re- pos. 60P–1 as shown in fig. 1.
frigerant–cooled Oil Cooler for CMO Recipro- S Tighten the self–locking nut carefully with-
cating Compressor. out deforming the filter cartridge.
Replace the filter cartridge by dismantling the S Insert the complete oil filter together with
self–locking nut, pos. 60P–1 and the washer, the oil cooler (if mounted). Cf. Refriger-
pos. 60H. ant–cooled Oil Cooler
0171-370-EN 79
Oil pump
• 11A
11F
•
• 11C
11J
• 11K
11L
•
•
11E
• T0177142_0 V13
• 11G
• 11D
The oil pump is a gearwheel pump directly If you wish to change the direction of rotation,
coupled onto the end of the crankshaft. turn pump as described, and mark and bore
Power is transferred via 2 retention pins Pos. off 4 new holes for tightening screws.
16J fitted at the end of crankshaft and one
pin 11M equipped with teflon bushings. Thread M8 and effective thread depth 13
mm. Depth of hole for core drill max. 16 mm.
On compressors with normal rotating direc-
tion (indicated by an arrow on end cover at A compressor ordered for reverse direction of
shaft seal end) the oil pump is mounted with rotation is mounted with the pump in the cor-
the driving gearwheel at the bottom, as rect position.
shown on the drawing.
Dismantling of oil pump
If, because of the driving motor, the compres- 1. Dismantle all outer pipes and end cover
sor must have a reverse direction of rotation, Pos. 4A by the pump.
the oil pump must be turned 180° to take the 2. Remove screws Pos. 11B, after which
driving gearwheel to top position. Before only the guide pins Pos. 11G keep the
mounting the oil pump in its new position, pump in place.
dismantle oil pump cover Pos. 11D from
Normally, the oil pump has a very long life,
pump house Pos. 11C and turn it 180°. In this
thus repairs on it do not pay, instead it should
way the in- and outlet gates of the oil pump
be replaced by a new one.
remain in front of their respective connec-
tions to bearing cover Pos. 5A. Holes for
guide pins to the oil pump in this new position Remounting of oil pump
have been bored whereas threaded holes for On remounting of oil pump, turn shaft until
clamping have not. Hereby, wrong mounting retaining pin Pos. 11L catches the groove in
on compressors with normal direction of rota- retaining pin Pos. 11M. Pay attention to gas-
tion is avoided. ket Pos. 11A.
80 0171-370-EN
Oil pressure valve Adjustment
The oil pressure valve Pos. 22 regulates the Oil pressure: 4.5 bar.
oil pressure in the compressor. Mounted in
The oil pressure can be read off the suction
the cover Pos. 87A, it connects directly with
gauge or on UNISAB II.
the oil preessure chamber in the shaft seal
housing. On more recent compressor models the
The oil pressure is regulated by a spring adjusting screw may be locked by means
loaded cone, the spring pressure being ad- of an M6 pointed screw, fig. 1, which must
justed by turning an adjusting screw at the be loosened before adjustment can take
valve end. Use a screwdriver for this pur- place.
pose.
Service
Turning to the right (clockwise) raises the oil
Since the oil pressure valve is not subject to
pressure; turning to the left (anticlockwise)
any appreciable wear or soiling, it should not
lowers the pressure.
be disassembled during routine services.
22B
T0177083_0
0171-370-EN 81
Capacity regulation and unloaded start
The same type of regulating system is used Further, the regulating system must force the
in both CMO and TCMO compressors. It suction valves open at compressor standstill
should be pointed out, however, that on the or during its starting-up phase. In this way
CMO compressors all cylinders are connec- the motor is started with as little resistance
ted to the regulating system whereas only from the compressor as possible as there is
part of the TCMO cylinders can be connected no compression of gas in the cylinder. Once
to this system. the motor has reached its maximum moment,
the regulating system starts loading the com-
pressor with capacity.
The regulating function
Fig. 1 illustrates how the regulating system is
The purpose of the regulating system is to connected to the lubricating system of the
adapt the compressor capacity to the need compressor. As shown in fig. 2 the unloading
for cooling of the refrigeration plant. This is cylinders are controlled by three 3-way sole-
achieved by unloading cylinders or by putting noid valves. Oil pressure regulating valve
them to work. This is achieved by guiding the pos. 22 is set to maintain a constant oil pres-
suction valve fitted on each cylinder. sure of 4.5 bar in the oil system.
Fig. 1
11 9A
60
T0177131_0 V12
82 0171-370-EN
Function
1
Fig. 2
2 Three-way solenoid
3 valves
4A 2A 1A 3A
1A
2A
3A Relief cylinders
4A
3
2 22 Oil pressure
22
regulating valve
1
B
0171-370-EN 83
Assembling of unloading cylinder Mounting of unloading cylinder in the
compressor
By assembling of unloading cylinder, the two
1. Lubricate O-ring pos. 62H with refrigerant
sealing rings must be positioned as shown
machine oil.
on spare parts drawing.
2. Turn the two unloading cylinders pos. 12
so that the oil inlet holes are facing each
During mounting of circlip pos. 12J it is a go-
other and place them in the compressor
od idea to push bottom piece pos. 12C into
block.
the cylinder pos. 12E in a vice with soft jaws.
3. Press the two unloading cylinders against
each other, guiding them to engage with
Note:
oil pipe pos. 62A. Take care not to dama-
On assembling the unloading cylinder,
ge O-rings pos. 62H.
make sure that the two threaded holes in
the bottom piece pos. 12C are on a level 4. Press the two unlading cylinders down in-
with the hole for oil supply to the cylinder to the recess in the block and tighten with
pos. 12E. screws pos. 12A and washers pos. 12B.
84 0171-370-EN
Capacity stages and regulating sequence
Compressor Capacity in %
Compressor Capacity in %
CMO 24 100 75 50 25
CMO 26 100 67 50 33
TCMO 100 67 50 33
CMO 28 100 75 50 25
Solenoid 1 2 3
Solenoid valve no
1 2 3
valve no
Regulating sequence
Unloading takes place in numerical order The sequence of unloading of the cylinders
with rising figures, whereas loading takes is shown on the following principle diagram,
place in reverse order with falling figures. fig. 3.
Fig. 3
4 4 HP
4 4
2 2 1 2
1 1
Shaft end
1 1 3 4 1 1 LP
2 3
3 3 CMO 24 2 3
CMO 26
CMO 28 TCMO 28
T0177142_0 V10
0171-370-EN 85
Pilot solenoid valves
Fig. 4 shows the position of the solenoid
valves on the side cover.
Fig. 4
22
1 2 3
T0177142_0 V17
86 0171-370-EN
Dismantling and assembly of solenoid and each part in the tube be dismantled.
valves Nozzle no. 1 can be unscrewed by means of
When electricity has been switched off to the an Allen screw. However, take care that you
solenoid coil, hand screw pos. 80N can be do not lose the small steel ball pos. 2.
dismantled and coil pos. 50B pulled out At assembly tighten the nozzle and the arma-
across armature tube pos. 80P. ture tube with 10 and 50 Nm, respectively.
There is no gasket in connection with the
The armature tube can now be unscrewed nozzle.
0171-370-EN 87
The TCMO 28 compressor
The TCMO 28 compressor is available in 2 Further, the solenoid valve must be control-
versions: with or without built-in capacity led by the capacity regulating system of the
regulating system. (Please refer to page 1 compressor so that when the compressor
to see which compressor version you have). capacity is regulated down to 50% or lower,
The systems are illustrated in the following solenoid valve H will open.
schematic drawings, fig. 1 and 2. This prevents the intermediate pressure in
the IP chamber from getting too low.
TCMO with capacity regulation
Unloaded start system:
Unloaded start of the compressor is obtained At compressor start, the pressure in the HP
partly by lifting suction valve plates on the chamber is usually equalized to intermediate
four low pressure cylinders, partly through a or suction pressure as non-return valve G
by-pass line with solenoid valve H, connect- closes against the discharge side of the
ing the high pressure chamber with the inter- plant.
mediate pressure chamber.
The solenoid valve H must be connected to To be on the safe side open solenoid valve H
the star-delta starter of the motor in order to on starting the compressor, hereby equali-
energize the valve coil (open valve) whenev- zing any excess pressure in the HP chamber
er pilot voltage is connected and the motor to the pressure in the IP chamber. At the sa-
starter is in star position. me time the four cylinders on the LP side ha-
Whenever the motor starter switches to its ve been unloaded. All these factors put toget-
delta position, the current to the solenoid val- her result in a proper start unloading of the
ve H is disconnected and is closes. compressor.
Fig. 1
IP LP
H
IP
A: LP suction gas inlet
B B: HP discharge gas outlet
A
G 26 D: Oil pressure connection
HP 58 E: Oil return to crankcase
25
100% 67% 50%
22 E
D
1 2 3
88 0171-370-EN
Capacity regulation
Capacity regulation takes place by lifting the Unloading takes place in numerical sequence
suction valve plates on four of the six LP cyl- with rising figures, whereas loading takes
inders. The stagewise unloading appears place with falling figures.
from fig.1 and from the sketch earlier on.
Solenoid valve no 1 unloads two cylinders, When the LP-cylinders are unloaded, a bal-
thus reducing capacity to 67%. ance no longer exists in the cylinder ratio be-
Solenoid valve no 2 further unloads one tween HP- and LP-cylinders. In order to keep
valve, thus reducing capacity to 50%. the intermediate pressure at a suitable value
Valve no 3 unloads one more cylinder, reduc- under these circumstances, solenoid valve
ing capacity to 33%, which is the lowest H must open together with unloading
capacity at which the compressor is able to stage 2 and remain open also during un-
work. loading stage 3.
Fig. 2
22 E
D
Unloaded start system: in delta position, the valve coil must be de-
Unloaded start of the compressor takes place energized (closed valve).
partly by means of lifted suction valve plates
on four LP-cylinders, partly through a by- At start-up of compressor the HP-chamber
pass line with solenoid valve H, connecting must have been unloaded to intermediate
the HP chamber with the IP intermediate pressure. For this purpose a non-return valve
pressure chamber. G has been fitted in the disharge pipe in or-
der to prevent flashback of the condensing
The solenoid valve must be connected to the pressure into the HP-chamber.
star-delta starter so as to energize the valve
coil (open valve) at standstill and with the At start-up, the four LP cylinders are un-
starter in star position. With the motor starter loaded until the oil pressure has built up.
0171-370-EN 89
Cooling of intermediate discharge gas on the TCMO 28 compressor
The TCMO 28 compressor compresses the S Cooling of the intermediate pressure gas
refrigerant gas in two stages with 6 LP-cylin- by means of an intermediate cooler.
ders and 2 HP-cylinders, respectively. The gas is carried to a vessel with liquid
from the condenser. The superheated gas
Each stage has its own suction and pressure
from the LP stage is carried through the
chamber. The HP stage suction chamber and
refrigerant liquid and this reduces the su-
the LP stage pressure chamber is connected
perheat considerably.
by means of an external piping.
S Cooling of the intermediate gas by means
of liquid injection into the intermediate
IP HP pipe.
Liquid refrigerant is mixed with the inter-
mediate gas and reduces the superheat
IP IP when it evaporates.
LP LP IP IP
S The injection system can also incorporate
a plate heat exchanger in which the liquid
LP
for injection into the intermediate pipe sub-
cools the liquid to the evaporating system.
90 0171-370-EN
Heating rods, pos. 30
In order to keep the lubricating oil in the com- As illustrated on the drawing the heating rod
pressor warm during a period of standstill, consists of an electric heating element, incor-
the oil reservoir has one or two heating rods porated in a dia. 30 mm pipe. The entire hea-
built in. Before start-up, the heating rod (s) ting cartridge is screwed on tight at the
must have been activated for 6-8 hours in G 1 1/4” thread.
order to ensure that there is only a minimum
of refrigerant in the oil. When containing Note:
much refrigerant, the oil will lose its lubricat- The heating rod must not be energized if
ing property and the following operational in- the oil level in the reservoir is below the
terruptions may occur: minimum mark in the sight glass, and it
should generally be switched off during
In reciprocating compressors there is a
compressor operation. Remember to turn
serious danger of vigorous oil foaming when
off the heating rod whenever the crank-
the compressor starts as a result of a falling
98.05
refrigerant dissolved in the oil, there is a risk The following table indicates which heating
of the compressor being stopped by the Flow rods are used for the various compressor
Switch as the oil will be foaming owing to the types. In the spare parts lists for compressor
fall in pressure through oil pipe and oil filter. or unit you will find the current part numbers.
Marking: Prod. nr.
NV 50 Watt
G 1 1/4” Volt
Manu. date
Ø 30
30
50
L1
80 L2
Heating rods
Power Voltage L1 L2 Used for:
Watt V mm mm
270 250
270 230 CMO - TCMO - SMC 100 - TSMC 100
270 115*
158 175
460 250 HPO - HPC, SMC 180 - TSMC 180
460 230 VMY 347 /447 – 536
460 115* SAB 110 – 128 – 163 – 202 – 330
* Can be delivered with a UL approval.
All heating rods are executed in Degree of Protection IP54.
0178-017 – EN 91
Stop valves pos. 23 and 42
23G
Fig. 1
Danv
42A 42H
Fig. 2
95.03
0171-463-EN
42G
42D 42B
T0177156_0
The compressor is fitted with stop valves trating the valves whenever they are not
pos. 23 for charging of oil and pos. 42 for used.
draining of oil. They are service-free valves
and should as a rule not be dismantled. S If the valve is used as an oil charging
valve it is fitted with a nut pos. 23C and
The valves are safeguarded against inadver- threaded nipple pos. 23B as shown by
tent opening by means of a red cap. fig. 1.
The red cap can further be used for opening S If the valve is used as a purge valve it is
or closing the valve by unscrewing it and fitted with a screwed connection as illus-
turning it upside down. The square hole in trated by fig. 2.
the top of the cap fits the square in the valve
spindle. The purge valve is fitted either directly on
the top cover or by means of an intermedi-
The valves are equipped with a blank nut ate connection in the cast pressure chan-
pos. 23G/42H that prevents dirt from pene- nels in the frame.
92 0171-487-EN
Sundry clearances and check dimensions
– – – – – –
91.04
Crankshaft end-play
min. 0.30 0.30 0.30 0.40 0.75 0.95
max. 0.55 0.55 0.55 0.64 1.00 1.20
The end–play can be adjusted by means of the gasket under the bearing cover.
The gasket is available in the following thicknesses: 0.3, 0.5, 0.75 and 1.0 mm.
Bushing and bearing halves can be supplied for all above journals.
0172-133-EN 93
Undersize Bearing Diameters for Crankshaft
Reciprocating Compressors with 4 to 8 Cylinders
B
A A
B C
R=2.5 R=2.5
R=d
a
b
°
96.05
45
c
T0177137_0
0171-904-EN
A B C a b c d
Main bearing Connecting rod bearing
Compressor First Super First Super
type grinding finish grinding finish
or or
Final Final
grinding grinding
mm mm mm mm mm mm mm mm mm
–0.060 –0.060 –0.030 –0.035 0.0 0.0
HPO 59.5 59.5 54.5 54.5 35 0.2 1.0 2.5 2.5
–0.070 –0.090 –0.049 –0.050 –0.1 –0.3
CMO 2
Ra=0,20 Ra=0,20
HPC, 0.0
40
SMC/TSMC –0.1
100 S
–0.070 –0.070 0.000 0.000
79.5 79.5 79.5 79.5 0.0
SMC/TSMC –0.080 –0.090 –0.010 –0.020 50 0.2 1 3 3.5
100 L Ra=0.35 Ra=0.35 –0.1
SMC/TSMC 0.0
60
100 E –0.1
94 0172-133-EN
Torque moments for screws and bolts
ft.lbf. 2.1 3.9 6.8 16 30 50 80 110 170 220 270 370 490
Nm 2.7 5.2 9.2 22 40 69 108 147 225 295 375 510 670
94.12
ft.lbf. 3.0 5.7 10 23 44 75 120 160 240 320 400 550 720
T0177082_0
0172-133-EN 95
Bolt on discharge valve
HPO/CMO HPC/SMC 100 SMC 180
depending
VMY on the 312 7/16” 5.6 40 55
motor size
350 1/2” 13 95 128
96 0172-133-EN
Refrigeration Plant Maintenance
1. Incorrect control of liquid supply to the 3. Start up the compressor. Adjust regulat-
evaporator. ing system to lower suction pressure.
dirt.
If the receiver has an extra stop valve in
6. Congestion due to iron oxides. the feed line, this can be closed; practical-
0171-464-EN
0171-702-EN 97
3. Note: Tightness testing and pump-down
If the piping system is colder than the sur- of refrigeration plant
roundings, there is a considerable risk of
Before charging refrigerant into that part of
damp precipitation (condensation) on cold
the refrigeration plant which has been
plant parts. Plant components to be dis-
opened, this should be pressure-tested as
mantled must be warmer than the ambi-
described in the section entitled Pressure
ent temperature.
testing.
4. No two points in the system should be Afterwards, pump down in order to eliminate
opened at the same time. air and moisture. In this regard, consult the
section on Evacuation.
5. Plug, close or at least cover opening with
Otherwise, follow the instructions given in the
oiled paper or suchlike.
separate instruction manual on plant compo-
6. Be aware of the possibility of filters nents.
being very moist. Note:
If the oil in the crankcase of the piston
compressor or the oil separator of the
screw compressor has been in contact
with the atmospheric air for any length of
time, it must be replaced with fresh oil of
the same grade and make.
98 0171-702-EN
TroubleĆshooting on the Reciprocating Compressor
Plant
In the following chart, each individual error Any explanatory comments will be stated in
option is indicated by a code number in the the section that follows.
0171-231-EN 99
Error
code Observed error Cause code
1 Compressor fails to start 1, 2, 3, 4, 5, 6, 7, 9, 10, 12, 14.
2 Compressor starts and stops too often 9, 10, 11, 13, 21, 22, 23, 24, 32, 34, 35, 36, 37,
40, 41, 43, 44, 51, 52, 54, 56, 59.
3 Compressor starts but stops again immediately 3, 5, 6, 9, 10, 11, 12, 13, 14, 15, 17, 18, 41,
42, 49, 50, 55, 61.
4 Compressor operates continuously 8, 21, 22, 24, 41, 46, 52, 53, 56, 60.
5 Abnormal noise from compressor 16, 17, 18, 19, 26, 48, 49, 50, 51, 52, 53, 54, 56,
57, 58.
6 Insufficient capacity on compressor 13, 15, 17, 18, 20, 21, 22, 23, 24, 32, 34, 35, 36,
37, 40, 41, 44, 45, 46, 49, 50, 51, 52, 53, 56, 60.
7 Liquid stroke in compressor during start up 16, 18, 26, 37, 38, 39, 44, 56, 61.
8 Liquid stroke in compressor during operation 21, 23, 26, 37, 39.
14 Excessive discharge pipe temperature 11, 21, 22, 23, 28, 29, 30, 31, 33, 34, 35, 36, 37,
40, 41, 46, 52, 54.
15 Too low discharge pipe temperature 26, 32, 39.
16 Excessive oil temperature 33, 34, 35, 36, 37, 40, 50, 52.
17 Oil level in crankcase falling 16, 18, 20, 26, 51, 57, 58.
18 Oil foaming vigorously in crankcase 16, 26, 39, 61.
19 Crankcase sweating or frosting up 16, 18, 26, 37, 39.
20 Capacity regulating oscillating 13, 15, 16, 17, 18, 49, 55, 56.
21 Impossible to bleed plant 10, 43, 51, 52, 53, 54, 60.
100 0171-231-EN
Code Case Code Case
0171-231-EN 101
Remedying malfunctions
1. Compressor fails to start
1.6 Control current circuit open owing Pinpoint open switch and
to activated: remedy cause of
pressure cut-outs interruption.
thermostats
motor protection device
defrosting timer
1.9 High-pressure cut-out has cut Reset pressure cut-out and investigate cause
of high condenser pressure.
1.10 Low-pressure cut-out has cut Compressor cannot start before suction pres-
sure has risen above set point for pressure
cut-out restarting.
2.10 Low-pressure cut-out cuts at too Low suction pressure - see section 12.
low suction pressure.
If low-pressure cut-out is set too high, adjust
pressure cut-out.
2.11 Low-pressure cut-out differential is Increase differential pressure - see also special
too small between stopping and instructions.
starting
2.13 Compressor capacity too high Check operating conditions and, if need be,
reduce capacity.
102 0171-231-EN
3. Compressor starts but stops again immediately
3.10 Low-pressure cut-out has cut Open any suction stop valve which is closed.
3.15 Oil charge insufficient Top up with oil and investigate cause of oil
shortage.
3.18 Oil pressure failing owing to for- Reduce capacity. See sections 17 and 18.
mation of foam in oil.
4.21 Restricted supply of refrigerant to Remove dirt in filters and check function of ex-
evaporator. Compressor working pansion device as per special instructions.
at too low suction pressure.
0171-231-EN 103
5. Abnormal noise from compressor
5.26 Liquid refrigerant in suction line Liquid stroke. See points 7 and 8.
Adjust expansion or float valves.
5.48 Incorrect alignment of motor and Check alignment as per special instructions.
compressor
Loose bolts in coupling Tighten with torque wrench
5.56 Capacity regulation oscillating Low oil pressure - see section 13.
owing to failing oil pressure
6.15 Insufficient oil charge Top up with fresh oil of same type and make.
104 0171-231-EN
7. Liquid stroke in compressor during start-up
Liquid stroke in the compressor should not occur, as in the worst instance this can
cause rupture to the valve ring plates and damage to the inbuilt relief devices. Fur-
thermore, it can result in damage to the connecting rod bearings and cylinders if the
coolant degreases the faces and impairs the lubricating capacity of the oil.
7.26 Refrigerant has condensed in suc- Heating element in crankcase should be con-
tion line or crankcase nected for 6-8 hours before starting, so that
refrigerant dissolved in oil can be boiled out
before starting compressor up.
Suction line has free fall towards Start with throttled suction stop valve - stop
compressor when hammering is heard.
Liquid separator should be mounted in suction
pipe.
0171-231-EN 105
9. Excessive condenser pressure
In the event of abnormally high pressures in the refrigeration system, there is a risk of
damage to the compressor. At very high pressures (see pressure testing), the risk of
the components in the refrigeration plant exploding can constitute a threat to life.
Abnormally high pressures can occur in the case of:
- extreme heating of plant parts (fire, solar radiation or other abnormal heating);
- volumetric expansion of fluids in sealed-off premises.
9.25 Overfilling with refrigerant Refrigerant fills condenser and reduces its ef-
fective area.
Draw off coolant.
10.51 Defective piston rings or worn cy- Replace worn parts. See compressor instruc-
linders tions.
10.52 Discharge valves are defective or See compressor instructions. Check valve ring
leaky plates and piston rings.
10.54 Bypass between high-pressure Check compressor for internal leakage by per-
side and suction side of compres- forming pressure-drop test.
sor
See compressor instructions.
106 0171-231-EN
11. Excessive suction pressure
11.54 Open by-pass between suction si- Check system for any by-pass detectable as a
de and high-pressure side of com- warm connection.
pressor. Safety valve leaky, or
opens prematurely. Adjust or repair leaky valves.
12.35 Freezing-up of expansion valve Thaw out expansion valve with hot, wet cloths.
(HFC/HCFC plant)
Replace dessicant in drying filter.
12.36 Thermostatic expansion valve has Valve fails to open - change valve.
lost charge
0171-231-EN 107
12.41 Filter in liquid line clogged Check and clean filter in liquid line.
12.42 Solenoid valve in liquid line fails to Coil may have blown. Control signal lacking.
open
13.15 Too little oil in compressor Top up compressor with oil and investigate
cause of oil consumption.
If, after approx. 1 hour’s operation, the discharge pipe temperature is more than
10°C higher than indicated in the table, the error may be due i.a. to:
14.52 Leaky discharge valves Leaking in discharge valves gives rise to gen-
eration of heat.
Change defective valves.
14.54 Open by-pass between high and Localize by-pass and remedy any leakages.
low-pressure side of compressor,
e.g. leaky safety valve
108 0171-231-EN
15. Too low discharge pipe temperature
15.26 Low suction temperature as result Adjust liquid regulating valve. Increase super-
of overflow of liquid refrigerant heating.
from evaporator
During operation, the heat of the compressor crankcase must be 40-70°C. When
working with R717 and R22, it may be necessary to supply the compressor with oil
cooling.
See point 14.
Where HFC/HCFC refrigerants are used, there will be some blending of refrigerant
and oil during the initial operating period. It may therefore prove necessary to top up
the oil after initial start-up of the plant.
Note:
The oil level must always be visible in the oil level sight glass on the compressor.
17.20 Filter in solenoid valve or jet in oil Oil return pipe must be warm during opera-
return line clogged tions. Clean filter.
17.26 Liquid in suction line and crank- Examine evaporator system and check super
case may cause foaming in oil heating of suction gas.
and thus increase oil consumption
17.51 Worn-out piston rings or cylinders Renew piston rings and, if need be, renew pis-
tons and cylinder linings.
17.57 Solenoid valve in oil return line de- Coil in solenoid valve defective.
fective - Replace coil.
- Electrical control signal lacking.
0171-231-EN 109
18. Heavy oil foaming in crankcase
18.61 Too much refrigerant dissolved in - Before starting compressor, heating element
oil must have been on for at least 8 hours in
order to boil refrigerant out of oil. During
start-up phase, capacity should be con-
nected at a slow rate to prevent sudden drop
in pressure on suction side with resultant
foaming.
- Under normal operating conditions, com-
pressor should operate under as stable
pressure conditions as possible.
19.37 Expansion valve sensor misplaced Check positioning of expansion valve sensor -
cf. instructions for expansion valve.
19.39 Liquid regulating valve or float val- Increase superheating on thermostatic expan-
ve producing too much liquid sion valve.
21.43 Solenoid valve leaky Pinpoint and seal leak, or change leaky com-
ponent.
21.51 Defective piston rings Check and replace any defective parts.
21.52 Defective discharge valves Check and replace any defective parts.
21.53 Defective suction valves Check and replace any defective parts.
110 0171-231-EN
Selecting lubricating oil for SABROE compressors
During the past few years YORK Lubricating oils with relatively high viscosities
Refrigeration has experienced a number of must be used to ensure satisfactory lubrica-
problems with mineral oils, particularly in tion of refrigeration compressors.
R717 plants. The problems can be divided
To obtain the best lubrication, the oil must:
into two groups:
S Provide the required fluidity at the lowest
a: The oil changes viscosity evaporating temperature encountered in
b: The oil decomposes (becomes very black) the plant and at the highest permissible
temperatures in the compressors.
The problems have been seen with several
S Provide acceptable fluidity at start-up.
mineral oil brands, often occuring within a
few operating hours and resulting in severe S Provide sufficient oxidation stability (the oil
consequences for both compressor and must be moisture-free when added to the
system).
plants.
S Provide sufficient chemical stability when
99.02
Following the careful investigation undertak- used together with the particular refriger-
en by YORK Refrigeration during the past ant.
few years, it has been decided to introduce a In addition, the extent to which different re-
0170-151-EN
range of synthetic oils which can fulfil the de- frigerants dissolve in the oil must be deter-
mands of modern refrigeration plants. mined, so that the oil return systems, etc. can
be designed to function properly.
Mineral oils may continue to be used in re-
frigeration plants, providing the lubricating Stratification
quality is carefully monitored. For modern, It should be noted that in certain plants, par-
high capacity refrigeration plants, where long ticularly with HFC and HCFC refrigerants, the
lifetime for both lubricants and moving parts oil may stratify into layers in the refrigerant
is expected, YORK Refrigeration recom- receivers and evaporators at certain operat-
mends the choice of synthetic lubricating oils. ing conditions and at particular oil concentra-
tions.
The application areas and specifications for
these synthetic oils can be found in the fol- The Oil recommendation diagrams for
lowing pages. Installers and/or users are at SABROE compressors for HFC and HCFC
liberty to choose either YORK Refrigeration’s will indicate the limits for Sabroe oils at which
own or alternative oil brands which fulfil the this stratification occurs. The oil concentra-
necessary specifications. tions stated in these diagrams must not be
exceeded. This will enable suitable oil rectifi-
General cation/return systems to be designed to bal-
This recommendation only deals with the lu- ance with the compressor oil ”carry-over” so
brication of the compressor. The perfor- that the maximum concentration is not ex-
mance of the lubricant in the plant (receiver, ceeded.
evaporator, etc.) must, however, also be tak- For area A in the diagrams, the max oil con-
en into consideration. centration in liquid phase must not exceed
0170-151-EN 111
2%. For the other area, the max. oil con- In the oil recommendation diagrams for each
centration must not exceed 5%. For area B: refrigerant and compressor type, it is pos-
please contact YORK Refrigeration. sible to determine the code number for the
oil best suited to the operating conditions.
Plants with several different compressor With this code number, it is possible to se-
types/makes lect the correct Sabroe oil for the application.
In plants comprising several different inter- The marked area on each side of the sepa-
connected compressor types and makes, it is rating line in the diagram shows the zone
strongly recommended that all compressors where both oils are useable.
should use the same type of oil. This is es-
sential where automatic oil return systems Oil types and oil companies
are employed. As a result of the large number of oil compa-
nies world-wide that deals in oil for refrigera-
If it is intended to change the oil from one tion plants, it is impossible for YORK
type to another, please refer to the Oil chang- Refrigeration to test the many different
ing on SABROE compressors later in this brands of oil on the market. It is our experi-
publication. ence, however, that some oil brands during
use can change character and thus no longer
Selecting the lubricating oil fit the specifications given by the companies
There are a number of operating diagrams at delivery. We have thus experienced
for the selection of lubricating oils for Sabroe changes in the specifications as well as in
compressors operating with various refriger- the formula and performance without having
ants. Once the general conditions concern- had any information about this from the oil
ing the lubrication of the compressor and oil company. This makes it very difficult for
type in the plant have been considered, the YORK Refrigeration to give a general ap-
specific plant conditions must be taken proval of the various oil brands.
into consideration.
Use the Oil recommendation diagrams to se- For this reason YORK Refrigeration has, in
lect the appropriate oil code number. cooperation with a large recognised oil com-
pany, developed a series of three oils which
The oil code number consists of letters des- cover most purposes. YORK Refrigeration
ignating the oil type together with the Sabroe has however, also listed a limited number of
viscosity grade number. oils which can be supplied through YORK
Refrigeration. The typical data of these oils
Code can be found in the Data Sheet for Sabroe
Oil types
design Oils. We suggest you to use these Sabroe
M Mineral oil oils, which are delivered in 20 litre pails and
Synthetic oil based on 208 litre drums and can be ordered using the
A
Alkylbenzene
parts no. listed in the List of Oils.
Synthetic oils based on
PAO
Polyalphaolefin
AP Mixture of A and PAO-oils It is of course possible to use similar oils from
E Synthetic ester-based lubricants other oil companies, and in this connection,
112 0170-151-EN
the Data Sheet for Sabroe Oils may be help- Screw compressors:
ful. The oil temperature before injection in
the compressor, but after the oil cooler
Please note, however, that YORK
Refrigeration has not tested any other oils Max. permitted oil temperature = set-
than our own brand, and hence we cannot ting point for alarm
answer for the quality, the stability or the suit- Min. permitted oil temperature = set-
ability of other oils for any purposes. The oil ting point for alarm
company in question is thus solely responsi- • Condensing pressure
ble for the quality and suitability of the oil de- • Evaporating pressure
livered, and if any problems are experienced
S Oil viscosity in the compressor during
with these oils in the compressors or in the
operation and under the influence of:
refrigeration plant, the oil supplier should be
contacted directly. • Refrigerant type and solubility of refrig-
erant in the oil
When choosing oils from other oil compa-
• Operating temperatures
nies, please pay particular attention to the
oil’s effectiveness in the compressor and the • Vapour pressure in the oil reservoir
refrigeration plant as a whole. Reciprocating compressor: Suction
pressure and oil temperature in the
Pay particular attention to the following as- crankcase.
pects:
Screw compressor: Discharge pressure
S Oil type and gas temperature.
Reciprocating compressors:
For this reason it is not recommended to
Normal oil temp. in the crankcase change oil type from M oil to PAO oil as a
50-60 °C leakage may occur if the O-rings are not
Max. permitted oil temperature = Set- changed. YORK Refrigeration therefore
ting point for alarm recommends using the Sabroe AP68 oil
Min. permitted oil temperatures = set- as it reduces the risk of leaks considerably
ting point for alarm - if fitted in this case.
0170-151-EN 113
YORK Refrigeration can supply a calculation YORK Refrigeration is aware, however, that
showing the operating data on request. several customers have been using mineral
oils for many years without problems. Those
Attention is drawn to the following viscosity customers who wish to continue using miner-
limits during operation: al oils in existing, as well as new, compres-
sors can do so, providing the compressor
S Optimum viscosity range
type and operating conditions are similar to
(to be designed for) = 20 to 50 cSt
the existing ones (excepting the HPC and
S Max. permissible viscosity =100 cSt HPO series compressors).
S Min. permissible viscosity =10 cSt
(only applicable to HCFC and HFC under YORK Refrigeration has therefore decided to
cartain operating conditions: 7cSt)
market a brand of mineral oil which has been
S Max. permissible viscosity during the tested and found to be suitable for most gen-
starting of the compressor = 500 cSt eral refrigerating purposes.
Maximum refrigerant concentration in the oil
at running condition: 25% - also if viscosity If another brand of mineral oil is chosen, the
requirements are met. specifications in the data sheet in this recom-
mendation should be followed as a guideline.
Use of mineral oil
Lately we have experienced a number of
Mineral oil can be used in refrigerating
problems with mineral oil, particularly in R717
plants, providing the lubricating quality is
plants. The problems can be divided into two
carefully monitored. For modern, high capac-
groups:
ity refrigeration plants, in which a long life-
a: The oil changes viscosity within a few time for both lubricant and moving parts is
operating hours. expected, YORK Refrigeration recommends
b: The oil decomposes (becomes very using synthetic lubricating oils.
black) within a few operating hours.
A benefit of using the synthetic lubricant oil is
The problems have been seen with several
a much lower oil carry-over to the plant and
oil brands and have resulted in severe con-
longer intervals between oil changes.
sequences for both compressors and plants.
A better fluidity at lower temperatures also
gives an easier drainage at the cold parts of
When using mineral oil, it is thus important
the plant.
that the plant is monitored very closely, that
oil samples are taken regularly (every
1-2,000 hours) and that the condition/colour
How to use the oil recommendation dia-
of the oil is checked on a weekly basis.
grams:
YORK Refrigeration therefore recom- To determine the code number, first refer to
mends only to use M oil at moderate oper- the Oil recommendation diagram for the re-
ating conditions - cf. the attached oil rec- frigerant and compressor type and then plot
ommendation diagrams. the proposed operating conditions.
114 0170-151-EN
Example (recip. compressors): the example above, a oil code number E5
Refrigerant: R134a can be selected.
Condensing temp. TC +35°C
Evaporating temp. TE –3°C Code no Area no
1 2
Please observe !
E5 Y
Plants may operate at different conditions
from time to time, for example at different E9 Y
evaporating temperatures due to plant
In plants which incorporate both screw and
variations or at different condensing tem-
reciprocating compressors and where the
peratures due to seasonal changes.
recommendations indicate the use of differ-
By plotting TC and TE in the oil recom-
ent oil types, please contact YORK
mendation diagram, this example would
Refrigeration for advice.
require a No 1 oil. If, however, TE
changes at certain times, e.g. from –3 to Changing oil on Sabroe compressors
+7°C, a No 2 oil should be utilised. But, as
The oil should never be changed to another
+7°C is inside the marked area, the No 1
type without consulting the oil supplier. Nor is
oil can be utilised also at this TE.
it advisable to ”top up” compressors with an
R134a other oil than the one already used for the
ÎÎ
TC
particular plant and compressor.
°F °C
158 70
140 60 ÎÎ
ÎÎ 2
Mixing different oils may result in operating
problems in the refrigerant plant and damage
122 50
ÎÎ
ÎÎ
to the compressors. Incompatibility between
Condensing temperature
• •
104 40
the different oil types may degrade the lubri-
86 30
68 20 1 ÎÎ
ÎÎ
cating properties or may cause oil residues to
form in the compressor or oil separator or in
50 10
the plant. These oil residues can block filters
32 0
and damage the moving parts in the com-
14 -10
pressor.
-4 -20
0170-151-EN 115
It is imperative that oil is only used from the Oil drums should, ideally, be ”racked” and
original container and that both the make and mounted with a proper barrel tap to ensure
type complies with the specification for the an effective airtight seal.
plant.
Oil changing intervals
Ensure that the original container is sealed A list of the recommended intervals for
during storage to prevent moisture from the changing the oil can be found in the com-
air being absorbed into the oil - many oils, pressor instruction manual. These are pro-
particulary the polyolester oils, are extremely vided for guidance only. The actual interval
hygroscopic. Consequently, it is recom- between oil changes will often be determined
mended that the oil is only purchased in con- by a variety of operating parameters within
tainers corresponding to the amount to be the plant.
used on each occasion.
It is strongly recommended to monitor the
If the oil is only partially used, make sure that quality of the oil by carrying out oil analyses
it is effectively re-sealed in the original con- with regular intervals. This will also give a
tainer and that it is stored in a warm, dry good indication of the condition of the plant.
place. Ideally with nitrogen blanking of the oil The service can be supplied by YORK
to keep the water content below 50 ppm. Refrigeration or the oil suppliers.
ÑÑ
ÜÜ
SH : Suction gas superheat, K (Kelvin)
ÜÜ
: Zone in which both oils are useable
: Calculation must be performed using COMP1
116 0170-151-EN
Data sheet for listed Sabroe oils
Typical data for lubricating oils for Sabroe compressors
The listed data are typical values and are intended as a guideline only when selecting a similar
oil from a different oil company. Data equivalence alone does not necessarily qualify the oil for
use in YORK Refrigeration’s Sabroe compressors.
0170-151-EN 117
List of part numbers for available Sabroe oils
Part no.
Oil brand Oil code no.
20 litre pail 208 litre pail
Mobil Gargoyle Arctic 300 M 1 (M68) 1231-264 1231-296
Sabroe Oil A100 A 3 (A100) 1231-263 1231-262
Sabroe Oil AP68 AP 1 (AP68) 1231-257 1231-260
Sabroe Oil PAO68 PAO 3 (P68) 1231-256 1231-259
Mobil Gargoyle Arctic SHC 228 PAO 5 (P100) 1231-282 1231-283
Mobil Gargoyle Arctic SHC 230 PAO 9 (P220) 1231-284 1231-285
Mobil EAL Arctic 68 E 3 (E68) 1231-272 1231-273
Mobil EAL Arctic 100 E 5 (E100) 1231-274 1231-275
Mobil EAL Arctic 220 E 9 (E220) 1231-279
Sabroe H oil E11 (E370) 3914 1512 954 1) 9415 0008 000
1) 18.9 litre pail (5 US gallons)
The oils recommended by the former Stal Refrigeration correspond to the following oils:
118 0170-151-EN
R717 TC
one-stage
°F °C
reciprocating
122 50
compressors
104 40
Condensing temperature
86 30
68 20 1
50 10
32 0
-22 -30
AP 1 l/Y -60 -50 -40 -30 -20 -10 0 10 20 °C
TE
M1 See note -76 -58 -40 -22 -4 14 32 50 68 °F
Evaporating temperature
Note: YORK Refrigeration recommends that the use of M oils is restricted to moderately loaded compressors and
that the oil quality is monitored carefully via regular oil analyses.
Y : In case of a new plant. Very suitable.
lĂ : In case you wish to change from mineral oil
0170-151-EN 119
R717 TC
two-stage
°F °C
reciprocating
122 50
compressors
104 40
Condensing temperature
86 30
1
68 20
50 10
32 0
-22 -30
AP 1 l/Y -60 -50 -40 -30 -20 -10 0 10 20 °C
TE
M1 See note -76 -58 -40 -22 -4 14 32 50 68 °F
Evaporating temperature
Note: YORK Refrigeration recommends that the use of M oils is restricted to moderately loaded compressors and
that the oil quality is monitored carefully via regular oil analyses.
Y : In case of a new plant. Very suitable.
lĂ : In case you wish to change from mineral oil
120 0170-151-EN
R717 TC
HPO and HPC
°F °C
reciprocating
176 80
compressors
158 70
Condensing temperature
140 60
1
122 50
104 40
86 30
68 20
50 10
Code no Area no
1 32 0
PAO 5 Y -30 -20 -10 0 10 20 30 40 50 °C
TE
-22 -4 14 32 50 68 86 104 122 °F
Evaporating temperature
Please observe: PAO 5 oil is the only oil which can be used in the HPO and HPC compressors.
Y : In case of a new plant. Very suitable.
0170-151-EN 121
R22 TC Contact YORK Refrigeration
one-stage
°F °C
reciprocating 2
122 50
compressors
104 40
Condensing temperature
86 30
1
68 20
50 10
32 0
14 -10 A
Code no Area no -4 -20
1
-22 -30
A3 Y
-60 -50 -40 -30 -20 -10 0 10 20 °C
TE
-76 -58 -40 -22 -4 14 32 50 68 ° F
C Evaporating temperature
122 0170-151-EN
R22 TC
two-stage
°F °C
reciprocating
122 50
compressors
104 40
Condensing temperature
86 30 1
A
68 20
50 10
32 0
14 -10
0170-151-EN 123
R134a
TC
ÑÑ
°F °C
one-stage
ÑÑ
158 70
reciprocating
ÑÑ
140 60 2
compressors
Condensing temperature
122 50
ÑÑ
ÑÑ
ÑÑ
104 40
86
68
30
20 1
ÑÑ
ÑÑ
50 10
32 0
14 -10
Code no Area no
-4 -20
1 2
-22 -30
E5 Y
E9 Y
-60 -50 -40 -30 -20 -10 0 10 20 30 ° C
TE
-76 -58 -40 -22 -4 14 32 50 68 86 ° F
Evaporating temperature
ÑÑ
YĂ:
ÑÑ :
In case of a new plant. Very suitable.
Zone in which both oils are useable
124 0170-151-EN
R134a TC
two-stage °F °C
reciprocating 158 70
compressors 140 60
122 50
1
Condensing temperature 104 40
86 30
68 20
50 10
32 0
14 -10
-4 -20
Code no Area no
-22 -30
1
-40 -40
E5 Y
-70 -60 -50 -40 -30 -20 -10 0 10 20 30 °C
TE
-94 -76 -58 -40 -22 -4 14 32 50 68 86 ° F
Evaporating temperature
0170-151-EN 125
R407C TC
one-stage
°F °C
reciprocating
122 50
compressors
104 40
Condensing temperature
86 30
68 20
1
50 10
32 0
14 -10
B
Code no Area no -4 -20
1
-22 -30
E3 Y -60 -50 -40 -30 -20 -10 0 10 20 °C
TE
-76 -58 -40 -22 -4 14 32 50 68 °F
C Evaporating temperature
126 0170-151-EN
R407C TC
two-stage
°F °C
reciprocating
122 50
compressors
104 40
Condensing temperature
86 30 1
68 20 B
50 10
32 0
14 -10
0170-151-EN 127
R404A TC
one-stage
°F °C
reciprocating
compressors
122 50 ÑÑÑ
ÑÑÑ
104 40
ÑÑÑ
ÑÑÑ
2
ÑÑÑ
Condensing temperature
86 30
68 20 ÑÑÑ
ÑÑÑ
50 10 1
ÑÑÑ
32 0
1 2
-4 -20
E3 Y
-22 -30
E5 Y -60 -50 -40 -30 -20 -10 0 10 20 °C
TE
-76 -58 -40 -22 -4 14 32 50 68 °F
C Evaporating temperature
ÑÑ
YĂ: In case of a new plant. Very suitable.
ÑÑ
C : Min suction temperature –50°C: at TE< –50°C superheating must be introduced.
: Zone in which both oils are useble
128 0170-151-EN
R404A TC
two-stage
°F °C
reciprocating
122 50
compressors
104 40
Condensing temperature
86 30
1
68 20
50 10
32 0
14 -10
0170-151-EN 129
R410A TC
HPO og HPC
°F °C
reciprocating
122 60
compressors
50
104
40
86
Condensing temperature
30
68 20
10 1
50
0
32
A
-10
14
-20
Code no Area no -4
-30
1
-22 -40
E5 Y
130 0170-151-EN
R507 TC
one-stage
°F °C
reciprocating
122 50
compressors
104 40
Condensing temperature 86 30
68 20
1
50 10
32 0
14 -10
0170-151-EN 131
R507 TC
two-stage
°F °C
reciprocating
122 50
compressors
104 40
Condensing temperature
86 30
1
68 20
50 10
32 0
14 -10
132 0170-151-EN
R717 TC
Screw compressors °F
ÜÜÜÜÜÜÜÜ
°C
122 50
ÜÜÜÜÜÜÜÜ
ÜÜÜÜÜÜÜÜ
Condensing temperature
104 40
ÜÜÜÜÜÜÜÜ
ÜÜÜÜÜÜÜÜ
ÜÜÜÜÜÜÜÜ
86 30
68 20
ÜÜÜÜÜÜÜÜ
ÜÜÜÜÜÜÜÜ
1
50
32
10
0
ÜÜÜÜÜÜÜÜ
14 -10
Code no Area no
1 -4 -20
PAO 3 Y
-22 -30
AP 1 l/Y 20 °C
-60 -50 -40 -30 -20 -10 0 10
TE
M1 See note -76 -58 -40 -22 -4 14 32 50 68 °F
C Evaporating temperature
Note: YORK Refrigeration recommends that the use of M oils is restricted to moderately loaded compressors and
that the oil quality is monitored carefully via regular oil analyses.
HLI: Calculation must be performed using COMP1
YĂ : In case of a new plant. Very suitable.
lĂ : In case you wish to change from mineral oil
ÜÜ
C :
ÜÜ :
Min suction temperature –50°C: at TE< –50°C superheating must be introduced.
Calculation must be performed using COMP1.
0170-151-EN 133
R22 TC
ÜÜÜÜÜÜ
ÚÚÚÚÚÚÚÚÚÚÚ
ÔÔÔÔÔÔÔÔÔÔÔ
ÒÒÒÒÒÒÒÒÒÒÒ
ÔÔÔÔÔÔÔÔÔÔ
SH25
Screw compressors °F °C
ÜÜÜÜÜÜ
ÚÚÚÚÚÚÚÚÚÚÚ
ÔÔÔÔÔÔÔÔÔÔÔ
ÒÒÒÒÒÒÒÒÒÒÒ
ÔÔÔÔÔÔÔÔÔÔ
ŠŠŠŠŠŠŠŠŠŠ
ÜÜÜÜÜÜ
ÚÚÚÚÚÚÚÚÚÚÚ
ÒÒÒÒÒÒÒÒÒÒÒ
ŠŠŠŠŠŠŠŠŠŠ
122 50
2
104 40
ÜÜÜÜÜÜ
ÚÚÚÚÚÚÚÚÚÚÚ
ÒÒÒÒÒÒÒÒÒÒÒ
ŠŠŠŠŠŠŠŠŠŠ
ÜÜÜÜÜÜ
ÚÚÚÚÚÚÚÚÚÚÚ
ÒÒÒÒÒÒÒÒÒÒÒ
ŠŠŠŠŠŠŠŠŠŠ
Condensing temperature SH20
ÜÜÜÜÜÜ
ÚÚÚÚÚÚÚÚÚÚÚ
ŠŠŠŠŠŠŠŠŠŠ
86 30 SH5
68 20
ÜÜÜÜÜÜ
ÚÚÚÚÚÚÚÚÚÚÚ
ŠŠŠŠŠŠŠŠŠŠ
ÜÜÜÜÜÜ 1
SH10
50 10
ÜÜÜÜÜÜ
ÒÒÒÒÒÒÒÒ
32 0 ÒÒÒÒÒÒÒÒ
A
ÒÒÒÒÒÒÒÒ
Code no Area no
14 -10
ÒÒÒÒÒÒÒÒ
ÒÒÒÒÒÒÒÒ
ÒÒÒÒÒÒÒÒ
1 2* SH20
-4 -20
A3 Y
-22 -30
PAO 5 Y -60 -50 -40 -30 -20 -10 0 10 20 °C
TE
-76 -58 -40 -22 -4 14 32 50 68 °F
C Evaporating temperature
Using the calculating programme COMP1 it is possible to optimize the requirement for suction superheat values
(SH) as stated in the diagram. See Oil types and oil companies in this section. Due to the ongoing development of
lubrication oils, please contact YORK Refrigeration for an update on the requirement for superheat.
Ü
SH : Suction gas superheat, K (Kelvin)
: Calculation must be performed using COMP1
134 0170-151-EN
R134a TC
Screw compressors °F °C
ÜÜÜÜÜÜÜÜÜ
ÏÏÏÏÏÏÏÏ
ÒÒÒÒÒÒÒÒÒÒÒ SH30
158 70
ÜÜÜÜÜÜÜÜÜ
ÏÏÏÏÏÏÏÏ
ÒÒÒÒÒÒÒÒÒÒÒ
ÚÚÚÚÚÚÚÚÚÚ
ÜÜÜÜÜÜÜÜÜ
ÒÒÒÒÒÒÒÒÒÒÒ
ÚÚÚÚÚÚÚÚÚÚ
ŠŠŠŠŠŠŠŠ
ÜÜÜÜÜÜÜÜÜ
ÚÚÚÚÚÚÚÚÚÚ
ŠŠŠŠŠŠŠŠ
140 60 SH20
122 50
ÜÜÜÜÜÜÜÜÜ
ÚÚÚÚÚÚÚÚÚÚ
ŠŠŠŠŠŠŠŠ
ÑÑÑÑÑÑ
ÜÜÜÜÜÜÜÜÜ
Condensing temperature 104 40 ÚÚÚÚÚÚÚÚÚÚ
ŠŠŠŠŠŠŠŠ
ÑÑÑÑÑÑ
ÜÜÜÜÜÜÜÜÜ
ŠŠŠŠŠŠŠŠ
ÑÑÑÑÑÑ
2 SH10
ÜÜÜÜÜÜÜÜÜ
ŠŠŠŠŠŠŠŠ
ÑÑÑÑÑÑ
ŠŠŠŠŠŠŠŠ
ÑÑÑÑÑÑ
86 30
SH5
68 20
ÑÑÑÑÑÑ
ÒÒÒÒÒÒÒ
ÑÑÑÑÑÑ
ÒÒÒÒÒÒÒ1
ÒÒÒÒÒÒÒ
50 10
Code no Area no
32 0
ÒÒÒÒÒÒÒ
ÒÒÒÒÒÒÒ
ÒÒÒÒÒÒÒ
(See note) 14 -10
1 2 SH20
E5 Y -4 -20
E9 Y -50 -40 -30 -20 -10 0 10 20 30 °C
TE
-58 -40 -22 -4 14 32 50 68 86 ° F
Evaporating temperature
Note: For the compressors type ”S”, ”Rotatune”, ”SAB 81”, ”SAB 83”, and ”SAB 85” only Sabroe oil H is approved.
Using the calculating programme COMP1 it is possible to optimize the requirement for suction superheat values
(SH) as stated in the diagram. See Oil types and oil companies in this section. Due to the ongoing development
of lubrication oils, please contact YORK Refrigeration for an update on the requirement for superheat.
HLI: Calculation must be performed using COMP1.
YĂ : In case of a new plant. Very suitable.
ÑÑ
SH : Suction gas superheat, K (Kelvin)
ÜÜ
: Zone in which both oils are useable
: Calculation must be performed using COMP1
0170-151-EN 135
R404A TC
Screw compressors
ÜÜÜÜÜÜÜ
ÚÚÚÚÚÚÚÚÚÚ
ÖÖÖÖÖÖ
°F °C
ÜÜÜÜÜÜÜ
ÚÚÚÚÚÚÚÚÚÚ
ÖÖÖÖÖÖ
SH15
104 40
ÜÜÜÜÜÜÜ
ÚÚÚÚÚÚÚÚÚÚ
ÑÑÑÑÑÑÑ
ÜÜÜÜÜÜÜ ÖÖÖÖÖÖ
Condensing temperature
86 30
ÚÚÚÚÚÚÚÚÚÚ
ÑÑÑÑÑÑÑ
ÜÜÜÜÜÜÜ
ÑÑÑÑÑÑÑ 3 SH10
2 (3)
ÜÜÜÜÜÜÜ
ÑÑÑÑÑÑÑ
68 20
50 10
ÜÜÜÜÜÜÜ
ÑÑÑÑÑÑÑ
ÖÖÖÖÖÖÖ
ÜÜÜÜÜÜÜ ÖÖÖ
32 0 ÑÑÑÑÑÑÑ
ÖÖÖÖÖÖÖÖÖÖ
ÑÑÑÑÑÑÑ
ÖÖÖÖÖÖÖ 1
(2)
14 -10
ÑÑÑÑÑÑÑ
ÖÖÖÖÖÖÖ
ÖÖÖÖÖÖÖ
B
ÖÖÖÖÖÖÖ
Code no Area no
(See note) -4 -20
ÖÖÖÖÖÖÖ
1 2 3 SH15
E3 Y -22 -30
E5 Y -70 -60 -50 -40 -30 -20 -10 0 10 °C
E9 Y TE
-94 -76 -58 -40 -22 -4 14 32 50 °F
C Evaporating temperature
Note: For the compressors type ”S”, ”Rotatune”, ”SAB 81”, ”SAB 83”, and ”SAB 85” only Sabroe oil H is approved.
Using the calculating programme COMP1 it is possible to optimize the requirement for suction superheat values
(SH) as stated in the diagram. See Oil types and oil companies in this section. Due to the ongoing development
of lubrication oils, please contact YORK Refrigeration for an update on the requirement for superheat.
HLI: Calculation must be performed using COMP1.
ÑÑ
C : Min suction temperature –50°C: at TE< –50°C superheating must be introduced.
ÑÑ
ÜÜ
SH : Suction gas superheat, K (Kelvin)
: Zone in which both oils are useable
136 0170-151-EN
R407C TC
Screw compressors
°F
122
°C
50 ŠŠŠŠŠŠŠŠŠ
ÜÜÜÜÜÜÜ ÚÚÚÚÚ
ŠŠŠŠŠŠŠŠŠ
ÜÜÜÜÜÜÜ ÚÚÚÚÚ
ŠŠŠŠŠŠŠŠŠ
ÜÜÜÜÜÜÜ ÚÚÚÚÚ
SH10
ŠŠŠŠŠŠŠŠŠ
ÜÜÜÜÜÜÜ
104 40
SH5
ÜÜÜÜÜÜÜ
ÑÑÑÑÑÑÑÑÑ
Condensing temperature 2
86 30
ÜÜÜÜÜÜÜ
ÑÑÑÑÑÑÑÑÑ
ÜÜÜÜÜÜÜ
ÑÑÑÑÑÑÑÑÑ
68 20
50 10
ÜÜÜÜÜÜÜ
ÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑ
ŠŠŠŠŠ 1
32 0
B
14 -10
ŠŠŠŠŠ
ŠŠŠŠŠ
ŠŠŠŠŠ
Code no Area no -4 -20
(See note) SH5
1 2
-22 -30
E3 Y -70 -60 -50 -40 -30 -20 -10 0 10 20 °C
E9 Y TE
-94 -76 -58 -40 -22 -4 14 32 50 68 ° F
C Evaporating temperature
Note: For the compressors type ”S”, ”Rotatune”, ”SAB 81”, ”SAB 83”, and ”SAB 85” only Sabroe oil H is approved.
Using the calculating programme COMP1 it is possible to optimize the requirement for suction superheat values
(SH) as stated in the diagram. See Oil types and oil companies in this section. Due to the ongoing development
of lubrication oils, please contact YORK Refrigeration for an update on the requirement for superheat.
HLI: Calculation must be performed using COMP1.
YĂ : In case of a new plant. Very suitable.
B : Max oil concentration in liquid phase: contact YORK Refrigeration
C : Min suction temperature –50°C: at TE< –50°C superheating must be introduced.
ÑÑ
SH : Suction gas superheat, K (Kelvin)
ÜÜ
: Zone in which both oils are useable
: Calculation must be performed using COMP1
0170-151-EN 137
R507 TC
Screw compressors
ÜÜÜÜÜÜÜ
ÑÑÑÑÑÑÑÑÑ
ŠŠŠŠŠ
°F °C
104 40
ÜÜÜÜÜÜÜ
ÑÑÑÑÑÑÑÑÑ
ÜÜÜÜÜÜÜ ŠŠŠŠŠ
ÑÑÑÑÑÑÑÑÑ
ŠŠŠŠŠ 2
ÜÜÜÜÜÜÜ
ÑÑÑÑÑÑÑÑÑ
ŠŠŠŠŠ
86 30 SH5
Condensing temperature
ÜÜÜÜÜÜÜ
ÑÑÑÑÑÑÑÑÑ
ÖÖÖÖÖÖÖÖÖÖ
ÜÜÜÜÜÜÜ ŠŠŠŠŠ
ÑÑÑÑÑÑÑÑÑ
ÖÖÖÖÖÖÖÖÖÖ
ŠŠŠŠŠŠŠŠŠŠŠ
68 20
50 10
ÜÜÜÜÜÜÜ
ÖÖÖÖÖÖÖÖÖÖ
ŠŠŠŠŠŠŠŠŠŠŠ
ÜÜÜÜÜÜÜ
1 SH5
ÖÖÖÖÖÖÖÖÖÖ
ŠŠŠŠŠŠŠŠŠŠŠ
ÖÖÖÖÖÖÖÖÖÖ
ŠŠŠŠŠŠŠŠŠŠŠ
ÏÏÏÏÏÏ
32 0
SH15
ÖÖÖÖÖÖÖÖÖÖ
ŠŠŠŠŠŠŠŠŠŠŠ
ÏÏÏÏÏÏ
ÖÖÖÖÖÖÖÖÖÖ
ŠŠŠŠŠŠŠŠŠŠŠ
ÏÏÏÏÏÏ
14 -10
Note: For the compressors type ”S”, ”Rotatune”, ”SAB 81”, ”SAB 83”, and ”SAB 85” only Sabroe oil H is approved.
Using the calculating programme COMP1 it is possible to optimize the requirement for suction superheat values
(SH) as stated in the diagram. See Oil types and oil companies in this section. Due to the ongoing development
of lubrication oils, please contact YORK Refrigeration for an update on the requirement for superheat.
HLI: Calculation must be performed using COMP1.
Ñ
SH : Suction gas superheat, K (Kelvin)
Ü
: Zone in which both oils are useable
: Calculation must be performed using COMP1
138 0170-151-EN
List of major oil companies
The oil from the companies listed below are NOT tested by YORK Refrigeration and are there-
fore NOT approved by YORK Refrigeration either. The following list reflects the information pro-
vided by the companies themselves. The assessment of durability and suitability of specific oils
for specific purposes are entirely at the companies’ own discretion. Oils tested and approved by
YORK Refrigeration can be found in the ”List of part numbers for available Sabroe oils”.
0170-151-EN 139
Notes:
140 0170-151-EN
Alignment of unit, AMR coupling
Where the compressor and motor are directly manufacturer prior to delivery. The following
interlinked, an AMR coupling is used; this is a sections will deal with the individual points
torsionally rigid coupling with enough radial concerning the fitter.
and axial flexibility to assimilate small move-
ments between the two machines. Alignment of unit with foundation
Whenever installing a unit directly onto the
In order to ensure compressor and motor a
foundation or machine floor, it should stand
long life as well as noise- and vibration-free
free of stresses and press down evenly on all
operation, compressor unit and coupling
supports.
need to be aligned with care. Misalignment of
the compressor unit or coupling may The unit can be installed in the following
produce stresses and vibrations which can ways:
be transmitted to the compressor and motor
S on vibration dampers
bearings and thus cause major damage.
S straight onto a foundation, using founda-
95.03
0178-225-EN 141
Installation on vibration dampers
1
A1
A2
H Hmax
A1
A2
T0177040_0
142 0178-225-EN
Installing directly on foundation Perform this check with the bolts loosened. If
slip occurs at one or more resting surfaces,
When installing a unit directly on a concrete
shim up before tightening. If unaligned, there
foundation, the foundation should be cast in
is a risk of stresses occurring in the compres-
accordance with the foundation drawings dis-
sor frame, which will damage the bearings.
patched.
When the foundation has been cast - with the Alignment of motor with base frame
holes shown for foundation bolts - and has Check the contact faces of the motor against
set, place the unit in position, allowing it to the base frame in the same way as for the
rest on beams levelled at a suitable height so compressor.
that the foundation plates are recessed
slightly into the foundation. Stresses from piping connections
In order to prevent stress being transmitted
Check that the foundation plates are right
from piping connections between unit and
next to the base frame. This can be achieved
plant, pipes must be laid so as not to gener-
by binding them to the resting surfaces of the
ate compressive stresses or tensile strains in
base frame with steel flex.
the event of expansions or contractions due
The concrete cast down around the founda- to temperature changes. Steel piping ex-
tion bolts should contain only a small amount pands approx. 1 mm per metre per 100°C.
of water, so that it can be well tamped around We recommend that piping be laid as shown
the bolts. Low water content produces no in example 2 of the sketch. Example 1 dem-
contraction of the setting concrete. onstrates too rigid pipe laying.
Check that the entire footing of the compres- Final alignment of compressor and motor can
sor makes full contact against the milled-off be performed once all piping has been con-
faces of the base frame. nected to the unit.
0178-225-EN 143
Fitting and alignment of AMR-type coupling
Installation and alignment Important:
Before any work on the coupling, ensure
In principle, alignment involves manoeuvring
that the compressor motor cannot be
the motor so as to make the shaft form an
started inadvertenly.
extension of the crankshaft.
Fig. 1
1
Compressor Motor
Z
2
X
a
A
B
C
T0177120_0/V2
HPC/SMC
312 S 103,5 147 55 0,2 0,1/0,3 0,2
104-108
SMC
350 S 114,5 147 128 0,2 0,1/0,3 0,2
112-116
SMC
450 S 149,0 295 275 0,3 0,1/0,4 0,3
180
* See Final mounting, pt. 4
144 0178-225-EN
Preliminary installation Alignment
S Check tightening of coupling flange on Check that the motor with loose bolts stands
compressor. with all four feet on the base frame. Insert
any liner plates needed where there is an air
S Tighten 8 coupling bolts securing lamellar gap beneath the feet. Tauten the bolts slight-
segments to intermediate piece to pre- ly.
scribed moment stated in table. It is worth-
while doing this before placing the inter- Achieving parallel shafts in
mediate piece in position.
horizontal plane
S Mount retaining plate from coupling S Turn coupling so that alignment gauge is
screen onto compressor and insert sup- in upper position. See fig. 1.
port ring for coupling screen over motor S Guide measuring pin (Pos. 2) towards
flange. coupling flange, using a 1.0 mm feeler
gauge, and fix pin. Remove feeler gauge.
S Insert coupling intermediate piece. Create
space between flanges either by shifting S Rotate coupling 180° and measure
entire motor or just motor coupling flange. change in distance from measuring pin to
The intermediate piece should only be flange, using feeler gauges. This change
secured to the compressor flange. Do is called ”x”.
not insert the last four bolts in the mo- S Insert shims of thickness ”y” either under
tor flange until the coupling has been both front feet or both rear feet, thereby
aligned. tilting motor in direction required. Shim
As the compressor shaft rotates during the thickness ”y” is calculated using the fol-
alignment procedure, the motor must turn lowing formula (see drawings):
with it, as the bolts in the intermediate
b
piece engage in the free holes in the mo- y = X •
2xa
tor coupling flange.
0178-225-EN 145
Achieving correct centre height S Turn coupling 180° and, using feeler
gauges, measure deviations from one mil-
S Turn coupling so that alignment gauge
limetre at both pins.
faces vertically down.
S Guide measuring pin (pos. 1) towards S Moving and turning motor and repeating
coupling flange, using a 1.0 mm feeler this measurement, align motor in accord-
gauge, and fix pin. Remove feeler gauge. ance with pos. 1 horizontal and pos. 2 in
S Rotate coupling 180° and measure in- table. Remember that the motor must be
crease in distance ”z” from one millimetre firmly secured during any measurements.
using feeler gauges.
Final installation
S Then lift motor by placing shims of thick-
ness equal to half value of ”z” under all S Tighten foundation bolts on motor (see
four feet. torque table).
S After securing motor, repeat measurement S Fit four bolts into motor coupling flange so
and compare result with table values in that thin shims are placed between flange
pos. 1 vertical. Remember that the centre- and lamellae, with rounded side facing la-
line of the motor shaft must be at least mella. There are no thin shims on cou-
0.05 mm higher than the centreline of the plings for CMO and HPO.
compressor, corresponding to a minimum
S Tighten bolts to torque specified in table.
of 0.1 mm distance less at the top position
of the alignment gauge. S Readjust flange distance ”C” so that la-
mellae are aligned, by moving motor
Achieving parallel shafts in vertical flange on shaft and fastening motor
plane flange.
S The motor is now positioned at its correct S Check alignment of coupling in horizontal
height. What now remains is to push and and vertical planes for pos. 1 and pos. 2.
turn the motor at the level on which it is
already lined up. S Dismantle measuring pin and tighten
screw to prescribed torque.
S Turn coupling so that alignment gauge
faces out to one side horizontally. S Fit coupling guard.
S Guide both measuring pins towards coup- S Once normal operating temperature has
ling with a 1.0 mm feeler gauge in be- been achieved, double-check coupling
tween. alignment.
146 0178-225-EN
Boring of motor flange for AMR coupling
A MAX. 0.02 mm
B
92.03
MAX. 0.02 mm
T0177131_0 V12
Unless the necessary data for the motor are S The bore should then be made to the rele-
010-502-EN
known prior to dispatch, the motor flange for vant dimensions and to the following toler-
the AMR coupling will not be supplied in ances:
ready bored form.
H8 for AMR 312, 350 and 450,
In such case, the motor flange is supplied H7 for AMR 225.
prebored and balanced.
S Cut keyways.
Finish-boring is done as follows:
For reasons of balance, coupling AMR
S Secure flange in lathe or jig-boring ma- 312, 350 and 450 must be executed with
chine. Observe following tolerances for the two keyways shown.
alignment purposes:
S Make the width of the keyway to a toler-
Max. axial eccentricity ance of H7.
measured at point A 0.02 mm
S The keyway must be deep enough to al-
Max. axial eccentricity 0.02 mm low a clearance between parallel keys
measured at point B
and hub of 0.2-0.3 mm.
Max. boring diameter:
Compressor CMO - TCMO - HPO SMC - TSMC 100 - HPC SMC - TSMC 180
Boring tolerance H7 H8 H8
0171-487-EN 147
VĆbelt drive for piston compressor types
(T)CMO and (T)SMC
If your SABROE compressor is belt driven, V-belts are used with profiles specified in the
table below.
95.06
SMC - TSMC 186 - 188 SPC (21 x 18) 1230 9,00 6,50
0171-469-EN
Fig. 1 Fig. 2
C
C/2
15 mm
T0177084_0
148 0171-370-EN
question, as stated in the table. Tighten S When changing worn V-belts, the whole
belt drive so that sag is approx. 15 mm for set should be replaced.
all V-belts.
S A new belt drive always has to be tight- S A set of V-belts must always be within the
ened to the max. value. same tolerance group.
S Run transmission for a few minutes and S Never use belt lubricant.
then check tension.
0171-370-EN 149
Thermo pump cooling of R717
reciprocating compressors
types SMC 104Ć106Ć108Ć112Ć116 / TSMC 108Ć116 /
CMO 24Ć26Ć28, TCMO 28
The thermo pump is a compressor cooling The pumping cycle of the thermo pump, i.e.
system for R717 reciprocating compressors. a filling and an evacuation period, lasts be-
Its purpose is to cool the oil in the crankcase tween 4 and 8 minutes depending on the
as well as the compressor discharge gas in number of cylinders of the compressor, its
order to lower the temperature in the entire capacity, the oil temperature in the crank-
compressor. case, and the operating pressure and tem-
peratures of the plant. The filling period itself
The thermo pump is mounted as a side cover
lasts 45 sec.
on the compressor and works by pressing
refrigerant under the top covers and into an During a pumping cycle the discharge gas
oil cooler which - depending on the operating temperature varies as no cooling of the dis-
conditions - has been built into the crank- charge gas takes place during the filling
case. period.
98.10
On TSMC compressors only the high pres-
Usually, the variation will be +/–10K of the
sure covers are cooled, and there is no oil
estimated discharge gas temperature
0171-361-EN
cooler in the crankcase.
stated in the table of this instruction manual.
The thermo pump works under the influence See table of contents.
of the heat coming from the oil in the crank-
case, thus regulating its own pump capacity. However, please notice that under normal
This means that the thermo pump works at a operating conditions the discharge gas tem-
slow pace whenever the compressor oil is perature must not be below the table value
cold, e.g. after start-up of the compressor, less the variation of approx. 10K .
but as the oil temperature increases so does
The important advantage of the thermo pump
pump capacity.
is that the refrigerant pumped by the thermo
However, the thermo pump will not start until pump is led directly into the compressor dis-
the discharge gas temperature of the com- charge gas and as a consequence has no
pressor is above 80°C. influence on the compressor capacity.
150 0178-910-EN
Principle drawings
98U 98U
98 98 98M
98M
98H 98H
C B C
B
3185184_1 3185185_1
98U
4 1 HP 98G 1 S 98G
A HP IP A
LP
2 3 S 2
98M 98
98
98H 98H
B C B C
3185186_1 3185187_2
0178-910-EN 151
SMC 112 SMC 116
98M 98M 98M 98M 98M
98M 98M
98Z 98Z
4
6 A 4 6
2 LP A
LP X
98G X 2 8 98G
98B 98B
98 98
98H 98H
98K B 98K
B
98K 98K 98V
98V
98Y
80 98Y 80
D
D
98M 98M
98M 98M
98M 98M 98M
HP 98Z
3 7
HP 98Z
5 LP A
1 3 A 1 98 5 98G
LP
98G
98
98T 98B
98T 98B
98M
98H
98M
98K
98H
98K B C
98K
98V
C 98Y
B 98K 98V 80
80 98Y D
D
3185168_2 3185169_1
TSMC 116
98M 98M
S 4
HP A
IP
3 S 98G
98B
98
98H
B C
2 S
1 5
98T 98M
3185188_0
152 0178-910-EN
CMO 24 CMO 26
98U
98U
98M 98M
98M 98M 98M
98Z
1
98Z
98H
98H
B 98K C 98K
B C
98K
98K 98V
98V
80
98Y 80
98Y
D D
3185195_1
3185196_1
CMO 28 TCMO 28
98Z
1 IP 98G
2
3 4 HP
LP 98G
98B
98B
98
98
98H 98H
B B 98K C
98K C
98K
98K 98V 98V
80 98Y 80 98Y
D D
3185197_1 3185198_1
0178-910-EN 153
Structure of the thermo pump control the solenoid valves, pos. 98G and
Together with the cooling cover, pos. 98Q, pos. 98H, so that they are open and shut si-
the side cover, pos. 98A, forms a pump ves- multaneously. The thermo pump is safe-
sel, pos. 98, which is supplied with heat from guarded by the following systems:
the oil bath in the crankcase. The cooling (See principle drawing)
cover is equipped with cooling fins in order to a: A thermostat built into the control box pos.
provide a satisfactory thermal contact with 98B with sensors pos. 98X fitted on the
the oil. compressor discharge pipe.
As illustrated in the principle drawings, the
Fasten the sensor to the discharge pipe
pump vessel has the following three pipe
right next to the discharge stop valve by
connections:
means of two clips. Ensure a proper
S Connection pos. A which is linked to the thermal contact.
compressor suction side and which can be
blocked by means of solenoid valve pos. The thermostat is factory set to start up
98G. Used to lower the pressure in pump the thermo pump once the discharge gas
vessel pos. 98. Part of the pumping cycle. temperature is above 80°C.
S Connection pos. B emerges from the re- b: An evacuation system emptying the pump
ceiver or the priority tank and goes right to vessel through solenoid valve pos. 98V
the valve block pos. 80 which is of the sa- whenever the thermo pump stops.
me type as the one described in the sec- Please, notice that the pipe connection
tion on: Solenoid valve controlled oil
pos. D to the plant evaporating side must
return in this instruction manual.
be made at a spot where there is no risk
Please, note that the size of orifice
of the liquid flowing back to the compres-
pos. 80I must be 3.3 mm.
sor. Connection should, f.inst., be made to
S Connection pos. C is connected to the top the liquid separator or the evaporator.
covers and the oil cooler pos. 98T through c: A safety circuit with a non-return valve
a number of nozzles pos. 98M. pos. 98Z that opens for the flow at a pres-
Filling and evacuation of the pump vessel is sure 3 bar higher in the pump vessel than
controlled by two level sensors, pos. 98C, the one in the compressor discharge gas
which by means of the control box, pos. 98B, line.
98G 80 B 98B 98A
98Q
A
98C
98D 98E
98F
98L
C
98H 98X
T3185085_5
154 0178-910-EN
Description of pumping cycle Capacity regulation of thermo pump
On reducing the compressor capacity it be-
Filling of pump vessel comes necessary also to reduce the cooling
As soon as the liquid leaves the bottom level effect of the thermo pump. This is done as
sensor, the control box will activate the sole- follows:
noid valves pos. 98H in valve block pos. 80
SMC 104-106-108, TSMC 116
and pos. 98G.
CMO 24-26-28
Hereby, solenoid valve pos. 98G opens in the The pipe connection from the pump vessel to
pipe connection to the compressor suction the top covers is on its way divided into two
side and the pressure in the pump vessel de- pipe lines. In one of these pipe lines a sole-
creases slightly. At the same time solenoid noid valve, pos. 98U, is fitted.
valve pos. 98H opens and refrigerant liquid This solenoid valve is connected to the the
starts flowing to the pump vessel through capacity regulating system of the compressor
pipe connection B. and closes when the compressor capacity
has been reduced, as indicated in the follow-
Evacuation of pump vessel ing table:
The pressure in the pump vessel now rises SMC 104 100% 50%
as a consequence of the heat impact from
the compressor oil and - when exceeding the SMC 106 100-67% 33%
pressure on the compressor discharge side -
will make the refrigerant flow through the SMC 108 100-75% 50-25%
pipe connections to the top covers and the oil
TSMC 116 100-83-67% 50-33%
cooler.
CMO 24 100-75% 50-25%
At the top covers the refrigerant expands
through the nozzles pos. 98M directly into the CMO 26 100-67% 50-33%
hot discharge gas, with immediate cooling of
the discharge gas. CMO 28 100-75% 50-25%
0178-910-EN 155
positioned at the compressor shaft end and Similarly, the other green diode for the bot-
marked X on the principle drawing. tom sensor will only be switched off from the
moment the bottom level has been registered
The disconnection is achieved through the
and until the liquid rises once more on filling
connection of the thermo pump via terminals
of the vessel.
5 and 6/7 or 8 to the capacity regulating sys-
tem of the compressor. The supply voltage to At the bottom level a time lag of a few se-
the thermo pump must be switched off once conds has been built in order to prevent the
the compressor capacity has been reduced solenoid valves from clattering in the event of
to the values indicated in the table below. any lapping in the vessel.
156 0178-910-EN
Possible sources of error Both diodes are constantly lit
In case the above tests should reveal that If one or both diodes are constantly lit, even
one or both of the diodes do not light up with no liquid on the sensor, this may be due
when touched, this may be due to: to a conductive connection between the inner
and the outer part of the level sensor rod.
1. No voltage to the control box.
Outside the side cover the level sensor rod is
2. Loose power connection. protected by O-rings and a protective cap
preventing water and moisture from making
3. Defective control box. contact.
(To be replaced by a new one)
An oil drop may have slipped inside the side
In case both diodes switch on and off correct- cover. In this case it is recommended to strip
ly but the built-in relay is not working, replace down the sensor rod and clean the parts. On
the control box. mounting make sure that the sensor rod cen-
ters in the sensor tube.
If the diodes light up and the relay is working,
the error may be found in the solenoid If, after remounting, the error persists, the
valves: control box must be replaced.
1. Loose connections to the solenoid valves.
Ensuring liquid to the thermo pump
2. Burnt coils in the solenoid valves. The thermo pump must always be ensured
liquid from the plant, no matter whether the
3. Some other malfunction in the solenoid plant lacks liquid or some other factor pre-
valves. vails.
If the above-mentioned sources of error are Thus, the thermo pump must also be en-
not present and the thermo pump still fails, sured liquid during a possible pump down by
the reason may be: means of the compressor.
1. Closed stop valve in the liquid line. In other words: During operation the com-
pressor must never be short of cooling.
2. Clogged filter in the liquid line.
This safety is achieved by either taking the
3. Dirt in the solenoid valves. liquid directly from the receiver, pipe connec-
tion B or by building a priority tank into the
4. Flash-gas in the liquid supply pipe or liquid liquid line of the plant (see drawing).
shortage. The liquid volume A of the priority vessel
must be minimum 10 litres per thermo pump.
5. A very low differential temperature be-
tween oil and condensing temperature. The liquid tube from the priority vessel to the
thermo pump must be dimensioned to pre-
6. Clogged nozzles pos. 98M. vent the formation of flash gas along the way.
0178-910-EN 157
1 1
3
Receiver
Priority tank
3
B
B
2
158 0178-910-EN
Oil return in parallel operation for
reciprocating compressors
on compressor
0171Ć474ĆEN
T0177089_0/2
0171-370-EN 159
Schematic diagram
Standard
Oil separator with
solenoid valve controlled oil return
Parallel system,
fitted on unit Alternative
Oil separator with
float valve controlled oil return
Compressor 1 Compressor 2
5 5
1 1 5
2 2
3 7 3 7 8 12
4 6 4 6 11 13
9
10
Oil charging
Heating cartridge 9 Liquid level glass
Oil receiver
160 0171-370-EN
Unscrew the cap on the vent valve and acti- connected to the discharge side of the plant,
vate the spring-loaded valve in the branch by as shown in the schematic diagram.
pressing it down with a screwdriver or similar.
In the pipe connection to the discharge side,
mount a 0.4 mm diameter nozzle Pos. 12
If the float-valve controlled oil return Pos. and a solenoid valve Pos. 11, which must be
8 is used, the oil tank must - in order to main- open also when only one compressor is op-
tain the driving pressure at 1 bar - also be erating.
0171-370-EN 161
Refrigerant cooled oil cooler for
CMO reciprocating compressor
97.03
trated in fig. 2A an 2B. 4242-087
0171-356-EN
mm, emerges from receiver or priority vessel
and is conveyed to valve block pos. 80 which
is the same type as the one described in sec-
tion entitled: Solenoid controlled oil return of
this instruction manual.
Please, note that nozzle size pos. 80I must
be 3.3 mm.
Fig. 2A
162 0171-370-EN
Oil cooling system R717
Fig. 2B
Connect oil cooling system to the liquid sys- arrangement also contains a filter that can be
tem of the refrigeration plant where a point at taken apart and cleaned as described earlier.
liquid refrigerant is always present, and carry
The liquid will pass the solenoid valve which
out pipe connection so that no gas bubbles
is electrically coupled to thermostat KP77.
will occur in the liquid before the expansion
This opens the solenoid valve whenever the
valve.
oil temperature is above 55°C. (See table :
Pressure and temperature settings)
Pipe dimension is shown on fig. 3 and 4. A
priority vessel may possibly be used as de- Adjustment of liquid flow to the oil cooler
scribed under Ensuring liquid supply to Ther- takes place through the expansion valve
mopump in section Thermopump system for which for R22 compressors is a thermostattic
cooling. expansion valve with thermo sensor placed
on the discharge pipe of the oil cooler as
Function shown in fig. 3.
The valve arrangement Pos. 1 has a built–in For R717 it is a thermostatic injection valve
stop valve with which the cooling system can with thermo sensor placed at the compressor
be cut off from the refrigeration plant. The discharge branch as shown in fig. 4.
0171-370-EN 163
CMO 2 compressors for R22 Adjustment
Fig. 3 Adjustment of the thermostatic expansion
HP valve for R22 appears from table: Pressure
Thermo filter and temperature settings.
LP
From receiver
In order to facilitate the replacement of oil
filter cartridge, see section on Oil Filter, it is
DN 15 recommended to dismantle oil cooling spiral
3185-133 as described in the following:
Mounting:
OD10 On remounting cooling spiral, counter
Oil cooler
DN 15
4849-063
164 0171-370-EN
Oil Separator and Oil Return
on CMO 24Ć26Ć28 and TCMO 28
Fig. 1
R22 CMO
Solenoid valve controlled Float valve controlled
execution execution
Discharge Discharge
gas out gas out
2 2
To compressor
housing via
valve block L 1
pos. 80 To compressor housing L 1
Discharge
gas in
Discharge gas in
T0177142_0 V14
0171-370-EN 165
Fig. 2 R22-R717 TCMO
1 1
Discharge
gas in Discharge gas in
To compressor
housing via L
valve block L
pos. 80 To compressor housing
T0177142_0 V14
Fig. 3 Fig. 4
1 • D
2
M
To compressor
housing via L
valve block To compressor
pos. 80 housing via
valve block
pos. 80
166 0171-370-EN
Function Fig. 5
Also make sure that the fine filter is fitted cor- t4241347_1
rectly against the intermediate plate pos. H.
0171-370-EN 167
Oil return to the compressor a: Solenoid valve controlled
The separated oil leaves the oil separator oil return
through the connecting branches pos. L As illustrated in fig. 6 the oil is conveyed from
and in case of the fine filter oil separator
the oil separator through the screwed con-
fig. 4 also through branch pos. M. This
nections pos. 80A and 80B. Fig. 6 pos. also
means that two oil return systems are used
shows that pos. 80A is of such a length that it
for the fine filter oil separator.
pierces the base plate by approx. 10mm.
The oil flow from the connecting branches
pos. L and M can be regulated by the fol-
lowing systems: In this way any dirt particles may be collected
S Solenoid valve controlled oil return on the bottom of the oil separator instead of
S Float valve controlled oil return being returned with the oil to the compressor.
Fig. 6 80 m Compressor
Oil separator
Solenoid valve
80 m 80 c
Stop valve 80 m
L/M Filter
80 A
dia. 8/6
80 B
Valve block pos. 80C, shown in fig. 7, con- 80E, which can be removed by dismounting
sists of a stop valve pos. 80D, which is cover pos. 80F. The filter can be cleaned in a
closed and opened by turning of the spindle. cleansing fluid and blown clean with com-
This valve may be dismantled by unscrewing pressed air.
the big union nut from the valve block. On remounting tighten the cover with a
On refitting the nut, tighten it with 60 Nm. torque of 60 Nm. Remember gasket pos.
From the stop valve the oil passes filter pos. 80G.
168 0171-370-EN
Fig. 7 During start-up of the compressor, the sole-
1,4 Nm
80N noid valve can be kept closed for 20 to 30
80K mins. by means of a time relay, available as
80H
an additional equipment. This prevents any
80J
A
refrigerant from entering the compressor.
80M
80P
The seat of the solenoid valve pos. 80I also
60 Nm 80L
50 Nm
10 Nm
acts as a nozzle that regulates the oil flow
80Q back to the compressor.
80I
Select the nozzle size on the basis of table 8.
80
80D
We recommend not to use a bigger nozzle
size than prescribed. In order to replace the
nozzle the compressor must first be depres-
surized. Next, dismantle coil pos. 80J and
B
80E
armature tube pos. 80P.
80G The nozzle is screwed into the valve block
60 Nm 80F
and, on remounting, use gasket pos. 80Q
for the nozzle and gasket pos. 80L for the
armature tube. Tighten with the prescribed
moments of 10 and 50 Nm – see fig. 7.
After the oil has been cleaned, it flows to the On mounting the coil keep it in place by
solenoid valve pos. 80H, which is always using hand screw pos. 80N and O-ring pos.
closed at compressor standstill. 80K and 80M.
Fig. 8
Two stage compressor
R717 One stage compr. Booster compr. TCMO TSMC TSMC
Mk 2 100 180
CMO SMC SMC CMO SMC SMC
Mk 2 100 180 Mk 2 100 180 LP HP LP HP LP HP
Number of cylinders
0171-370-EN 169
b: Float valve controlled oil return
Fig. 9
To the compressor
A D
For the oil separators shown in fig. 1 and 2 the float valve will open and lead the oil back
the float valve is built into the oil separator. to the compressor crankcase.
After the oil separator has been depressu-
rized, this valve can be removed by disman-
The filter pos. D and the float valve can be
tling of the bottom cover.
cleaned by dismantling the threaded nipple
As to the oil separator types as shown in fig. on the stop valve housing and removing the
3, drain the separated oil from the float valve cover on the float housing after the valves
pos. C, as outlined in fig. 9, once the valves pos. A and B are closed and the pressure in
pos. A and B are open. At a rising oil level the compressor equalized to atmospheric.
170 0171-370-EN
Connections on CMO/HPO 24Ć26Ć28
H N G L 1 2 K K K K,P
A B M R F S E O D C J
T0177142_0 V6
(OPT) KP15
93.11
MP55
0171-339-EN
1 LP-suction stop valve + Is present on compressor block unit and used for
2 LP-discharge stop valve - Not present on compressor block
0178-225-EN 171
Connections on TCMO 28
X H N L T V 3 1 U 2 P K
T0177142_0 V6
A B M R F S E G O D C J
(OPT) KP15
MP55
C G T H L O
1 LP-suction stop valve + Is present on compressor block unit and used for
2 LP-discharge stop valve - Not present on compressor block
3 I-pressure stop valve
172 0178-225-EN
Water cooling of the reciprocating compressor
CMO 24 Ć 26 Ć 28 and TCMO 28
HPO 24 Ć 26 Ć 28
The piston compressor can be cooled with cooling fins on the interior of the side cover
water on the top and side covers, the cooling Pos. 3A provide excellent cooling of the oil in
requirement being dependent on the operat- the crankcase.
ing conditions and the refrigerant on which
the compressor operates. When dismantling top or side covers with wa-
ter covers, it is a good idea first to dismantle
See page 1 for details. the topmost covers on the compressor. In
addition, you should ensure that the two cov-
Water cooling is obtained by mounting an ex- ers are kept tight against the intervening gas-
tra cover (water cover) Pos. 2K/3K on the ket. This will prevent water flowing into the
outside of top and side covers with the inter- compressor block.
vening gaskets Pos. 2L and 3L and 2P/3P in
97.03
Pos. 2C, which are longer than the bolts for sembling parts. These are provided loose.
the air-cooled version. This avoids damage to the parts in transit. Fit
See the Spare-parts list at the end of this in- the cooling water hoses as shown in the fol-
struction manual for details. lowing drawing, corresponding to the specifi-
cation enclosed with the delivery.
For water cooling of the side covers, only a
special finned side cover Pos. 3A is used to- Please note:
gether with a water cover Pos. 3K and a gas-
S The direction of water throughflow is
kets Pos. 3L and 3P. These are also listed in
shown by arrows on the drawing.
the spare-parts list.
S The hose length is indicated opposite the
The water cover, together with the cover on respective Pos. nos. on the drawing.
which it is mounted, forms a ducting system
in which the water is channelled back and S The hoses must not be in contact with the
forth and effectively cools the top or side cov- frame, covers, discharge pipe or similar
er. By virtue of their large surface area, the components.
In the supply pipe to the water system a solenoid valve must be fitted which shuts off the water flow in
the refrigeration system at compressor standstill.
However, we do recommend to continue the water cooling for approx. 10 mins after the compressor has
been stopped as this protects the cooling water hoses against excessive temperatures
0178-225-EN 173
4
2
3
3 CMO 28 & TCMO 28 Pos. A mm
HPO 28 1 365
5
2 610
1 3 150
4 205
5 230
6 590
6
2
3
3
1 4
CMO 26 Pos. A mm
HPO 26
1 370
2 705
3 275
4 190
5 5 575
3
4
2
CMO 24 Pos. A mm
1 HPO 24 1 465
2 520
3 410
4 260
5 550
5
1 710
2 590
1
2
T0177142_0 V7
174 0178-225-EN
Pressure loss in water cooling system
on CMO/TCMO & HPO compressors
Pressure loss
p (mVS) CMO/
11 TCMO 28
HPO 28
10 CMO 26
HPO 26
9 CMO 24
HPO 24
8
0
0 200 400 600 800 1000 1200 1400 1600
Volumetric flow
V(l/hour)
0178-225-EN 175
Reciprocating compressors used for air conditioning
CMO 24Ć26Ć28 and SMC 104Ć106Ć108
When the CMO or SMC compressor is used connected to any of the above pressure
for air conditioning, you can choose to control cut-outs.
the compressor capacity by means of one or
Pressure cut-out A must be set to a close at
two KP1 pressure cut-outs.
a pressure approx. 0.5 bar higher than the
CMO compressors are all controlled by three setpoint for cut-out B.
solenoid valves. When these are to be con-
A third cut-out, the low-pressure cut-out,
trolled with pressure cut-outs, cut-out A must
must be set to break at a pressure equal to
be connected in parallel with solenoid valves
the lowest evaporator temperature that can
nos. 1 and 2. Cut-out B must be connected
occur, however, never lower than started in
with solenoid valve no. 3.
section Pressure and temperature settings.
The SMC 108 must be connected in the At this temperature, the compressor must
91.06
same way as CMO. stop. This control form provides the following
capacity stages:
The SMC 106 is controlled by two solenoid
valves, where pressure cut-out A must be
0171-348-EN
connected to solenoid valve no. 1 and cut-out
B to solenoid valve no. 2. Capacity in %
Capacity stage 1 2 3
The SMC 104 is controlled by a solenoid val-
ve to be connected to pressure cut-out A. CMO 24 100 50 25
Only one cut-out is to be used for the SMC CMO 26 100 50 35
104. CMO 28 100 50 25
SMC 104 100 50 –
If the compressor features a solenoid valve SMC 106 100 66 33
for totally unloaded start, this must not be SMC 108 100 50 25
3 4 1
2 1 1 2 3
2
1
A A 1 A 2
1 2 3
1 B 2 B 3
A B
176 0171-370-EN
Cooling of the intermediate gas on
TCMO and TSMC 100 and 180
CT
LP IP HP
LPIP
Intermediate cooling system with Suction filter
intermediate cooler type DVEA,
R717 Equalizing pipe
0171-370-EN 177
In the liquid subcooling spiral, the refrigerant liquid refrigerant into the intermediate pipe.
flowing from the receiver to the evaporator This is achieved with the following systems 1
side of the refrigeration plant is cooled. The and 2:
intermediate cooler is dimensioned so that
1: Intermediate cooling with thermostatic
the cooled gas is free of liquid refrigerant be-
expansion valve type:
fore leaving the top of the intermediate cool-
TEA (R717) or TEX (R22)
er. It is important to check that the float valve
TCMO and TSMC 100/180
is functioning correctly and keeping the liquid
level constant. Frosting of the liquid level Fig. 3
pipe on the intermediate cooler indicates the TCMO and TSMC
liquid level. Oil separator
• CT
In order to avoid violent foaming of the liquid
in the intermediate cooler, the compressor IP HP Suction filter (opt.)
LP LP IP •
should run for a few minutes after start-up at
the lowest capacity stage to stabilize plant LP
Make sure that the equalizing pipe on the in- TEA or TEX 80
178 0171-370-EN
It is essential to make sure that the inter- before the HP-stage suction filter. The sensor
mediate cooling system functions correctly in must be fitted on the side of the pipe and in-
order to prevent too much liquid refrigerant sulated as shown in fig. 5
from being injected into the IP gas.
Position the sensor of the expansion valve on S SABROE has adjusted the valve to 10 K
the intermediate pressure pipe immediately superheat.
0171-370-EN 179
2: Intermediate cooling with thermostatic Fig. 7
injection valve type:
TEAT (R22) 83A
TCMO and TSMC 100/180
B: TSMC 100/180
HP
IP Fig. 8
LP
KP 77
80
T
Oil separator
Liquid subcooler CT
To evaporator IP HP
TEAT LP LP IP Mixing chamber
LP
From receiver Liquid tank 4L
A
TEAT
Liquid supply
From receiver To evaporator
HESI
As illustrated in fig. 6 the intermediate gas is On TSMC 100 and 180 plants, the intermedi-
cooled by injecting refrigerant into the low ate cooling system can be designed as illus-
pressure stage pressure chamber in the trated in fig. 8, in which the intermediate cool-
compressor. The liquid is thoroughly mixed ing is carried out by a thermostatic injection
with the hot discharge gas by means of the valve of the TEAT type, and in which the sub-
distributor pos. 83A as may be seen from cooling takes place in a HESI heat exchang-
fig. 7. er.
180 0171-370-EN
Adjusting the TEAT valve: Adjustments are made by rotating the regu-
For both systems, A and B, the following lating spindle clockwise, 5 turns for every
applies: 10K of temperature increase.
The sensor of the TEAT valve is placed in a
Example:
sensor pocket at the discharge branch of the
compressor, and a proper thermal contact is Refrigerant R22
obtained by means of the heat conducting Regulating temperature
compound. factory setting 75°C
Before using the valve, the regulating tem- At reduced compressor capacity, the dis-
perature must be changed to the same value charge gas temperature may rise somewhat;
as the discharge gas temperature indicated under these circumstances it should be
in the table Anticipated discharge gas tem- checked that the discharge gas temperature
peratures in this instruction manual. does not exceed the Set point for the KP98.
0171-370-EN 181
Ordering Spare Parts
When placing an order for spare parts, ber. If you are in any doubt, add the spare
please state the following: part no. too.
94.05
with the following: If you require a certificate from a Classifica-
tion authority, please mark the order
a) Spare part no. – which is a reference
appropriately, as the inspection and issuing
0171-466-EN
number to facilitate finding a part in the
procedures take extra time and incur extra
drawing and cross-referencing in the parts
expenses.
list or vice versa.
b) Designation of the part.
5. Quotation No.
c) Part no. – a 7-digit number which refers to
If a quotation no. has been given during earli-
SABROE’s stores.
er correspondence, please refer to this when
When you order spare parts, please always placing your order – it will help us to identify
advise at least the designation and part num- and execute your order quickly.
182 0178-925-EN
Spare parts sets for compressors and units
CMO/TCMO Ć SMC/TSMC 100 Ć SMC/TSMC 180
0171-941-EN 183