s a bro ecmo instruction manual

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

Instruction ManualCMO 24-26-28/TCMO 28 Mk 2

Reciprocating Compressor

0171-478-EN Rev. 00.08

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CMO 24 - 26 - 28 Mk 2TCMO 28 Mk 2

0171

-355

-EN

97.0

3

99.06

0171-370-EN 1

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The CMO/TCMO-type piston compressor canbe fitted with a range of equipment, depend-ing on the function and requirements it iscalled on to meet.

Some of these variants are discussed in this

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

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

Control

Compressor

Refrigerant

Serial number

Compressor type

UNISAB II Control- and regulating system

cooling

Drive type

Explosion-proof electrical design

Additional suction filter

Oil return on parallel systems

Compressor used for air conditioning

Designation

Capacity regulation

Analogous control system

Water cooled top and side covers

Thermopump

Air-cooled top covers and water-cooled side covers

Air-cooled top- and side covers + oil-cooling

Air-cooled top- and side covers

Coupling

V-belts

With capacity regulation system

Without capacity regulation system

Oil separatorWith solenoid valve controlled oil return

With float valve controlled oil return

Intermediatecooling system

With internal intermediate cooling system

With external intermediate cooling system

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

0171

-500

-EN

96.0

6

2 0171-702-EN

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

� the function and maintenance of theindividual components;

� service schedules;

� procedure for dismantling andreassembling of the compressor.

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

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

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

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

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

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

SABROE REFRIGERATION A/S

P.O. Box 1810, DK–8270 Højbjerg

Chr. X’s Vej 201, Århus, Denmark

Phone: Telefax: +45 86 27 44 74

+45 86 27 12 66

0171-370-EN 3

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Specifications for CMO 24-26-28 Mk2 and TCMO 28 Mk2 1. . . . . . . . . . . . . . . . . . . . . . . . .

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

Contents 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Description of compressor CMO 24-26-28 & TCMO 28 Mk 2 6. . . . . . . . . . . . . . . . . . . . . . .

Safety Precautions 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reciprocating compressors 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General safety instructions and considerations 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Handling of the compressor, areas of application, safety equipment and symbols, safety at servicing 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety equipment 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety symbols 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . First Aid for accidents with Ammonia 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . First aid for accidents with HFC/HCFC 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Protecting the operator as well as the environment 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sound data for reciprocating and screw compressor units – all types of compressors21

Vibration data for compressors - all types 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compressor data for reciprocating compressor 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating limits 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R717 - Operating limits single stage compressorsCMO, SMC 100 S-L, SMC 180 27. . R717 - Operating limits single stage compressors SMC 100 E 28. . . . . . . . . . . . . . . . . . . R717 - Operating limits two-stage compressors TCMO TSMC 100 S-L-E, TSMC 18029R22 - Operating limits single stagecompressors CMO,SMC 100 S-L, SMC 180 30. . . . R22 - Operating limits two-stage compressorsTCMO, TSMC 100 S-L, TSMC 180 31. . R134a - Operating limits single stage compressors CMO SMC 100 S-L 32. . . . . . . . . . . R134a - Operating limits two-stage compressors TCMO TSMC 100 S-L 33. . . . . . . . . . R404A - Operating limits single stage compressors CMO, SMC 100 S-L 34. . . . . . . . . . R404A - Operating limits two-stage compressors TCMO, TSMC 100 S-L 35. . . . . . . . . . R507 - Operating limits single stage compressors CMO, SMC 100 S-L 36. . . . . . . . . . . R507 - Operating limits two-stage compressors TCMO, TSMC 100 S-L 37. . . . . . . . . . .

General operating instructions for CMO/TCMO, SMC/TSMC piston compressors 39. . . . . Starting up compressor and plant 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stopping and starting-up compressor during a short period of standstill 40. . . . . . . . . . . Stopping plant for brief periods (until 2-3 days) 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stopping plant for lengthy periods (more than 2-3 days) 41. . . . . . . . . . . . . . . . . . . . . . . . Automatic plants 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure testing refrigeration plant 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pumping down refrigeration plant 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating log 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Servicing the reciprocating compressor 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure drop test: 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing refrigerant from compressor 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubricating oil 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricating oil requirements 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 0171-370-EN

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 CrankshaftReciprocating Compressors with 4 to 8 Cylinders 94. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Torque moments for screws and bolts 95. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0171-370-EN 5

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 conditioningCMO 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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T0177142_0 V16

The CMO 2 is a reciprocating compressorwith several cylinders in the same block. The first digit in the type number indicatesthe stage of development of the compressor.The compressor comes in 4-, 6- and 8-cylin-der versions, indicated by the last digit in thetype number.

The TCMO 28 is a 8-cylinder version, whichcompresses the gas in two stages, with 6low-pressure cylinders and 2 high-pressurecylinders. The type can be determined by thecompressor’s name-plate which is located atthe bottom on one side of the compressor.

SABROE

Shop noMax. speed

Test pressureWorking pressureSwept volume

Type Refrigerant

barbar

r.p.m.

T0177093_2

AARHUS DENMARK

m3/h

Year

Similarly, the name-plate indicates the com-pressor’s serial number, which is alsostamped into the compressor housing at thetop by the end cover facing away from cou-pling/belt drive.

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

The pistons of the compressor have a diame-ter of 70 mm and a stroke of 70 mm.

The pistons work in replaceable cylinder lin-ings, inserted in the frame and located withtwo cylinders under each top cover.

The suction valve, which is a ring plate valve,is mounted at the very top of the cylinder lin-ing. The discharge valve forms the top of thecylinder and is kept in place by a powerfulsafety spring. This spring allows the dis-charge valve to rise slightly by liquid strokes.This prevents overloading of the connectingrod bearings.

The crankshaft is embedded in slide bearingsAble to assimilate both radial and axialforces. The oil pressure for the bearings and

0171-370-EN 7

the capacity regulating system is suppliedfrom the gearwheel oil pump built into thecompressor.

At the shaft end, the crankshaft is equippedwith a balanced shaft seal of the slide-ringtype, consisting of a cast-iron ring rotatingwith the crankshaft and a stationary spring–loaded carbon ring.

As standard equipment the compressorshave a hydraulic capacity unloading systemthat forces the suction valves open, thus pre-venting compression. This unloading systemis designed in such a way to ensure that thecompressor always starts totally unloaded.

The TCMO 28 compressor is available witheither a built-in intermediate cooling systemor an external intermediate cooling system,which may be seen from the table on page 1as well as from the description further on inthis instruction manual.

The compressor can be delivered withoutcapacity regulating functions but still with thestart unloading function for totally unloadedstart-up.

The capacity regulation is controlled by sole-noid valves, mounted in one of the compres-sor side covers.

The following table shows the capacitystages 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

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

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Reciprocating compressors

Read related safety precautions be-fore operating this machine. Failure tofollow safety instructions may result inserious personal injury or death.

WARNING

ImportantThe safety precautions for this Sabroe Re-frigeration machine have been prepared toassist the operator, programmer and mainte-nance personnel in practicing good shopsafety procedures.

Operator and maintenance personnel mustread and understand these precautions com-pletely before operating, setting up, running,or performing maintenance on the machine.

These precautions are to be used as a guideto supplement safety precautions and warn-ings in the following:

a. All other manuals pertaining to the ma-chine.

b. Local, plant, and shop safety rules andcodes.

c. National safety laws and regulations.

General safety instructions andconsiderations

Personal safety

Machine owners, operators, setup men,maintenance, and service personnel must beaware of the fact that constant day-to-daysafety procedures are a vital part of their job.

Accident prevention must be one of the prin-cipal objectives of the job regardless of whatactivity is involved.

Know and respect your machinery. Read andpractice the prescribed safety and checkingprocedures. Make sure that everyone whoworks for, with, or near you fully understandsand – more importantly – complies with thefollowing safety precautions and procedureswhen operating this machine.

Observe and follow safety warnings on thecompressor/unit.

Use safety protective equipment. Wear clearapproved eye or face protection as you workwhen operating parts containing refrigerant.Safety-toe shoes with slip-proof soles canhelp you avoid injury. Keep your protectiveequipment in good condition.

Never operate or service this equipment ifaffected by alcohol, drugs or other sub-stances or conditions which decrease alert-ness or judgement.

Work area safety

Always keep your work area clean. Dirtywork areas with such hazards as oil, debris,or water on the floor may cause someone tofall to the floor, into the machine, or onto oth-er objects resulting in serious personal injury.

Make sure your work area is free of hazard-ous obstructions and be aware of protrudingmachine members.

Report unsafe working conditions to your su-pervisor or safety department.

Tool safety

Always make sure that the hand tools are inproper working condition.

0170-123-EN 9

Remove hand tooling such as wrenches,measuring equipment, hammers, and othermiscellaneous parts from the machine im-mediately after usage.

Lifting and carrying safety

Contact Sabroe Refrigeration if you have anyquestions or are not sure about the properprocedures for lifting and carrying.

Before lifting or carrying a compressor/unit orother parts, determine the weight and size byreferring to such things as tags, shippingdata, labels, marked information, or manuals.

Use power hoists or other mechanical liftingand carrying equipment for heavy, bulky, orhard to handle objects. Use hookup methodsrecommended by your safety departmentand know the signals for safely directing acrane operator.

Never place any part of your body under asuspended load or move a suspended loadover any part of another person’s body. Be-fore lifting, be certain that you have a safespot for depositing the load. Never work on acomponent while it is hanging from a craneor other lifting mechanism.

If in doubt as to the size or type of liftingequipment, method, and procedures for lift-ing, contact Sabroe Refrigeration before pro-ceeding to lift the compressor, motor, unit orits components.

Always inspect slings, chains, hoists, andother lifting devices prior to use. Do not uselifting devices found to be defective or ques-tionable.

Never exceed the safety rated capacity ofcranes, slings, eyebolts, and other liftingequipment. Follow standards and instructionsapplicable to any lifting equipment you use.

Before inserting an eyebolt, be certain thatboth the eyebolt and the hole have the samesize and type threads. To attain safe workingloads, at least 90% of the threaded portion ofa standard forged eyebolt must be engaged.

Failure to follow safety instructionson this page may result in seriouspersonal injury or death.

WARNING

Installation and relocation safety

Before lifting the compressor, unit or otherparts of the plant consult the machine manu-al or Sabroe Refrigeration for proper meth-ods and procedures.

An electrician must read and understand theelectrical schematics prior to connecting themachine to the power source. After connect-ing the machine, test all aspects of the elec-trical system for proper functioning. Alwaysmake sure the machine is grounded properly.Place all selector switches in their OFF or

neutral (disengaged) position. The doors ofthe main electrical cabinet must be closedand the main disconnect switch must be inthe OFF position after the power source

connection is complete.

When the compressor is installed, be surethat the motors rotate in the proper indicateddirection.

10 0170-123-EN

Failure to follow safety instructionson this page may result in seriouspersonal injury or death.

WARNING

Setup and operation safety

Read and understand all the safety instruc-tions before setting up, operating or servicingthis compressor. Assign only qualified per-sonnel, instructed in safety and all machinefunctions, to operate or service this compres-sor.

Operators and maintenance personnel mustcarefully read, understand, and fully complywith all machine mounted warning andinstruction plates. Do not paint over, alter, ordeface these plates or remove them from thecompressor/unit. Replace all plates whichbecome illegible. Replacement plates can bepurchased from Sabroe Refrigeration.

Safety guards, shields, barriers, covers, andprotective devices must not be removedwhile the compressor/unit is operating.

All safety features, disengagements, and in-terlocks must be in place and functioning cor-rectly prior to operation of this equipment.

Never bypass or wire around any safety de-vice.

Keep all parts of your body off the compres-sor/motor/unit during operation. Never leanon or reach over the compressor.

During operation, be attentive to the com-pressor unit process. Excessive vibration,unusual sounds, etc., can indicate problemsrequiring your immediate attention.

Maintenance safety

Do not attempt to perform maintenance onthe compressor unit until you read and un-derstand all the safety instructions.

Assign only qualified service or maintenancepersonnel trained by Sabroe Refrigerationto perform maintenance and repair work onthe unit. They should consult the servicemanual before attempting any service or re-pair work and when in doubt contact SabroeRefrigeration. Use only Sabroe Refrigerationreplacement parts; others may impair thesafety of the machine.

Before removing or opening any electricalenclosure, cover, plate, or door, be sure thatthe Main Disconnect Switch is in the OFF

position and the main fuses are dismantled.

0170-123-EN 11

If any tool is required to remove a guard, cov-er, bracket, or any basic part of this compres-sor, place the Main Disconnect Switch in the

OFF position, lock it in the OFF position.

If possible, post a sign at the disconnectswitch indicating that maintenance is beingperformed.

Dismantle main fuses to the unit.

Before working on any electrical cir-cuits, turn the machine Main Dis-connect Device ”OFF” and lock it.Dismantle the main fuses to thecompressor unit.Unless expressly stated in applica-ble Sabroe Refrigeration documen-tation or by appropriate Sabroe Re-frigeration Field Service Represen-tative, do NOT work with electricalpower ”ON”. If such express state-ment or advice exists, working withelectrical power ”ON” should beperformed by a Sabroe Refrigera-tion Field Service Representative.The customer and subsequenttransferees must determine that anyother person performing work withelectrical power ”ON” is trained andtechnically qualified.FAILURE TO FOLLOW THISINSTRUCTION MAY RESULT INDEATH OR SERIOUS PERSONALSHOCK INJURY.

DANGER:HIGH VOLTAGE

Whenever maintenance is to be performed inan area away from the disconnect and the

disconnect is not locked, tag all start buttonstations with a ”DO NOT START” tag. Ade-quate precautions, such as warning notices,or other equally effective means must be tak-en to prevent electrical equipment from beingelectrically activated when maintenance workis being performed.

When removing electrical equipment, placenumber or labeled tags on those wires notmarked. If wiring is replaced, be sure it is ofthe same type, length, size, and has thesame current carrying capacity.

Close and securely fasten all guards, shields,covers, plates, or doors before power is re-connected.

An electrial technician must analyse the elec-trical system to determine the possible use ofpower retaining devices such as capacitors.Such power retaining devices must be dis-connected, discharged, or made safe beforemaintenance is performed.

Working space around electrical equipmentmust be clear of obstructions. Provide ade-quate illumination to allow for proper opera-tion and maintenance.

Materials used with this product

Always use Sabroe Refrigeration originalspare parts.

Please, note the type of refrigerant on whichthe compressor is operating and the precau-tions that you need to pay attention to as de-scribed in the following sections:

� First aid for accidents with Ammonia.

� First aid for accidents with HFC/HCFC.

� Protecting the operator as well as the en-vironment.

12 0170-123-EN

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Direction of rotation

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

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

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

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

Seen towards shaft end

Handling of compressor and unit

For lifting of the compressor the large modelsare equipped with a threaded hole for mount-ing of the lifting eye. As to the weight of thecompressor, this can be seen from the ship-ping documents.

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

WARNING

The unit is lifted by catching the lifting eyeswelded onto the unit frame. These have beenclearly marked with red paint. The weight ofthe unit can be seen from the shipping docu-ments.

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

Areas of application of the recipro-cating compressorsCompressor types:

BFO 3-4-5CMO-TCMO, SMC 100-TSMC 100 Mk3, S, L, ESMC 180-TSMC 180, HPO-HPC

Application

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

The compressor may ONLY be used:

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

� With the following refrigerants:R717 – R221 – R134a1 – R404A1 – R5071

– R6001 – R600A1 – R2901 – LPG1 1) Exempted are the following compres-sors:SMC-TSMC 100 E (only R717)HPO and HPC (only R717)

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

0170-123-EN 13

� As a heat pump:

– BFO 3-4-5

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

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

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

The compressor must NOT beused:

� For evacuating the refrigera-tion plant of air and moisture,

� For putting the refrigerationplant under air pressure inview of a pressure testing,

� As an air compressor.

WARNING

Safety equipment

Emergency device

The compressor control system must beequipped with an emergency device.

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

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

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

Other demands to the emergency device:

� It must be possible to operate it by meansof an easily recognizable and visiblemanual handle, to which there is free ac-cess.

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

Combustion motors

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

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

Safety symbols

Before putting a compressor/unit into opera-tion they must be provided with warningsigns corresponding to the actual design ofcompressor/unit and in accordance with therules and regulations in force.

The CAUTION sign

A CAUTION tag is fixed on the compressorlike the one illustrated below. This sign im-poses upon the users to read the Safety Pre-cautions section in the manual before han-dling, operating or servicing the compressorand unit.

14 0170-123-EN

Before handling, installing, operating orservicing the compressor and unit, readthe Safety Precautions section in theInstruction Manual.It is the responsibility of the operator orhis employer that the instruction manualis always available.This sign must not be removed nor bedamaged in any way.

Antes de manejer, instalar, poner en mar-cha o dar servicio al compresor y la uni-dad, leer la sección Precauciones de seguridad en el Libro de Instrucciones.Es respondabilidad del operarío o de supatrón, que el libro de instruccionespermanezca siempre al alcance de lamano.Esta señal no debe de ninguna manerasuprimirse o dañarse.

2516-297

CAUTION

DANGER: The high voltage sign

DANGER:HIGH VOLTAGE

Before working on any electrical circuits, turnthe machine Main Disconnect Device ”OFF”and lock it. Dismantle the main fuses to thecompressor unit.Unless expressly stated in applicable SabroeRefrigeration documentation or by appropri-ate Sabroe Refrigeration Field Service Rep-resentative, do NOT work with electrical po-wer ”ON”. If such express statement oradvice exists, working with electrical power

”ON” should be performed by a Sabroe Re-frigeration Field Service Representative. Thecustomer and subsequent transferees mustdetermine that any other person performingwork with electrical power ”ON” is trained andtechnically qualified.

Failure to follow this instructionmay result in death or seriouspersonal shock injury.

WARNING

Explosion-proof electrical execution

If the compressor is delivered in an explo-sion-proof electrical execution it will, furtherto the SABROE name plate, be equippedwith an Ex-name plate like the one illus-trated below.

T2516273_0

The temperature of tangible surfaces

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

Consequently, the compressors will be equip-ped with yellow warning signs informingyou that pipes, vessels and machine partsclose to the warning signs during operationare so hot that your skin may be burnt from 1second’s touch or longer.

0170-123-EN 15

Internal protection

Compressor blocks and units are usually de-livered without any refrigerant or oil contentin the crankcase.

In order to protect the compressors againstinternal corrosion, they are delivered eva-cuated of all athmospheric air and chargedwith Nitrogen (N2) to an overpressure of 0.2 bar.

In such cases a yellow label like the oneshown below are stuck on the compressorsurface.

Påfyldt beskyttelsesgasCharged with inert gasEnthält SchutzgasChargé du gaz protecteurContiene gas protector

N20,2 bar3 PSI

1534-169

Safety at servicing

Read related safety precautions be-fore operating this machine. Failure tofollow safety instructions may result inserious personal injury or death.

WARNING

Before dismantling a compressor or unitattention should be paid to the followingpoints:

� Read related Safety Precautions sectionin this manual before opening the com-

pressor and other parts of the refrigerationplant.

� Make sure that the motor cannot start upinadvertently. It is recommended to re-move all main fuses.

� Switch off all electric components on thecompressor/unit before the dismantling.

� Make sure that there is neither overpres-sure nor any refrigerant in the part to bedismantled. Close all necessary stopvalves.

� Use gloves and protective glasses andmake sure to have a gas mask ready tobe used in connection with the current re-frigerant.

� Use the prescribed tools and check thatthey are properly maintained and in goodworking condition. In explosion-proofareas use tools specially suited for thisspecific purpose.

� On dismantling top covers attentionshould be paid to the very considerablespring force beneath the covers. Whenscrews a are loosened the cover must liftitself from the frame as described in theinstruction manual.

•

••

Top coverSprings

� Before dismantling the side covers emptythe crankcase of its oil content.

� Check that the heating rod in the crank-case is de-energized.

16 0170-123-EN

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

WARNING

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

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

Basic rules for first aid1. Call a doctor immediately.

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

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

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

Inhalation

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

2. Call a doctor/ambulance with oxygenequipment immediately

3. Keep the patient still and warmly wrappedin blankets.

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

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

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

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

Eye injuries from liquid splashes or con-centrated vapour

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

2. Call a doctor immediately.

Skin burns from liquid splashes or con-centrated vapour

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

2. Call a doctor immediately.

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

0170-123-EN 17

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WARNING

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

Basic rules for first aid1. When moving affected persons from low-

lying or poorly ventilated rooms wherehigh gas concentrations are suspected,the rescuer must be wearing a lifeline, andbe under continuous observation from anassistant outside the room.

2. Adrenalin or similar heart stimuli must notbe used.

Inhalation

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

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

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

Eye injuries

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

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

Skin injuries – Freeze burns

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

2. Treat exactly like heat burns and seekmedical advice.

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

18 0170-123-EN

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WARNING

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

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

Be especially careful with the following sub-stances:

� refrigerants

� cooling media (brines etc)

� lubricating oils.

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

High concentrations of refrigerant vapoursare suffocating when they displace air; if highconcentrations of refrigerant vapours are in-haled they attack the human nerve system.

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

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

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

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

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

Ammonia

R717

Unit

Time weighted ave-

rage during a week

vol.% 0,1 0,005

Warning smell vol.% 0,2 0,002

TWA

R134a R404A R507 R22

0,10,10,1

Halogenated refrigerants

0170-123-EN 19

Further, it may be said aboutrefrigerants:� If halogenated refrigerants are released

directly to the atmosphere they will breakdown the ozone stratum in the strato-sphere. The ozone stratum protects theearth from the ultraviolet rays of the sun.Halogenated refrigerants must, therefore,never be released to the atmosphere. Usea separate compressor to draw the refrig-erant into the plant’s condenser/receiveror into separate refrigerant cylinders.

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

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

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

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

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

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

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

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

� Refrigerants must not be released to theatmosphere.

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

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

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

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

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

Never empty brines down a sewer or intothe environment.

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

20 0170-123-EN

Lubricating oils

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

– mineral oil

– semi-synthetic oil

– alkyl benzene-based synthetic oil

– polyalphaolefine-based synthetic oil

– glycol-based synthetic oil.

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

NOTE

This instruction provides only general information. The owner of the refrigeration plant isresponsible for ensuring that all codes, regulations and industry standards are compliedwith.

0170

-114

--E

N99

.06

0170-114-EN 21

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

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

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

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

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

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

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

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

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

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

Dimensional tolerances are:

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

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

The dimensional values are stated for 100%capacity.

Fictional frame

Reflecting plane

Fig. 1

1 meter

Dimensional plane

1 meter

22 0170-114-EN

Note the following, however:

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

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

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

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

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

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

0170-114-EN 23

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

Compressor block LW LP

CMO 24 84 69

CMO 26 86 71

CMO 28 87 72

SMC 104 S 95 79

SMC 106 S 96 80

SMC 108 S 97 81

SMC 112 S 99 82

SMC 116 S 100 83

SMC 104 L 96 80

SMC 106 L 97 81

SMC 108 L 98 82

SMC 112 L 100 83

SMC 116 L 101 84

SMC 104 E 96 80

SMC 106 E 97 81

SMC 108 E 98 82

SMC 112 E 100 83

SMC 116 E 101 84

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


SMC 186 101 83

SMC 188 102 84

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

TCMO 28 81 66

TSMC 108 S 95 79

TSMC 116 S 97 81

TSMC 108 L 96 80

TSMC 116 L 98 82

TSMC 108 E 96 80

TSMC 116 E 98 82

LW LPCompressor block

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


TSMC 188 100 82

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

HPO 24 91 76

HPO 26 93 78

HPO 28 94 79

HPC 104 97 81

HPC 106 98 82

HPC 108 99 84


24 0170-114-EN

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

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

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

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

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

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

SV 17 100 83SV 19 101 84

FV 19* 101 86

SV 24 103 85

FV 24* 104 86

SV 26 103 85

FV 26* 107 85

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


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

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

Number of revolutions = 2950 rpm.

Compressor unit LW LP

SAB 163 BM 106 88

SAB 163 BF 110 92

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



VMY 347 H 97 82

VMY 447 H 100 85

VMY 536 H 104 88

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



VMY 347 M 99 84

VMY 447 M 101 86

VMY 536 M 105 89

0170

-115

-EN

95.0

6

0178-250-EN 25

7�'�� "��

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

ISO 2372 group C

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

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

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

Ranges of vibration severityExamples of quality judgement

for separate classes of machines

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

0.280.450.71

1.121.82.84.5

7.1

11.2

1828

45

71

0.280.450.71

1.121.82.84.5

7.111.2

18

28

45

A

B

C

D

A

B

C

D

A

B

C

D

A

B

C

D

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

Pay attention to the following, however:

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

– 85-95% for screw compressor units

– 80 % for recip. compressor units

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

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

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

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

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

0171

-476

-EN

99.0

4

26 0171-370-EN

��

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

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

Compressortype

Number ofcylinders

Bore

mm

Stroke

mm

Max/minSpeed

RPM

Swept volume

max RPM*m3/h

Weight(max.)

compr. blockkg

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

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

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

TE

TC°C

–30

–20

–10

–60 –50 –40 –30 –20 –10 0 10 20 30 40

0

10

20

30

40

50

60

70

T24

5400

_0/2

Co

nd

ensi

ng

tem

per

atu

re

Evaporating temperature

1

�

�

.

°C–70–40

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

°F

–22

–4

14

32

50

68

86

104

122

140

158

–40

0171-370-EN 27

R717Operating limits

single stagecompressors

CMOSMC 100 S-L

SMC 180

Type Area rpm Cooling

max min Booster Single and HP-stage compr.

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

3-41800 900

Water-cooled Thermopump or water-cooled

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

SMC 100 S-L 31500

700

4 1200Water-cooled Thermopump or water-cooled

1 750

SMC 180 2-3 1000 450 Water-cooled

4 900

# Including refrigerant-cooled oil cooler

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

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

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

T24

5400

_0/2

1

�

1�

TE

TC°C

–30

–20

–10

–60 –50 –40 –30 –20 –10 0 10 20 30 40

0

10

20

30

40

50

60

70

Co

nd

ensi

ng

tem

per

atu

re


°C–70–40

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

°F

–22

–4

14

32

50

68

86

104

122

140

158

–40

28 0171-370-EN



SMC 100 E

Type Area rpm Cooling

max min Booster Single and HP-stage compr.

1-(1a) 1500SMC 100E

2 1200700 Water-cooled Thermopump or water

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


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

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

0171-370-EN 29


two-stagecompressors

TCMOTSMC 100 S-L-E

TSMC 180

Type Area rpm Cooling Note

max min top and side

TCMO 1–2 1800 900 Thermopump or water-cooled

TSMC 100 S-L-E

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

1 7501)TSMC 180

2 1000450 Water-cooled 1)

Oil cooling is always necessary.

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


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

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

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

1

�

0177

128_

0 V

IEW

3,1

TE

TC°C

–30

–20

–10

–60 –50 –40 –30 –20 –10 0 10 20 30 40

0

10

20

30

40

50

60

70

Co

nd

ensi

ng

tem

per

atu

re


°C–70–40

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

°F

–22

–4

14

32

50

68

86

104

122

140

158

–40

1

�

.

�

TE

TC°C

–30

–20

–10

–60 –50 –40 –30 –20 –10 0 10 20 30 40

0

10

20

30

40

50

60

70

Co

nd

ensi

ng

tem

per

atu

re


°C–70–40

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

°F

–22

–4

14

32

50

68

86

104

122

140

158

–40

0177

128_

0 V

IEW

4,1

30 0171-370-EN

R22Operating limits


CMOSMC 100 S-L

SMC 180

Type Area rpm Oil-cooling Notemax min required 1)

1 no

21500

noCMO

3900

At less than 50% capacity

41800

yes

1 1000 no

2 1200 noSMC 100 S

3 1500700

At less than 50% capacity

4 1200 yes

1 Not applicable

2 1000 noSMC 100 L

3 1200 700 At less than 50% capacity

4 1000 yes

1-2 Not applicable

SMC 180 3 At less than 50% capacity

4750 450

yes

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

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

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

thermostatic expansion valve.

1�

.

�

TE

TC°C

–30

–20

–10

–60 –50 –40 –30 –20 –10 0 10 20 30 40

0

10

20

30

40

50

60

70

Co

nd

ensi

ng

tem

per

atu

re


°C–70–40

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

°F

–22

–4

14

32

50

68

86

104

122

140

158

–40

0177

128_

0 V

IEW

5,1

0171-370-EN 31

R22 Operating limits


TCMOTSMC 100 S-L

TSMC 180

Type Area rpm Oil-cooling Note

max min required 1)

1-2 1500TCMO

3-4 1800900 no

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

4 1500

1 Not applicableTSMC 2 1000

2)100 L3-4 1200

700 yes 2)

1-2 Not applicableSMC 180

3-4 750 450 yes 2)





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

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

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

32 0171-370-EN

R134a Operating limits


CMOSMC 100 S-L


max min required 1)

1200 no1-2

1500 At less than 50% capacityCMO

1500900

no3

1800 At less than 50% capacity

1 1000 no

2 1200 noSMC 100 S

1200700

no3


1 Not applicable

2 1000 noSMC 100 L

1000 700 no3


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

free choice between A and B.



T01

7712

8_ V

8,1

1�

.

TE

TC°C

–30

–20

–10

–60 –50 –40 –30 –20 –10 0 10 20 30 40

0

10

20

30

40

50

60

70

Co

nd

ensi

ng

tem

per

atu

re


°C–70–40

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

°F

–22

–4

14

32

50

68

86

104

122

140

158

–40

80 176

0171-370-EN 33

R134a Operating limits


TCMOTSMC 100 S-L


max min required 1)

1-2 15001)TCMO 28

3 1800900 1)

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

3 1500

1 Not applicableTSMC 2 1000

1) 2)100 L3 1200

700 1) 2)

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

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

T01

7712

8_0

V8,

1

1

�

.

TE

TC°C

–30

–20

–10

–60 –50 –40 –30 –20 –10 0 10 20 30 40

0

10

20

30

40

50

60

70

Co

nd

ensi

ng

tem

per

atu

re


°C–70–40

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

°F

–22

–4

14

32

50

68

86

104

122

140

158

–40

34 0171-370-EN

R404A Operating limits


CMOSMC 100 S-L


max min required 1)

1200 no1

1500 At less than 50% capacityCMO 20

1500900

no2


1 1000 no

SMC 100 S 1200 700 no2


1 1000 noSMC 100 L

2 1200700

no





2742

63.1

Rev

. 0

1

�

TE

TC°C

–30

–20

–10

–60 –50 –40 –30 –20 –10 0 10 20 30

0

10

20

30

40

50

60

Co

nd

ensi

ng

tem

per

atu

re


°C–70

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

°F

–22

–4

14

32

50

68

86

104

122

140

0171-370-EN 35

R404A Operating limits


TCMO TSMC 100 S-L


max min required 1)

11)TCMO 28

21800 900 1)

TSMC 1 12001) 2)

100 S 2 1500700 1) 2)

TSMC 1 10001) 2)

100 L 2 1200700 1) 2)



2742

63.3

Rev

. 0

1

�

TE

TC

°C

0

10

20

–60 –50 –40 –30 –20 –10 0

30

40

50

60

Co

nd

ensi

ng

tem

per

atu

re


°C–70–10

–76 –58 –40 –22 –4 14 32 °F–94

°F

32

50

68

86

104

122

140

14

36 0171-370-EN


single stagecompressors CMOSMC 100 S-L


max min required 1)

1 1200 no

2 1500 At less than 50% capacityCMO 20

2 1500900

no

3 1800 At less than 50% capacity

1 1200 no

SMC 100 S 2 1200 700 no

3 1500 At less than 50% capacity

1 1000 noSMC 100 L

2 1200700

no





7426

3.2

Rev

. 0

1

�

TE

TC°C

–30

–20

–10

–60 –50 –40 –30 –20 –10 0 10 20 30

0

10

20

30

40

50

60

Co

nd

ensi

ng

tem

per

atu

re


°C–70–40

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

°F

–22

–4

14

32

50

68

86

104

122

140

–40

0171-370-EN 37



TCMO TSMC 100 S-L

Area rpm Oil-cooling NoteType

max min required 1)

11)TCMO 28

21800 900 1)

TSMC 1 12001) 2)

100 S 2 1500700 1) 2)

TSMC 1 10001) 2)

100 L 2 1200700 1) 2)



2742

63.4

Rev

. 0

TE

TC

°C

0

10

20

–60 –50 –40 –30 –20 –10 0

30

40

50

60

Co

nd

ensi

ng

tem

per

atu

re


°C–70–10

–76 –58 –40 –22 –4 14 32 °F–94

°F

32

50

68

86

104

122

140

14

1

�

38 0171-370-EN

R407COperating Limits

one-StageCompressor type

CMO & SMC

Type Area rpm Oil-cooling Notemax min required 1)

1 1500 no

CMO 2 900 At less than 50% capacity

31800

yes

1 1200 no

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

3 1200 yes

1 1000 no

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

SMC 100 L 3 1000 yes

1 NOT APPLICABLE

SMC 180 2 At less than 50% capacity

3750 450

yes





Co

nd

ensi

ng

tem

per

atu

re


TE

–30

–20

–10

0

10

–60 –50 –40 –30 –20 –10 0 10 20 30

20

40

50

30

60

�

.

1

TC

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

°F

–22

–4

14

32

50

68

86

104

122

140

T245411_0 view 2

°C–70

°C

0171

-461

-EN

96.0

6

0178-900-EN 39

8��

� ��3��% ��3��

Starting up compressor and plant

� Before the initial start-up of the compres-sor following a lengthy stand-still period ofseveral months, the compressor must beprelubricated. Hereby, the bearings arelubricated and the oil system filled upwith oil before the compressor is set run-ning.Carry out the prelubrication by connect-ing the oil pump to the prelubricatingvalve which in the more recent SMC-TSMC-HPC compressors is connected tothe shaft seal housing pos. 8A and on theCMO-TCMO-HPO to the cover pos. 86Hor 87K. As prelubricating pump we recom-mend SABROE’s hand-operated oil pumppart no 3141-155, which is mounted asshown in fig. 1.

Fig. 1

��

��

� ��

��

��

��

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

Compressortype

Pump strokes w.SABROEs

hand-operated

Estimatedoil quantity

Liters

CMOTCMOHPO

SMC 104106-108TSMC 108HPC

SMC 112-116TSMC 116

SMC 186-188TSMC 188

appr. 25

appr. 35

appr. 45

appr. 50

2.5

3.5

4.5

5.0

oil pump

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

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

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

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

� Open discharge stop valve at compressor.

� Set capacity regulator to minimum capa-city.

40 0178-900-EN

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

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

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

� Start compressor motor and check suctionand oil pressures.

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

� Open main valve in liquid line.

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

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

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

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

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

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

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

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

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

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

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

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

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

� Cut off power supply to both master andcontrol currents.

0178-900-EN 41

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

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

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

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

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

� Cut off power supply to master and controlcurrents.

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

Automatic plants

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

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

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

– correct oil charging,

– automatic oil return,

– correct oil pressure,

– suction and condenser pressures, discharge pipe temperature,

– correct setting of safety automatics.

Pressure testing refrigeration plant

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

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

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

� air compressor for high pressure;

� nitrogen.

ImportantThe plant compressors must not beused to pressurize the plant.

Water or other fluids must not be usedfor pressure testing.

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

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

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

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

42 0178-900-EN

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

� The test pressure must never exceed thedisign pressure.

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

HP side: 24 barLP side: 17.5 bar

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

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

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

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

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

� date of pressure testing,

� person carrying out the test,

� comments.

Pumping down refrigeration plant

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

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

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

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

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

Boiling point ofwater °C

At pressuremm HG

5

10

15

20

6,63

9,14

12,73

17,80

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

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

ImportantNever use the refrigeration compressorto evacuate the plant.

0178-900-EN 43

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

It is recommended to carry out evacuation asfollows:

� Evacuate to a pressure lower than 5 mmHg.

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

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

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

44 0178-900-EN

Operating log

In order to keep tabs on the operating state

of the refrigeration plant, it is recommended

that an operating log be kept.

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

• Electrical panel

Oil level incompressor

Compressor motor’sconsumption in amps.

• Oil level sight glass

in compressor

• UNISAB II Control

• Compressor pressure gauge


Observation Measuring point Measurement unit

Date and timeTime

Suction pressure

Oil pressure

Oil temperature

Suction gas temp.

Discharge gas temp.

Recharding of oil oncompressor

Discharge pressure





• Thermometer in suction pipe immediately

before compressor


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


• UNISAB II (additional)

• See section on oilcharging

°C or bar

bar

°C

°C

Must be visible in oilsight glass

Number of litres

°C or bar

Amps

°C

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

0171

-462

-EN

99.0

5

0171-462-EN 45

��(�� $� ��

�� 3��% ��3��

166 �� 3�� 1�6

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

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

� The following must therefore be checkeddaily:

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

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

Pressure drop test:

Using the pressure drop test, it is possible tocheck the internal tightness of the compres-sor from discharge to suction side. The pres-

sure drop test is performed with the compres-sor at standstill, as described below:

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

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

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

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

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

� with defective seal Pos. 19K;

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

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

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

46 0171-462-EN

Removing refrigerant from compressor

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

1. Run compressor at lowest capacity stageand throttle suction stop valve slowly untilcompletely closed.

2. The compressor will then stop on the lowpressure cut-out. This can be adjusted tostop compressor at a pressure lower thannormal.

3. Close discharge stop valve and other pip-ing connections to compressor.

4. On HFC and HCFC compressors, removeremaining refrigerant gas using a pump-down compressor connected to purge val-ve Pos. 42.

R22

Evacuating pump

42

� On the R717 compressor, adopt the fol-lowing method:

Water

R717

42

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

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

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

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

0171-462-EN 47

Operatinghours

< 1200 rpm

Operatinghours

> 1200 rpm

Activity

75 50

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

1.2 Check tension of driving belts.

300 200

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

2.2 Clean suction filter.

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

2.4 Retighten external piping connections.

2.5 Check oil return system from oil separator.

2.6 Retighten coupling.

Scheduled services

No.

1

2

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


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

3.4 For heat pump operation, inspect: Valve seats Cylinder linings

Pistons, gudgeon pins and gudgeon pin bearingsPiston and oil scraper rings.

Change suction and discharge valve ring plates.

3.5 Finish off with a pressure drop test.

7500 50003

48 0171-462-EN

Operatinghours

< 1200 rpm

Operatinghours

> 1200 rpmActivity

15000 10000

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


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

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


No.

4

22500 15000

5.1 Check V-belt drive

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

Change:Suction and discharge valve ring plates.

5

0171-462-EN 49

OperatingHours

< 1200 rpm

OperatingHours

> 1200 rpmActivity

30000 20000

No.

6

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


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

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


60000 40000 Major overhaul; contact SABROE Refrigeration

37500 25000 As for service no. 5



7

8

9

10

Then repeat scheduled services from no. 3 inclusive.

50 0171-462-EN

9�'��

Lubricating oil requirements

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

General rules for use of lubricatingoil in refrigeration compressors

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

� Use grade of oil originally prescribed forcompressor.

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

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

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

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

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

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

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

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

0171-462-EN 51

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

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

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

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

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

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

� Avoid getting air or other impuritiessucked into compressor.

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

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

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

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

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

Changing oil in refrigeration com-pressor

� Cut off power to heating rod.

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

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

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

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

� Dismantle side covers.

� Replace oil filter cartridge with a new one.

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

� Reassemble side covers.

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

� Connect heating cartridge.

52 0171-462-EN

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

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

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

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

0171-462-EN 53

�$�� $� �� +��$ ��

Compressor

Type Size

Volume of oil in crankcase

Litres

BFO

CMOTCMO

SMC 100TSMC 100

Mk 3

SMC 180TSMC 180

345

242628

104106108112116

186188

1,545

141618

2628304750

8090

4 13

S-L-E

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

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

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

� type of refrigerant

� refrigerant charge (volume)

� size of plant

� temperature range in which refrigerationplant is to operate.

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

The oil level must always be visible in theoil level sight glass. The below table illus-trates, how many litres of oil a drop in theoil level of 10 mm is approximately equalto.

T0177162_0

Compressortype size

10 millimeter difference in

oil levels equals

SMC /TSMC100S-L-E

SMC /TSMC180

CMO/TCMO

242628

~1 litre of oil

104106108

~2 litres of oil

112116 ~6 litres of oil

186188 ~6 litres of oil

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

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

54 0171-462-EN

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

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

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

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

� be clear and shiny

� not contain any visible particles

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

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

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

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

As a special offer to our customers SABROE has developed an analytical con-cept, which is able to analyse all oil makes.This will mean a uniform reporting of the re-sults.

The analysis allows the following to be deter-mined:

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

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

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

Procedure

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

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

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

0171-462-EN 55

The analysisThe following table states some average values that can be applied in practice. How-ever, you should be on the alert whenever

the results of the analyses approach these

values. In some cases the water content of

100 ppm in HCFC plants may be too much

and thus lead to Cu–plating in the shaft seal.

Limiting values

Sabroe Oil PAO 68 Sabroe Oil AP 68 Sabroe Oil A 100

Parameter Unit Method TargetSpec. Max. Min.

TargetSpec. Max. Min.

TargetSpec. 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 1500

report report report

Pentane Insolubles W% MM 490 (5�m)

– 0.05 – 0.05 – – 0.05 –

Oxidation abs/cm IR,1700-1720/cm

– 5 – – 5 – – 5 –

Nitration abs/cm IR,1627-1637/cm

– 5 – – 5 – – 5 –

Nitro Compounds abs/cm IR,1547-1557/cm

– 0.5 – – 0.5 – – 0.5 –

Maximum values for metal content in the oil

Lead ppm ICP – 10 – – 10 – – 10 –

Copper ppm ICP – 10 – – 10 – – 10 –

Silicium ppm ICP – 25 – – 25 – – 25 –

Iron ppm ICP – 100 – – 100 – – 100 –

Chromium ppm ICP – 5 – – 5 – – 5 –

Aluminium ppm ICP – 10 – – 10 – – 10 –

Tin ppm ICP – 10 – – 10 – – 10 –

1): TAN (Total Acid Number) is only reported for non-ammonia-applications

2): SAN (Strong Acid Number) is only reported for non-ammo-nia-applications

56 0171-462-EN

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

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

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

If this is necessary, the oil must bepumped directly from the compressor unit

through a 3 micron filter and back to theunit. The system must be completelyclosed, to prevent the oil being affected bymoisture in the air.

� Whether the oil is no longer fit for use.

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

0170

-012

-EN

96.0

4

Safety valveon the compressor

High and intermediate

Low-pressure

Oil pressure cut-out

Discharge pipe

Oil thermostat

Thermostat forcompressor cooling

Injection valve for

By-pass valve

Oil pressure

Refrigerant

22 bar (special)

24 bar (standard)

3,5 bar

regulating valve

HP

IP

MP 55

* 120

* 150

° C° C

KP 98

KP 98 ° C 80

° C 55KP 77

Thermo valve forcompressor cooling

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

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

°C°C

TEAT

PMC +CVC

°C 45° C 75

° C° C-15

4.5 bar

x x x x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

*

**

**

12 bar

cut-out

cut-out

thermostat

KP 5(KP15)

KP 1(KP15)

Saf

ety

equ

ipm

ent

Co

ntr

ol e

qu

ipm

ent

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

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

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

SMC - TSMC - CMO2 - TCMO2 CMO4

3.5 bar1.3 bar4.5 bar1) 2)

-25

2)

1)

intermediate cooling

Factory set.

Factory set.

See below.

See below.

x

x

Adjust to min 10°C superheat

Adjust to min 10°C superheatT(E) X

TEA

R22

R13

4a

R40

4A

R50

7

R71

7

x

xx

x

x

x

x

x

x

x

x

x

x

x

Set to a pressure with saturation temp. 5°Klower than the lowest evaporating temper-ature.

Set so that the compressor stops at a pres-sure 2 bar lower than the safety valve set-ting.

0171-370-EN 57

�� *:��;

�� "��

0170-105-EN 96.02

580172-133-E

N

;<��$��

Su

ction

gas su

perh

eat°

C

Co

nd

ensin

g tem

p. °

C

HFC - HCFC

bar

bar

bar

10

20

30

20

25

30

35

40

45

8.8

10.1

11.5

5.7

6.6

7.7

8.8

10.1

11.5

5.7

6.6

7.7

8.8

10.1

11.5

20

25

30

35

40

45

20

25

30

35

40

45

38

44

49

53

57

61

48

54

63

67

71

58

64

69

73

81

41

45

50

54

59

63

51

55

60

64

69

73

61

65

70

74

79

83

43

48

53

58

63

67

53

58

63

68

73

77

63

68

73

78

83

87

48

52

58

64

69

74

58

62

68

74

79

84

68

72

78

84

89

94

55

59

66

74

79

82

65

69

76

84

89

92

75

79

86

94

99

8.2

9.5

11.1

14.5

16.5

8.2

9.5

11.1

12.7

14.5

16.5

8.2

9.5

11.1

12.7

14.5

16.5

37

47

55

68

72

81

48

57

65

73

82

90

59

69

75

84

92

99

48

57

65

74

82

90

59

68

76

84

92

98

70

78

86

95

101

108

61

69

77

85

94

100

72

80

88

96

103

109

83

91

98

106

111

117

76

84

92

99

106

112

88

95

102

109

115

121

97

105

111

118

123

128

91

101

108

115

120

126

103

110

117

123

128

133

113

120

125

131

135

139

53 71 91 110 131

10.7

12.6

14.6

16.9

10.7

12.6

14.6

16.9

10.7

12.6

14.6

16.9

65

77

89

101

110

65

77

89

100

111

121

78

90

102

112

123

132

83

95

106

117

126

83

95

106

116

127

136

96

106

118

128

138

148

102

113

123

133

143

103

114

125

134

144

154

115

126

136

146

155

165

121

133

141

151

161

122

132

142

152

162

171

134

144

154

163

–

–

142

151

160

170

–

143

153

162

–

–

–

153

163

–

–

–

–

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

° CDischarge gas temp.° C

°C °C

Co

nd

ensin

g p

ressure

10

20

30

20

25

30

35

40

45

5.7

6.6

7.7

20

25

30

35

40

45

20

25

30

35

40

45

8

9

11.

12.7

14

8

9

11

12

14

16

8

9

11

12

14

16

37

47

55

68

72

81

48

57

65

73

82

90

59

69

75

84

92

99

48

57

65

74

82

90

59

68

76

84

92

98

70

78

86

95

101

108

61

69

77

85

94

100

72

80

88

96

103

109

83

91

98

106

111

117

76

84

92

99

106

112

88

95

102

109

115

121

97

105

111

118

123

128

91

101

108

115

120

126

103

110

117

123

128

133

113

120

125

131

135

139

7.6 53 71 91 110 131

9.1

7.6

9.1

7.6

9.1

65

77

89

101

110

65

77

89

100

111

121

78

90

102

112

123

132

83

95

106

117

126

83

95

106

116

127

136

96

106

118

128

138

148

102

113

123

133

143

103

114

125

134

144

154

115

126

136

146

155

165

121

133

141

151

161

122

132

142

152

162

171

134

144

154

163

–

–

142

151

160

170

–

143

153

162

–

–

–

153

163

–

–

–

–

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

R134a R22 R404A/R507 R717

° C

°C

orintermediate temperature

°C


or

77

59

102

16.2

18.2

20.5

11.0

12.5

14.3

16.2

18.2

20.5

11.0

12.5

14.3

16.2

18.2

20.5

40

44

49

54

59

65

50

54

64

69

75

60

64

69

74

85

42

47

52

57

62

67

52

57

62

67

72

77

62

67

72

76

82

87

46

51

56

61

66

71

56

61

66

71

76

81

66

71

76

81

86

91

53

58

63

67

72

77

63

68

73

77

82

87

73

78

83

87

92

97

62

67

71

75

79

83

72

77

81

85

89

93

82

87

91

95

99

11.0

12.5

14.3

79

59

103

Co

nd

ensin

g p

ressure

Co

nd

ensin

g p

ressure


intermediate temperature

bar

Co

nd

ensin

g p

ressure °C

or



°C

or



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

0171

-470

-EN

97.0

7

0178-250-EN 59

��(�� $� ��

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

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

� the desired temperatures are observed,

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

� the condenser pressure is not excessivelyhigh, and

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

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

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

Change the drying filter regularly.

Check Interval Activity

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

Pressureand temp. Daily

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

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

Accumulated dirt causes reducedrefrigerant supply to the evapora-tor.

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

FiltersClean whenneeded

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

Dehumidi-fier When

needed

60 0178-250-EN

Check Interval Activity

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

rant Periodically

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

Periodically

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

Safety pressure controlsAutomatic operating controlsAlarms

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

Automaticcontrols

Periodically

Lubrication of electric mo-tors

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

motor Periodically

Alignment of couplingV-belt drive

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

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

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

Con-denser

Periodically– normallymin. 4 times a year

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

Evapora-tor

Whenneeded

0171

-358

-EN

98.0

7

0171-370-EN 61

��

�� % ��

General

When the compressor requires maintenance,it is important to follow the instructions givenbelow. In order to make sure that the com-pressor is working correctly, the gauge mea-surements and screw torques must be strictlyadhered to.

Before opening the compressor, it is expedi-ent to ensure that you have spares of thoseseals and gaskets to be stripped down or dis-mantled. An O-ring which has been exposedto oil and heat for any length of time mayhave expanded so much as to prevent it be-ing refitted.

All seals used are resistant to oil, HFC/HCFCand ammonia. All O-rings are made of neo-prene rubber.

Pump-down

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

1. If the compressor is operational

Run the compressor at minimum capacity atnormal operating temperature.

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

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

The suction pressure must be lowered slowlyenough to give the refrigerant dissolved inthe oil time to escape without the oil foaming.This is of great importance in compressors

running on HFC/HCFC. An ammonia com-pressor can stand having the pressure re-duced somewhat more quickly without the oilfoaming.

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

� Close suction stop valve.

� Cut off power to compressor motor.

� Close discharge stop valve.

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

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

� Remove all fuses, if any.

2. If the compressor is inoperative� Leave heating rod in crankcase connected

for a couple of hours before compressoris due to be opened in order to heat up oil.Warm oil does not contain as much refrig-erant.

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

� Keep discharge stop valve closed.

� Close suction stop valve and disconnectheating rod.

� Equalize pressure in compressor throughpurge valve Pos. 42.

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

� Remove all fuses, if any.

62 0171-370-EN

Dismantling and assembly

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

Top covers

Dismantling of top cover

Loosen and dismantle screws Pos. 2C, how-ever with exception of the two screws shownon drawing.

T0177142_0 V9

Loosen these screws approx. 1 mm andcheck 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 softhammer while keeping the two screws fit-

ted. Pay attention to the powerful springpressure under the top cover. After disman-tling of the two screws – unscrew alternately– the top cover can be removed.

Mounting of top cover

Check that gasket pos. 2B is intact and – ifnecessary – check that the clearance vol-ume has been adjusted as described later inthis instruction.

If the gasket Pos. 2B needs to be replaced,the graphitized side must face the compres-sor frame. After placing the top cover looselyon top of the springs pos. 21, it is recom-mended that all screws be fitted by hand, asthe bolts will jointly guide the top cover intoposition. Now tighten the top cover with thetwo screws mentioned above, then with theremaining ones.

Finally, cross-tighten all screws with the pre-scribed torque in the following sequence:

117 1 3

128 4 2

59

610

T0177142_0 V9

0171-370-EN 63

Discharge valve

T0177142_0 V2

Pos. 20

21

20F

20E

20D

20H

20C

20A

As shown in the drawing, the function of thedischarge valve Pos. 20 is partly to allow thecompressed gas to pass from the compres-sion chamber of the cylinder to the dischargechamber beneath the top covers and partly tocreate a seal from the discharge chamber tothe cylinder.

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

In order to avoid pressure of such intensityas to damage the bearings in the compres-sor, the discharge valve is retained in posi-tion by the safety spring Pos. 21, which al-lows it to lift a little bit under the strain of in-creased pressure.

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

Discharge valve types:

Depending on which refrigerant the compres-sor is operating on, various discharge valvesmust be used in order to achieve optimumfunction.

Marking

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

Refrigerant R717: All discharge valves are marked with onegroove.

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

64 0171-370-EN

Marked withone groove for R717two grooves for HFC/HCFC

Dismantling

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

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

� Bolt Pos. 20D, discharge valve seat Pos.20A and ring plate Pos. 20C can now bedisassembled by hand.

� Remove valve springs Pos. 20H by hand.

Assembling

� Before assembling the discharge valve,you must make sure that the valve springsPos. 20H are in good order and are firmlyfixed in their apertures.

Assemble the discharge valve in reverse or-der to that described above. Note the follow-ing, however:

� Tighten bottom nut Pos. 20E to torque of3,2 Kpm ≅ 31 Nm.

If necessary, exert counterpressure with 3mm Allen key on bolt head.

� Fit spring guide Pos. 20F and tighten topnut to same torque: 3,2 Kpm ≅ 31 Nm.

Leak testing of discharge valve

This is done by means of the pressure droptest, as described elsewhere in this instruc-tion manual. Please see list of contens.

Service life of discharge and suction valves

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

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

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

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

� The compressor ratio at which the com-pressor operates:At high compression ratios, the load onvalve ring plates and springs is appreci-ably larger than at low compression ratios.

When the valve ring plates are changed, thevalve springs should also be replaced.

0171-370-EN 65

Cylinder lining with suction valve

19H 19K 19K19G

T0177142_0 v1

Marking of suction valve stop

19J

1 groove for R7172 grooves for HFC/HCFC

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

The cylinder lining and suction valve form anintegral unit and can be dismantled by re-moving screws Pos. 19J.

Extracting cylinder lining

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

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

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

� Insert protective plate no. 5 (from tool kit)between piston and frame so the pistoncan rest on it. This makes it possible forpiston and piston rings to slide onto theprotective plate without being damagedwhen the crankshaft is turned.

Dismantling suction valve

Dismantling the screws Pos. 19J enables thesuction valve stop Pos. 19H and ring plate

Pos. 19F to be removed from the cylinderlining.

Mounting suction valve

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

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

� Before tightening screws 19J, ensure suc-tion valve plate can be moved freely in itsguide. Tighten screws Pos. 19J to atorque of 7.6 Nm.

Inserting cylinder lining

� Rotate crankshaft to position piston at topdead centre.

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

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

� Rotate piston rings on piston so as tostagger ring gaps at 180° to each other.Press cylinder lining down over pistoncarefully. The chamfering on the cylinderinterior will catch the piston rings andsqueeze them to the diameter of the cylin-der. If possible, fit cylinder in same placefrom which it was taken.

� Press cylinder lining down by hand andwithout using rotating movements, how-ever, it will not bear against gasket Pos.19K until discharge valve pos. 20, safetyspring Pos. 21 and top cover have beenmounted.

66 0171-370-EN

� In order to be able to check the size of theclearance volume. However, it is neces-sary to press cylinder lining down againstgasket Pos. 19K, using of 2 tighteningbars no. 1 to be mounted diagonallyabove the cylinder lining. To be used asshown on the following drawing.

19K T0177142_0 V3

X1

� Using a depth gauge, measure the dis-tance ”x” from discharge valve seat to thetop of the piston, with this in its top posi-tion.

The correct ”x” measure must be be-tween:

x min. = 0.8 mm x max. = 1.2 mm

Adjustment of ”x” measure is done by insert-ing one or more gaskets Pos. 19K which, asindicated in the parts lists, come in two sizes,0.5 and 0.8 mm.

Next, mount discharge valve Pos. 20, springPos. 21, and top cover. Before this, checkgasket Pos. 2B.

Connecting rod

Connecting rod Pos. 17 consists of a lightmetal alloy which, besides its excellentstrength properties, is also well-suited asbearing material.

Thus, the bearing surfaces of the connectingrod work directly on the crankshaft and thebearing surfaces of the gudgeon pin.

At the HP cylinder in the TCMO compressora needle bearing Pos. 17K is fitted. Theneedle bearing can – in a vice or hydraulicpress – be squeezed out from into the con-necting rod. Apply soft jaws in the vice anduse tools that do not damage the parts.

As indicated in the parts lists the connectingrods for the HP and LP stages each havetheir own part number and can further be de-livered with short measures on the big endbearing, for use at repairs, if any. See sectionon: Undersize bearing diameters for chank-shaft.

Fitting connecting rod

Before fitting the connecting rod in the com-pressor stand, piston and piston rings mustbe fitted onto the connecting rod. See the fol-lowing sections. In addition, the two connect-ing rod bolts Pos. 17C must be fitted asshown in the spare parts drawing.

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

� Position connecting rod interior throughlateral opening on frame, and fit nuts Pos.17H.

0171-370-EN 67

Note:The two parts of the connecting rod arenumbered with the same number; this isonly of importance when assembling.Parts with different numbers must not beassembled and it is important that thenumbers are fitted in the same directionas shown in Fig. 1.

916 916

T0177131_0 v2,b

Note:

Fig. 1

Stamped number on the same sideon assembly

� Tighten nuts Pos. 17H alternately with in-creasing torque and finish off with torquewrench.Torque: 20 Nm.

Piston

The piston is made of aluminium andequipped with a piston ring and an oilscraper ring.

Fitting piston rings in piston

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

Note:At the ring opening the oil scraper ring ismarked TOP. This mark must face the pis-ton top.

Assembling and stripping down pistonand connecting rod

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

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

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

� Guide connection rod (TCMO - with in-serted needle bearing) into place in thepiston pin without using tools.

� Fit the other circlip Pos. 18E.

Dismantling is done in opposite order. How-ever, do not heat the piston, but press out thepiston pin using a punch.

Procedure for removing piston and con-nection rod

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

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

� Dismantle top and side covers.

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

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

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

68 0171-370-EN

Shaft seal

10G 10BT0177142_0 V4

10K

10H 10F 10C 10A 8E 8A 8H 8B 10D 8D 8C 16G

7A

Fig. 2

Pos. no. Shaft seal

7 A -1 Bearing cover8 A -1 Shaft seal cover8 B -1 O-ring dia. 98.02 x 3.538 C -1 Hexagon screw M8 x 308 D -1 Locking washer8 E -1 Circlip8 F -1 Retention pin

10 A -1 Slide ring (cast iron)10 B -1 Slide ring (special carbon)10 C -1 O-ring dia. 53.57 x 3.5310 D -1 O-ring dia. 63.09 x 3.5310 F -1 Tightening flange10 G -1 Allen screw M5 x 1610 H -1 Circlip

10 K -1 Spring 16 G -1 Oil throw ring

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

It comprises a slide ring Pos. 10A, manufac-tured from special-purpose cast iron, which issecured to the crankshaft by means of thelocking ring Pos. 10H, tightening flange Pos.10F and the four screws Pos. 10G withspring washers.

The carbon slide ring Pos. 10B is pressedagainst the flat-machined, lapped slide ring atthe end of Pos. 10A by a series of springsPos. 10K, and the carbon slide ring is pre-vented from rotating by means of the reten-tion pin Pos. 8H.

0171-370-EN 69

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

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

The O-ring Pos. 10C creates a seal betweenthe slide ring Pos. 10A and the crankshaft.The O-ring Pos. 10D seals between the car-bon slide ring Pos. 10B and the shaft sealcover Pos. 8A.

When the shaft seal is operating, a tinyamount of oil drifts out between the slidefaces to lubricate them. An oil throw ring Pos.16G has therefore been fitted to prevent thisoil migrating along the axle to the transmis-sion linkage.

The oil splash ring ejects the oil into thegroove in the shaft seal cover Pos. 8A. Viainternal channels, the oil comes out underthe shaft seal and through a plastic hose, it iscollected in a plastic bottle.

1. Dismantling and stripping down shaftseal

1.1. Once the gas pressure in the compres-sor has been eliminated and the motorsafeguarded against inadvertentstart-up, dismantle coupling or V-beltdisk.

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

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

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

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

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

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

Circlip pos. 8E is now easily extractedby means of a screw driver withoutdamaging the slide surface of the car-bon slide ring.

After removing tool no. 2, the carbonslide ring pos. 10B, O-ring pos. 10Dand springs pos. 10K (see fig. 2) cannow be dismantled.

Fig. 3

••

10D 8A8E 10B

••

A

•

•

8C

70 0171-370-EN

1.5. Dismantle slide ring 10A by turning thefour Allen screws 10G a max. of 2-3turns; the entire unit can then be takenout with the fingers or using twoscrewdrivers inserted into the externalgroove on the slide ring Pos. 10A andmoved in the direction of the arrow asillustrated in fig. 4.

Fig. 4

•

10A

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

Assembling and mounting shaft seal

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

2. Unit with slide ring, Pos. 10A

2.1. Before fitting slide ring 10A, tightenscrews 10G until there is approx. 2 mmspacing and parallelism between thetwo flanges. Check also that locking ring10H is mounted as shown in the dra-wing and O-ring 10C is in position.

2.2. Position slide ring 10A on shaft and en-sure tightening flange makes contactwith shaft shoulder.

2.3. Crosswise, tighten screws Pos. 10G al-ternately with Allen wrench from tool kit.

The torque is specified in the instructionmanual.

3. Unit with shaft seal cover Pos. 8A

3.1. Mount O-ring 10D and the ten spiralsprings 10K in shaft seal cover 8A,then position carbon slide ring 10B carefully. Rotate carbon slide ring soslot fits in over retention pin 8H.

3.2. With tool no. 2-1 fitted as shown fig. 3press carbon slide ring 10B againstsprings with your fingers and fit circlip8G. Take care that the surface of thecarbon slide ring remains undamaged.

3.3. Give the complete shaft seal cover anextra oiling on the slide surface of thecarbon slide ring and guide it over theshaft. Pay attention to O-ring Pos. 8B.

3.4. By gently pressing the shaft seal coverand the carbon ring against slide ringPos. 10A without compressing thesprings Pos. 10K, measure the distancefrom shaft seal cover Pos. 8A to bearingcover pos. 7A (see sketch). By a subse-quent careful tightening of the screwsPos. 8C the shaft seal cover should onlybe tightened about 3 mm before achie-ving contact between Pos. 8A and 7A.

T0177142_0 V4B

10A 3 mm10B 8A 8C7A

••

•

• •

• •

10K

10G

0171-370-EN 71

In case the movement is bigger, checkwhether the tightening flange Pos. 10Fhas been pushed completely up againstthe crankshaft shoulder as described insections 2.2 and 2.3.

3.5. Make sure that the screws Pos. 8C areevenly tightened cross-wise. Hereby da-mage of the carbon slide ring is avoi-ded. Tighten screws Pos. 8C to prescri-bed torque, acc. to table in instructionmanual.

3.6. Mount oil throw ring Pos. 16G, asshown in drawing.

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

Crankshaft

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

At the centre and end of the crankshaft, theoil channels are blanked off with 3 blindplugs.

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

Dismantling crankshaft

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

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

� Dismantle top and side covers.

� Dismantle all cylinder linings.

� Extract all pistons and connecting rods.

� Pull off V-belt pulley or coupling half .

� Dismantle shaft seal cover and shaft seal.

� Dismantle pressure cut-outs and pipes tomanometers, or piping connections toUNISAB.

� Dismantle oil filter as well as its bracketPos. 59A.

� Dismantle end cover, pos. 4A.

� Dismantle bearing cover with oil pumpPos. 5A at screws Pos. 5C, then pull outbearing cover. It is not necessary to dis-mantle oil pump Pos. 11 from bearing cov-er. it is also normally not necessary tosupport the crankshaft.Now pull out crank from the frame, sup-porting it by hand through one of the sideopenings.

Inspection

� Check bearing journals at connecting rodsof wear and tear and, if necessary, mea-sure diameter of journals. Max. wear ofthe journals appear from section Variousclearances and adjustment measure-ments.

In most instances, the permissible play inthe bearing can be obtained by replacingthe connecting rods.

Normally, the journals are only slightlyworn at main bearings, but during com-plete overhauls they should be measured.

By wear and tear beyond the plays stated,the crankshaft can normally be ground to0.5 mm undersize.

Main bearings and new connecting rodswith a 0.5 mm undersize can be suppliedto the ground down crank, as stated in theparts list.

72 0171-370-EN

Drawing for grinding of crankshaft to un-dersize can be requested from SABROE.

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

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

Refitting crankshaft

Refit the crankshaft in the reverse order tothat for dismantling.

Note the following, however:

� After positioning the crankshaft in theframe, mount main bearing cover Pos. 5Awith a gasket Pos. 5B as a shim.

� Before refitting bearing cover, position androtate oil pump coupling on pump shaft sothat the retaining pins on the crankshaftengage the two nylon bushings.

� Check end play of crankshaft by pressingthe shaft against the main bearing Pos.6E, and measure clearance in the otherbearing, using a feeler gauge.

The permissible end play appears fromsection Various clearances and adjust-ment measurements.

Adjustment of end play is achieved bymeans of the gasket Pos. 5B.

The gasket can be supplied in the follow-ing thicknesses, as per the spare partslist:

0.25 mm 0.50 mm 0.75 mm 1.0 mm

Main bearings

Main bearings Pos. 5E and 6E consist of asteel bushing with collar, coated with a thinlayer of white metal inside the bushing andon the collar.

The bushings can be squeezed out and re-placed by new ones and require no finishingonce assembled.

When pressing in new bushings, the in- andoutlets of the lubricating duct for bushing atshaft seal end, pos. 6E, should be positionedas illustrated on the drawing. The cover isshown from the inside and as fitted on thecompressor.

The bushing at the oil pump end of the com-pressor, pos. 5E, must be placed so that thein- and outlets of the lubricating duct are fa-cing upwards.

Main bearing bushings can be supplied forground down crankshaft. See spare parts list.

T0177168_0

45° In- and outletsof lubricatingduct

0171-370-EN 73

By-pass valve pos. 24The compressor is equipped with a built-inmechanical by-pass valve, fig. 1, which safe-guards it against any inadvertent excesspressure if the electrical safety equipmentfails. The by-pass valve safeguards againstany excess pressure between the dischargeand suction sides of the compressor.

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

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

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

Further, the by-pass valve is independent ofthe pressure on the compressor suction side.Consequently, it only opens when the pres-sure on the discharge side exceeds the setpressure in relation to atmospheric.Thus, watch out that hole pos. B does notget covered or clogged.

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

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

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

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

T3137T02I_1

Fig. 1 24C 24B

B

•

A

74 0171-370-EN

Suction filterOn the inside of the end cover Pos. 7A thecompressor is equipped with a plate shapedsuction filter Pos. 7G with a very large filter-ing area. By non contaminated refrigerationplants it is therefore not necessary to cleansuction filters between main overhauls.

If the plant is not completely clean, the com-pressor will normally be equipped with an ex-tra suction filter as described below.

Extra suction filter

T0177142_0 V11

66J 66G 66H 66F 66C 66B 66K

The extra suction filter consists of an inde-pendent filter housing fitted on the compres-sor between end cover Pos. 7A and suctionstop valve Pos. 66A.

Remove filter strainer Pos. 66F as describedbelow. On delivery of the compressor, thefilter has a filter bag insert Pos. 66G, retain-ing very small dirt particles coming with thesuction gas from the refrigeration plant.

The filter bag is kept in place by a supportingspring Pos. 66H and must be used for thefirst 50 operating hours of the compressor. In

normally clean plants it may then be removedtogether with the supporting spring.

In case the filter is badly soiled after the50 operating hours mentioned, it is rec-ommended to fit a new filter bag foranother 50 operating hours. Similarly, afilter bag should be fitted for a period of50 hours after major repair works on therefrigeration plant.

Cleaning of extra suction filters

After evacuation af the compressor, disman-tle cover Pos. 66B, ectract filter strainer Pos.66F.

If filter bag Pos. 66B is fitted, it must be re-moved and renewed as previously described.The filter should be cleaned in a cleansingfluid with a suitable stiff brush, however, with-out damaging the filter mesh.

Blow dry the filter strainer with compressedair. Give the filter a regular cleaning in accor-dance with the stated servicing dates.

Note: It is important to keep the suction filterclean and in good order as a soiled orclogged filter reduces the capacity of thecompressor.

By total clogging there is also the risk that thefilter may burst and severely contaminate thecompressor.

When refitting of the filter, O-rings Pos. 66Jand 66C must be in place and in good order.Tighten screws Pos. 66K to the torque mo-ment prescribed in the table.

0171-370-EN 75

Stop valves

T0177142_0 V5

AG F C H D Q G N B J L P R M K

AK

AC

AD

E

Y U

T

S

A AJZ

POS. 25

The suction and discharge stop valves Pos.25 are used to isolate the compressor fromthe refrigeration plant.

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

Dismantling of valve

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

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

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

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

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

� The front and rear pieces Pos. 25C and25D can now be separated and the teflonring Pos. 25H removed. The teflon ring will be flattened on oneouter edge, which is normally of no impor-tance to its sealing ability providing it isfree of scratches and marks. If required,the teflon ring can be reversed when reas-sembling so that the other outer edgeseals towards the valve seat in the hous-ing.

76 0171-370-EN

Reassembling of valve

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

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

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

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

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

Adopt the following procedure:

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

� The packing screw joint Pos. 25M cannow be unscrewed for inspection or re-placement of O-rings Pos. 25R and 25P.Lubricate all parts thoroughly with oil be-fore reassembling.

0171-370-EN 77

Compressor lubricating system

T0177131_0 V12

11

60

9A

To capacitiyregulating system

To oil pressureregulating valve Pos. 22

The oil system has two functions: The oil lu-bricates and cools all movable parts in thecompressor and it works as a hydraulic sys-tem for regulation of the compressor pum-ping capacity. A description follows later.

The oil pump pos. 11M sucks oil from thecrankcase, through filter element Pos. 60,past the magnetic filter located inside the filter element. The pump forces the oilthrough an internal pipe Pos. 9A an on to the shaft seal housing.

The filter element Pos. 60 is a disposable fil-ter which cannot be cleaned. See descriptionof Oil filter.

The shaft seal housing acts as a distributionchamber for the oil. The oil pressure in theshaft seal housing is adjusted by means ofthe oil pressure regulating valve Pos. 22,which is mounted on the one side cover.

The regulation valve can be adjusted fromthe outside by means of a screwdriver.

Clockwise rotation incrases the pressure;anticlockwise rotation lowers the pressure.

Excess oil is returned to the crankcase.

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

� Through the hollow-bored chrankshaft tolubricate main and connection rod bear-ings. Lubrication of piston pin bearings isdone by splash lubrication through a coun-tersunk hole in the top of the connectingrod.

� To the oil differential pressure cut-out andpressure gauge. The effective oil pressurecan be read straight off the pressuregauge (the suction pressure gauge of thecompressor). In case the compressor isfitted with UNISAB, the oil pressure is tak-en through external pipe connections tothe control box.

� Through internal oil pipes the oil is takento the regulating cylinders, Pos.12, for un-loaded start and capacity regulation.

78 0171-370-EN

Oil filter

All oil to the lubricating system of the com-pressor is filtered through an oil filter, fitted inthe crankcase.

The filtration element is a filter cartridge, pos.60 A on Fig. 1, which cannot be cleaned andtherefore must be replaced by a new oneonce the filter capacity is used up.

It is important therefore, to keep a sparefilter cartridge in store at all times. It isalso recommendable to have gaskets,pos. 59C and pos. 60B, available beforereplacement of filter cartridge.

The filtered oil also passes a magnetic filterPos. 60J-K, where any small iron particlesare caught, before the oil flows to the oilpump.

Changing filter cartridge

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

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

Fig. 1

60B 60N 60M60P 60J 60A 60L60K 60H 60P-1

59A 59B59C

59D

The compressor must be discharged of oiland the pressure adjusted to atmosphericpressure before the oil cartridge can be re-moved from the compressor. Cf. The sec-tions Removing Refrigerant from Compressorand Changing Oil in Refrigeration Compres-sor for further information on this point.

ImportantBefore the compressor is opened, makesure that it cannot operate. This is en-sured by removing the motor main fuses.In addition, make sure that the heatingcartridge is switched off.

0171-370-EN 79

The easiest method of dismantling the oil fil-ter is via the left–hand side cover opening(the end of the compressor on which the ma-nometers/UNISAB are mounted). Dismantlethe oil filter by removing the screws, pos.59B. Mind the gasket, pos. 59C.

If a refrigerant–cooled oil cooler is mountedin the compressor, this should be dismantledtogether with the oil filter. Cf. the section Re-frigerant–cooled Oil Cooler for CMO Recipro-cating Compressor.

Replace the filter cartridge by dismantling theself–locking nut, pos. 60P–1 and the washer,pos. 60H.

Before mounting a new filter cartridge, cleanthe magnetic filter, pos. 60J–K, and thecentre shaft, pos. 60L, with a clean clothwithout disassembling the parts any fur-ther.

Filter Cartridge, pos. 60A, cannot becleaned and must therefore be replacedby a new unused one.

Mount the oil filter in the following order:

� Mount the gasket, pos. 60B

� Mount the filter cartridge, pos. 60A, thewasher, pos. 60H and the self–locking nut,pos. 60P–1 as shown in fig. 1.

� Tighten the self–locking nut carefully with-out deforming the filter cartridge.

� Insert the complete oil filter together withthe oil cooler (if mounted). Cf. Refriger-ant–cooled Oil Cooler

� Mount gasket, pos. 59C, and fasten oil fil-ter with the screws, pos. 59B.

� Mount the side cover. Fill up with new re-frigerant machine oil and carry out startprocedure as described in this manual.

80 0171-370-EN

Oil pump

T0177142_0 V13

••

•

••

•

••

11F

11C

11J

11K

11L

11E

11G

11D

• 11A

The oil pump is a gearwheel pump directlycoupled onto the end of the crankshaft.

Power is transferred via 2 retention pins Pos.16J fitted at the end of crankshaft and onepin 11M equipped with teflon bushings.

On compressors with normal rotating direc-tion (indicated by an arrow on end cover atshaft seal end) the oil pump is mounted withthe driving gearwheel at the bottom, asshown on the drawing.

If, because of the driving motor, the compres-sor must have a reverse direction of rotation,the oil pump must be turned 180° to take thedriving gearwheel to top position. Beforemounting the oil pump in its new position,dismantle oil pump cover Pos. 11D frompump house Pos. 11C and turn it 180°. In thisway the in- and outlet gates of the oil pumpremain in front of their respective connec-tions to bearing cover Pos. 5A. Holes forguide pins to the oil pump in this new positionhave been bored whereas threaded holes forclamping have not. Hereby, wrong mountingon compressors with normal direction of rota-tion is avoided.

If you wish to change the direction of rotation,turn pump as described, and mark and boreoff 4 new holes for tightening screws.

Thread M8 and effective thread depth 13mm. Depth of hole for core drill max. 16 mm.

A compressor ordered for reverse direction ofrotation is mounted with the pump in the cor-rect position.

Dismantling of oil pump

1. Dismantle all outer pipes and end coverPos. 4A by the pump.

2. Remove screws Pos. 11B, after whichonly the guide pins Pos. 11G keep thepump in place.

Normally, the oil pump has a very long life,thus repairs on it do not pay, instead it shouldbe replaced by a new one.

Remounting of oil pump

On remounting of oil pump, turn shaft untilretaining pin Pos. 11L catches the groove inretaining pin Pos. 11M. Pay attention to gas-ket Pos. 11A.

0171-370-EN 81

Oil pressure valveThe oil pressure valve Pos. 22 regulates theoil pressure in the compressor. Mounted inthe cover Pos. 87A, it connects directly withthe oil preessure chamber in the shaft sealhousing.

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

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

T0177083_0

22B

22A

Fig. 1

locking screw

Adjustment

Oil pressure: 4.5 bar.

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

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

Service

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

In the event of a malfunction, the completevalve should be replaced.

82 0171-370-EN

Capacity regulation and unloaded startThe same type of regulating system is usedin both CMO and TCMO compressors. Itshould be pointed out, however, that on theCMO compressors all cylinders are connec-ted to the regulating system whereas onlypart of the TCMO cylinders can be connectedto this system.

The regulating function

The purpose of the regulating system is toadapt the compressor capacity to the needfor cooling of the refrigeration plant. This isachieved by unloading cylinders or by puttingthem to work. This is achieved by guiding thesuction valve fitted on each cylinder.

Further, the regulating system must force thesuction valves open at compressor standstillor during its starting-up phase. In this waythe motor is started with as little resistancefrom the compressor as possible as there isno compression of gas in the cylinder. Oncethe motor has reached its maximum moment,the regulating system starts loading the com-pressor with capacity.

Fig. 1 illustrates how the regulating system isconnected to the lubricating system of thecompressor. As shown in fig. 2 the unloadingcylinders are controlled by three 3-way sole-noid valves. Oil pressure regulating valvepos. 22 is set to maintain a constant oil pres-sure of 4.5 bar in the oil system.

T0177131_0 V12

11

60

9A

Fig. 1

ATo capacity regulating system

To oil pressure regulating valve pos. 22

0171-370-EN 83

Function

T0177142_0 V8

1

2

3

B

A

B

22

4A 2A 1A 3A

A: Oil pressure from lubricating system

B: Oil return from crankcase

12 Three-way solenoid3 valves

1A2A3A4A

22

Relief cylinders

Oil pressure regulating valve

Fig. 2

One way of achieving capacity unloading isto swith off the current to solenoid valve no.1. This shuts off the oil pressure to unloadingcylinder no. 1A and at the same time the3-way function of the solenoid valve opens,hereby connecting the unloading cylinder tothe crankcase.

The springs in the unloading cylinder squee-zes the oil out of the unloading cylinder. Thepiston in the unloading cylinder moves up-wards and forces the suction valve open inorder to prevent compression in the com-pressor cylinder.

The TCMO compressor is not equipped withan unloading mechanism at the HP stageand on 2 LP cylinders. Thus, the torque ofthe electric motor must be sufficient beforethe oil pressure in the compressor starts loa-ding compressor capacity.

Dismantling of unloading cylinder

As the unloading cylinder is not exposed toany particular wear and tear, it will rarelyhave to be dismantled. It can be dismantledas one unit by removal of Allen screws Pos.12A, but in order to get to the screws, cylin-der linings, pistons, connecting rods must bedismantled, and possibly the crankshaft mustbe removed.

Once screws pos. 12A have been dismantledon both unloading cylinders, lift them out ofthe recess and pull them apart in order thatoil pipe pos. 62A and gaskets pos. 62H maybe released.

Disassembling of unloading cylinder

Press bottom piece Pos. 12C slightly into cyl-inder Pos. 12E and pull out circlip Pos. 12Jfrom its track by a rotating movement.

Once the circlip has been removed, the partscan be pulled apart.

84 0171-370-EN

Assembling of unloading cylinder

By assembling of unloading cylinder, the twosealing rings must be positioned as shownon spare parts drawing.

During mounting of circlip pos. 12J it is a go-od idea to push bottom piece pos. 12C intothe cylinder pos. 12E in a vice with soft jaws.

Note:On assembling the unloading cylinder,make sure that the two threaded holes inthe bottom piece pos. 12C are on a levelwith the hole for oil supply to the cylinderpos. 12E.

Mounting of unloading cylinder in thecompressor

1. Lubricate O-ring pos. 62H with refrigerantmachine oil.

2. Turn the two unloading cylinders pos. 12so that the oil inlet holes are facing eachother and place them in the compressorblock.

3. Press the two unloading cylinders againsteach other, guiding them to engage withoil pipe pos. 62A. Take care not to dama-ge O-rings pos. 62H.

4. Press the two unlading cylinders down in-to the recess in the block and tighten withscrews pos. 12A and washers pos. 12B.

0171-370-EN 85

Capacity stages and regulating sequence

Capacity stages

The CMO compressors can be capacityregulated in 4 stages with the various per-centages of full capacity as shown in thetable below.

CMO 24 100

100

100

75

67

75

50

50

50

25

33

25

CMO 26

CMO 28

1 2 3

Compressor Capacity in %

Solenoid valve no

The TCMO compressors have no unloading

cylinders on two HP and two LP cylinders,

and thus they can be capacity regulated as

shown in the following table.

TCMO 100 67 50 33

1 2 3

Capacity in %Compressor

Solenoidvalve no

Regulating sequenceUnloading takes place in numerical orderwith rising figures, whereas loading takesplace in reverse order with falling figures.

The sequence of unloading of the cylinders is shown on the following principle diagram, fig. 3.

3 3

CMO 28

CMO 26

T0177142_0 V10

CMO 24

44

2 2

1 1

4

1

2

4

1

3

1 2

3 4

2 3

1 1

HP

LP

TCMO 28

Shaft end

Fig. 3

86 0171-370-EN

Pilot solenoid valves

Fig. 4 shows the position of the solenoidvalves on the side cover.

Fig. 4

T0177142_0 V17

1 2 3

22

From the chamber under the oil dischargevalve Pos. 22 the oil flows through a boredchannel in the side cover to the valve block.Here oil is distributed through channel A toeach single solenoid valve.

� Channel B connects the solenoid valvewith the relevant unloading cylinder.

� Channel C takes the oil back to the crank-case from the unloading cylinders.

At a dead coil the relevant compressor cy-linder hereof is unloaded. The solenoid valvecloses between channels A and B andopens between channels B and C. Hereby,the oil pressure in the unloading cylinder isequalized to the pressure in the crank case.

At an energized coil the relevant compres-sor cylinder is working. The solenoid valveopens between channels A and B andcloses between channels B and C.

Fig. 5 shows a cross-section of the solenoidvalve.

Fig. 5

p9034_0.d23

A

B

C

2

1

50B

80P

80N

0171-370-EN 87

Dismantling and assembly of solenoid valves

When electricity has been switched off to thesolenoid coil, hand screw pos. 80N can bedismantled and coil pos. 50B pulled outacross armature tube pos. 80P.

The armature tube can now be unscrewed

and each part in the tube be dismantled.Nozzle no. 1 can be unscrewed by means ofan Allen screw. However, take care that youdo not lose the small steel ball pos. 2.

At assembly tighten the nozzle and the arma-ture tube with 10 and 50 Nm, respectively.There is no gasket in connection with thenozzle.

88 0171-370-EN

The TCMO 28 compressor

The TCMO 28 compressor is available in 2versions: with or without built-in capacityregulating system. (Please refer to page 1to see which compressor version you have).The systems are illustrated in the followingschematic drawings, fig. 1 and 2.

TCMO with capacity regulation

Unloaded start system:Unloaded start of the compressor is obtainedpartly by lifting suction valve plates on thefour low pressure cylinders, partly through aby-pass line with solenoid valve H, connect-ing the high pressure chamber with the inter-mediate pressure chamber.

The solenoid valve H must be connected tothe star-delta starter of the motor in order toenergize the valve coil (open valve) whenev-er pilot voltage is connected and the motorstarter is in star position.

Whenever the motor starter switches to itsdelta position, the current to the solenoid val-ve H is disconnected and is closes.

Further, the solenoid valve must be control-

led by the capacity regulating system of the

compressor so that when the compressor

capacity is regulated down to 50% or lower,

solenoid valve H will open.

This prevents the intermediate pressure in

the IP chamber from getting too low.

At compressor start, the pressure in the HP

chamber is usually equalized to intermediate

or suction pressure as non-return valve G

closes against the discharge side of the

plant.

To be on the safe side open solenoid valve H

on starting the compressor, hereby equali-

zing any excess pressure in the HP chamber

to the pressure in the IP chamber. At the sa-

me time the four cylinders on the LP side ha-

ve been unloaded. All these factors put toget-

her result in a proper start unloading of the

compressor.

Fig. 1

G 2658HP

A

22 E

D

100% 67% 50%25

B

IP

IP LP

H

1 2 3

A: LP suction gas inletB: HP discharge gas outletD: Oil pressure connectionE: Oil return to crankcase

0171-370-EN 89

Capacity regulation

Capacity regulation takes place by lifting thesuction valve plates on four of the six LP cyl-inders. The stagewise unloading appearsfrom fig.1 and from the sketch earlier on.

Solenoid valve no 1 unloads two cylinders,thus reducing capacity to 67%. Solenoid valve no 2 further unloads onevalve, thus reducing capacity to 50%. Valve no 3 unloads one more cylinder, reduc-ing capacity to 33%, which is the lowest capacity at which the compressor is able towork.

Unloading takes place in numerical sequencewith rising figures, whereas loading takesplace with falling figures.

When the LP-cylinders are unloaded, a bal-ance no longer exists in the cylinder ratio be-tween HP- and LP-cylinders. In order to keepthe intermediate pressure at a suitable valueunder these circumstances, solenoid valveH must open together with unloadingstage 2 and remain open also during un-loading stage 3.

TCMO without capacity regulation

Fig. 2

IP

B

G 2658HP

IP LP

22 E

A

D

25

H

A: LP suction gas inletB: HP discharge gas outletD: Oil pressure connectionE: Oil return to crankcase

Unloaded start system:Unloaded start of the compressor takes placepartly by means of lifted suction valve plateson four LP-cylinders, partly through a by-pass line with solenoid valve H, connectingthe HP chamber with the IP intermediatepressure chamber.

The solenoid valve must be connected to thestar-delta starter so as to energize the valvecoil (open valve) at standstill and with thestarter in star position. With the motor starter

in delta position, the valve coil must be de-energized (closed valve).

At start-up of compressor the HP-chambermust have been unloaded to intermediatepressure. For this purpose a non-return valveG has been fitted in the disharge pipe in or-der to prevent flashback of the condensingpressure into the HP-chamber.

At start-up, the four LP cylinders are un-loaded until the oil pressure has built up.

90 0171-370-EN

Cooling of intermediate discharge gas on the TCMO 28 compressor

The TCMO 28 compressor compresses therefrigerant gas in two stages with 6 LP-cylin-ders and 2 HP-cylinders, respectively.

Each stage has its own suction and pressurechamber. The HP stage suction chamber andthe LP stage pressure chamber is connectedby means of an external piping.

IPLP

IPIPLP

LP

IP HP

IP

In this piping, called the intermediate pipe,the intermediate pressure gas is cooled bymeans of 1 of the following 3 systems:

� Cooling of the intermediate pressure gasby means of an intermediate cooler. The gas is carried to a vessel with liquidfrom the condenser. The superheated gasfrom the LP stage is carried through therefrigerant liquid and this reduces the su-perheat considerably.

� Cooling of the intermediate gas by meansof liquid injection into the intermediatepipe. Liquid refrigerant is mixed with the inter-mediate gas and reduces the superheatwhen it evaporates.

� The injection system can also incorporatea plate heat exchanger in which the liquidfor injection into the intermediate pipe sub-cools the liquid to the evaporating system.

When these systems are used the super-heat must not fall below 10K.

Please refer to the section Cooling of the in-termediate gas for further information.

0170

-017

-EN

98.0

5

0178-017 – EN 91

#�� % ��/ .6

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

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

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

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

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

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

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

Marking: Prod. nr.WattVoltManu. date

L1

L2

NV 50G 1 1/4”

80

50

30 Ø 3

0

Heating rods

PowerWatt

VoltageV

L1mm

L2mm

Used for:

270270270

250230115*

CMO - TCMO - SMC 100 - TSMC 100

460460460

250230115*

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

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

0171

-463

-EN

95.0

3

92 0171-487-EN

�� (��(�� / �. ��

42DT0177156_0

42B

42G

42F 42E 42C

42A 42H

23A 23D

23G

23F 23C 23B 23E

Dan

v

��

��

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

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

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

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

trating the valves whenever they are notused.

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

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

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

0171

-901

-EN

91.0

4

0172-133-EN 93

��" �� $��

Bearing clearance

Main bearings

Connecting rodbearings

Piston pinbearings

Parallel topiston pin

At right anglesto piston pin

manufacturedmax.

manufacturedmax.

manufacturedmax.

manufacturedmax.

manufacturedmax.

0.080.20

0.080.15

0.040.10

0.18 –

0.110.30

0.080.20

0.080.15

0.040.10

0.18 –

0.110.30

0.080.20

0.080.15

0.040.10

0.18 –

0.110.30

0.080.20

0.100.20

0.040.10

0.20 –

0.150.40

0.080.20

0.100.20

0.040.10

0.20 –

0.150.40

0.140.35

0.140.30

0.090.20

0.25 –

0.350.90

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

TCMO 2 TSMC 65 TSMC 1004–10 cyl.

TSMC 10012–16 cyl.

TSMC 180

Mk1 & Mk2

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

Crankshaft end-playmin.

max.

0.30 0.30 0.30 0.40 0.75 0.95

0.55 0.55 0.55 0.64 1.00 1.20

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

Piston ring gapmin.

max.

0.25 0.25 0.25 0.33 0.33 0.66

1.00 1.00 1.00 1.30 1.30 2.50

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

Main bearing journals

Connecting rodbearing journals

Intermediate journals

Main bearing journals

Connecting rodbearing journals

Intermediate journals.

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

–0.06 –0.06 –0.06 –0.07 –0.07 –0.11

–0.09

–0.025

–0.040

–0.06

–0.09

–0.025

–0.040

–0.030 0 0 0 –0.015

–0.049 –0.02 –0.02 –0.02 –0.040

–0.06 –0.06 –0.07 –0.07 –0.11

–0.09 –0.09 –0.09 –0.09 –0.14

–0.025 0 0 0 –0.015

–0.040 –0.02 –0.02 –0.02 –0.040

–0.010

–0.029

–0.010

–0.029

55

50

54.5

49.5

60

55

59.5

54.5 54.5 79.5 79.5 134

55 80 80 135

55 80 80 135

80

54.5 79.5 79.5 134

79.5

Dimensions of crankshaft bearing journal

–0.09 –0.09 –0.09 –0.09 –0.14

All measurements stated are in mm

Pis

ton

New

Gro

und

dow

n

CMO4 HPO HPC

0171

-904

-EN

96.0

5

94 0172-133-EN

=��>� :�� $� �

�� +��$ � � � �"��

134.0

3559.5

79.5

134.0

59.5

79.5

134.0

54.5 54.5

79.5

134.0 70

Ra=0.35

Ra=0,63 Ra=0,63

Ra=0.35

40

50

1.0

Ra=0,20Ra=0,20

Compressor type

CMO 2

SMC/TSMC100 S

SMC/TSMC100 L

SMC/TSMC180

A

First

Main bearingSuper

orFinal

BConnecting rod bearing

a b c dC

mm mm mm mm mmmmmm mm mm

–0.060

–0.070

–0.070

–0.080

–0.110

–0.120

–0.060

–0.090

–0.070

–0.090

–0.110

–0.140

–0.030

–0.049

79.50.000

–0.010

0.000

–0.010

–0.035

–0.050

0.000

–0.020

–0.015

–0.040

0.0

–0.1

0.0

–0.1

0.0

–0.1

0.0

–0.1

0.16

0.2

0.2

1.15

1

0.0

–0.3

5

2.5

3

6

2.5

3.5

grinding finish

grinding

First Super

orFinal

grinding finish

grinding

Undersize bearings: See SABROE spare parts list.

HPC,

HPO

B

B

A

R=2.5

a

A

C

R=2.5

c

b

R=d

45°

T0177137_0

SMC/TSMC100 E 60

0.0

–0.1

0171

-465

-EN

94.1

2

T0177082_0

0172-133-EN 95

��&�� +� �� '��

Metric thread (ISO 8.8)

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

0.28

2.1

2.7

0.53

3.9

5.2

0.94

6.8

9.2

2.2

16

22

4.1

30

40

7.0

50

69

11

80

108

15

110

147

23

170

225

30

220

295

38

270

375

52

370

510

68

490

670

Kpm

ft.lbf.

Nm

Metric thread (ISO 12.9)

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

Kpm

ft.lbf.

Nm

0.42

3.0

4.1

0.78

5.7

7.6

1.4

10

14

3.2

23

31

6.1

44

60

10

75

98

16

120

157

23

160

225

34

240

335

44

320

430

55

400

540

76

550

745

100

720

980

Connecting rods with UNF thread

HPO/CMO HPC/SMC 100 SMC 180

UNF

Kpm

ft.lbf.

Nm

5/16”

2.1

15

20

3/8”

4.4

32

43

5/8”

17

130

167

A

A

A

AMR

NORMEX

Series 52

96 0172-133-EN

Bolt on discharge valve

HPO/CMO HPC/SMC 100 SMC 180

Kpm

ft.lbf.

Nm

3.2

23

32

10.2

75

101

35

255

344

Compressor type Coupling ThreadTorque (A)

Kpm. ft.lbf. Nm

34

55

128

275

22

22

34

34

41

55

128

177

245

275

25

40

95

200

16

16

25

25

30

40

95

130

175

200

3.5

5.6

13

28

2.2

2.2

3.5

3.5

4.2

5.6

13

18

25

28

5/16”

7/16”

1/2”

11/16”

M8

M8

AMR225

AMR312S

AMR350S

AMR450S

H148

H168

200

225

262

312

350

375

425

450

HPO/CMO/TCMO

104-108

112-116

186-188

128

163

depending

on the

motor size

HPC/

SAB

VMY

5/16”

5/16”

3/8”

7/16”

1/2”

9/16”

5/8”

11/16”

SMC/TSMC

Ser

ies

52N

OR

ME

X

34

41

25

30

3.5

4.2

5/16”

3/8”

225

262

128

163

Ser

ies

52

type

202 55405.6312 7/16”

0171

-464

-EN

94.0

5

0171-702-EN 97

��

Operational reliability

The prime causes of operating malfunctionsto the plant are:

1. Incorrect control of liquid supply to theevaporator.

2. Moisture in the plant.

3. Air in the plant.

4. Anti-freezing liquid is missing.

5. Congestion due to metal shavings anddirt.

6. Congestion due to iron oxides.

7. Congestion due to copper oxides.

8. Inadequate refrigerant charge.

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

Pumping down the refrigerationplant

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

1. Open suction and discharge stop valveson compressor.

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

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

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

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

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

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

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

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

Dismantling plant

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

1. No component should be opened un-necessarily.

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

98 0171-702-EN

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

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

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

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

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

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

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

0170

-335

-EN

91.0

5

0171-231-EN 99

��'��$�� $� ��

��

Operating condition

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

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

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

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

Using the trouble-shooting chart

In the following chart, each individual erroroption is indicated by a code number in the

lefthand column, the error being briefly de-scribed in the next column. The third columnstates code numbers for the possible causesof the error.

The code numbers refer to the subsequentchart.

The section entitled Remedying malfunctionsstates how to remedy the observed error.

See the following example for the correctprocedure.

Example

Observed error: discharge pipe temperaturetoo low - error code 15.

Cause codes: 26 (Liquid in suction line) 32 (Too much coolant/air to condenser) 39 (Expansion valve produces too little su-perheating)

Any explanatory comments will be stated inthe section that follows.

100 0171-231-EN

1 Compressor fails to start 1, 2, 3, 4, 5, 6, 7, 9, 10, 12, 14.2 Compressor starts and stops too often 9, 10, 11, 13, 21, 22, 23, 24, 32, 34, 35, 36, 37,

40, 41, 43, 44, 51, 52, 54, 56, 59.3 Compressor starts but stops again immediately 3, 5, 6, 9, 10, 11, 12, 13, 14, 15, 17, 18, 41,

42, 49, 50, 55, 61.4 Compressor operates continuously 8, 21, 22, 24, 41, 46, 52, 53, 56, 60.5 Abnormal noise from compressor 16, 17, 18, 19, 26, 48, 49, 50, 51, 52, 53, 54, 56,

57, 58.6 Insufficient capacity on compressor 13, 15, 17, 18, 20, 21, 22, 23, 24, 32, 34, 35, 36,

37, 40, 41, 44, 45, 46, 49, 50, 51, 52, 53, 56, 60.7 Liquid stroke in compressor during start up 16, 18, 26, 37, 38, 39, 44, 56, 61.8 Liquid stroke in compressor during operation 21, 23, 26, 37, 39.

9 Excessive condenser pressure 9, 25, 28, 29, 30, 31, 33.10 Too low condenser pressure 22, 32, 51, 52, 54, 60.11 Excessive suction pressure 13, 17, 26, 34, 39, 52, 53, 54, 5,. 60.12 Too low suction pressure 11, 13, 20, 21, 22, 23, 32, 35, 36, 37, 40, 41, 42,

44, 45, 56, 59.13 Too low oil pressure 12, 15, 17, 18, 26, 49, 50, 55.

14 Excessive discharge pipe temperature 11, 21, 22, 23, 28, 29, 30, 31, 33, 34, 35, 36, 37,40, 41, 46, 52, 54.

15 Too low discharge pipe temperature 26, 32, 39.16 Excessive oil temperature 33, 34, 35, 36, 37, 40, 50, 52.

17 Oil level in crankcase falling 16, 18, 20, 26, 51, 57, 58.18 Oil foaming vigorously in crankcase 16, 26, 39, 61.19 Crankcase sweating or frosting up 16, 18, 26, 37, 39.

20 Capacity regulating oscillating 13, 15, 16, 17, 18, 49, 55, 56.21 Impossible to bleed plant 10, 43, 51, 52, 53, 54, 60.

Errorcode Observed error Cause code

0171-231-EN 101

1 No power - master switch not cut in 2 Blown fuses - loose wiring or

connections 3 Electrical voltage too low 4 No control current 5 Motor protection device activated 6 Control current circuit open 7 Pump/fan not started 8 Welded contracts in motor protection9 High-pressure cut-out has cut

10 Low-pressure cut-out has cut 11 Low-pressure cut-out differential too

small 12 Oil pressure cut-out has cut 13 Capacity regulator incorrectly set 14 Defrosting timer breaks current 15 Oil charge insufficient16 Compressor capacity too high

during start-up 17 Oil pressure too low (adjust oil pres-

sure regulating valve) 18 Oil foaming in crankcase 19 Oil overcharge20 Poor oil return - oil in evaporators

21 Restricted supply of refrigerant22 Refrigerant charge insufficient 23 Refrigerant vapour in liquid line 24 Leaky refrigeration plant 25 Refrigerant overcharge26 Liquid in suction line 27 At low temperature operation, de-

gree of charge in evaporators rises 28 Insufficient coolant/air to condenser29 Temperature of coolant/air too high30 Non-condensable gases in

condenser 31 Condenser needs cleaning 32 Too much coolant/air to condenser 33 Water valve closed

34 External pressure equalization on expansion valve closed

35 Expansion valve partly clogged by ice, dirt, wax

36 Expansion valve has lost charge 37 Expansion valve sensor misplaced 38 Expansion valve is leaky 39 Expansion valve provides too little

superheating 40 Expansion valve produces excessive

superheating 41 Filters in liquid/suction line clogged 42 Solenoid valve in liquid/suction line

closed

43 Solenoid valve leaky 44 Evaporator iced up or clogged 45 Cooling air being recirculated

(short-circuited)46 Excessive load on plant 47 Refrigerant collecting in cold con-

denser (close off by-pass)48 Coupling misaligned or loose bolts 49 Oil pump defective 50 Bearings worn out or defective 51 Defective piston rings or worn

cylinder52 Discharge valves defective or leaky 53 Suction valves defective or leaky

54 Compressor by-pass open - leaky safety valve

55 Compressor oil filter clogged 56 Capacity regulator defective 57 Solenoid valve in oil return clogged/

defective 58 Filter in oil return clogged 59 Compressor capacity too high60 Compressor capacity too low61 Heating element in crankcase

defective

Code CodeCase Case

102 0171-231-EN

Remedying malfunctions1. Compressor fails to start

1.6 Control current circuit open owingto activated: pressure cut-outsthermostats motor protection device defrosting timer

Pinpoint open switch andremedy cause of interruption.

1.9 High-pressure cut-out has cut Reset pressure cut-out and investigate causeof high condenser pressure.

1.10 Low-pressure cut-out has cut Compressor cannot start before suction pres-sure has risen above set point for pressurecut-out restarting.

Oil-pressure cut-out has cut Compressor starts at reset. Check oil level. If oil foams in crankcase, see section 18.

1.12

2. Compressor starts and stops too often

Low-pressure cut-out cuts at toolow suction pressure.

High-pressure cut-out cuts at high pressure

High condenser pressure - see section 9.

Check condenser cooling and adjust pressurecut-out to correct breaking pressure -see table Pressure and temperature settings.

Replace defective pressure cut-out.

2.9

Low suction pressure - see section 12.

If low-pressure cut-out is set too high, adjustpressure cut-out.

2.10

Low-pressure cut-out differential istoo small between stopping andstarting

Increase differential pressure - see also specialinstructions.

2.11

Compressor capacity too high Check operating conditions and, if need be,reduce capacity.

2.13

discharge valves on compressorare leaky.

At compressor stop, pressure equalizes rela-tively quickly between suction and dischargeside

Clean or change discharge valves.

2.52

Filter in suction line clogged Check suction filters on compressor.2.41

Solenoid valve in liquid line doesnot close tight.

Check direction of flow.

Replace defective valve.

2.43

0171-231-EN 103

3. Compressor starts but stops again immediately

Oil charge insufficient Top up with oil and investigate cause of oilshortage.

3.15

Low-pressure cut-out has cut Open any suction stop valve which is closed.3.10

Oil pressure failing owing to for-mation of foam in oil.

Reduce capacity. See sections 17 and 18.3.18

Defective oil-pressure cut-out Replace cut-out - see special instructions.3.12

Motor protection cuts Look for cause of overloading.

If star-delta start, set starting time to minimum.

3.5

4. Compressor operates continuously

Thermostat or low-pressurecut-out does not cut at too lowtemperature/pressure

Adjust operating points.4.10

Refrigerant charge unsufficient Top up with refrigerant of correct type.4.22

Restricted supply of refrigerant toevaporator. Compressor workingat too low suction pressure.

Remove dirt in filters and check function of ex-pansion device as per special instructions.

4.21

104 0171-231-EN

5. Abnormal noise from compressor

Compressor capacity too high du-ring start-up

Reduce capacity.5.16

Capacity regulation oscillatingowing to failing oil pressure

Low oil pressure - see section 13.5.56

Oil pressure too low See section 13.5.17

Liquid refrigerant in suction line Liquid stroke. See points 7 and 8. Adjust expansion or float valves.

5.26

Incorrect alignment of motor andcompressor Loose bolts in coupling

Check alignment as per special instructions.

Tighten with torque wrench

5.48

Worn or defective bearings Overhaul or replace.5.50

Too much oil circulatingthrough the plant, resulting in toolow oil level in compressor

Check oil level.

Solenoid valve, filter or jets in oil return systemmay be clogged. Leaky suction valve ringplates, piston rings and worn-out cylinder mayalso produce such oil consumption.

5.515.535.575.58

6. Too little capacity on compressor

Insufficient oil charge Top up with fresh oil of same type and make.6.15

Iced-up evaporator Defrost evaporator; adjust defrosting time ifrequired.

6.44

Defective oil pump and hence fail-ing oil pressure

Repair or replace oil pump6.49

Defective capacity regulating sys-tem

Cause is most often failure in oil pressure orrefrigerant in oil; see section 4.5.

6.56

0171-231-EN 105

7. Liquid stroke in compressor during start-up

Refrigerant has condensed in suc-tion line or crankcase

Heating element in crankcase should be con-nected for 6-8 hours before starting, so thatrefrigerant dissolved in oil can be boiled outbefore starting compressor up.

7.26

Liquid stroke in the compressor should not occur, as in the worst instance this cancause rupture to the valve ring plates and damage to the inbuilt relief devices. Fur-thermore, it can result in damage to the connecting rod bearings and cylinders if thecoolant degreases the faces and impairs the lubricating capacity of the oil.

Adsorption of (H)CFC refrigerantin oil

Sudden reduction in pressureacross the oil sump (suction pres-sure) produces foaming

Reduce compressor capacity or start withthrottled suction stop valve.

Follow instructions in section 18.

7.18

Suction line has free fall towardscompressor

Start with throttled suction stop valve - stopwhen hammering is heard.

Liquid separator should be mounted in suctionpipe.

8. Liquid stroke in compressor during operation

Refrigerant gas in liquid line Expansion valve is oscillating.8.23

Superheating of expansion valveis set too low

Adjust superheating, which should normally be5-8°C.

8.39

106 0171-231-EN

9. Excessive condenser pressure

Overfilling with refrigerant Refrigerant fills condenser and reduces its ef-fective area.

Draw off coolant.

9.25

Presence of non-condensablegases (especially air) in conden-ser.

Blow air out at condenser. Follow instructionsfor condenser.

9.30

In the event of abnormally high pressures in the refrigeration system, there is a risk ofdamage to the compressor. At very high pressures (see pressure testing), the risk ofthe components in the refrigeration plant exploding can constitute a threat to life.

Abnormally high pressures can occur in the case of:

- extreme heating of plant parts (fire, solar radiation or other abnormal heating);

- volumetric expansion of fluids in sealed-off premises.

Insufficient condenser cooling,e.g. if cooling water fails, fan/coling water pump clogs, soiling,scaling or fouling of heat-transmit-ting surfaces

Regulate water/air supply or reduce compres-sor capacity, if called for. Check condenser asper instructions for same.

9.28

10. Too low condenser pressure

Excessive condenser cooling Regulate condenser cooling.10.32

Compressor lacks capacity. Check whether compressor capacity corre-sponds to load on plant. Reduce condensercooling.

10.60

Defective piston rings or worn cy-linders

Replace worn parts. See compressor instruc-tions.

10.51

Discharge valves are defective orleaky

See compressor instructions. Check valve ringplates and piston rings.

10.52

Bypass between high-pressureside and suction side of compres-sor

Check compressor for internal leakage by per-forming pressure-drop test.

See compressor instructions.

10.54

0171-231-EN 107

11. Excessive suction pressure

Error in setting of liquid regulationvalve

Liquid refrigerant in suction line.

Adjust, repair or replace expansion valve.

11.26

Compressor lacks capacity. Regulate compressor capacity.

Check whether all cylinders are operating.

Check function of capacity regulator.

11.60

Leaky suction valves See compressor instructions. Remove cylindercovers; check valve plates. Renew if needed.

11.53

Open by-pass between suction si-de and high-pressure side of com-pressor. Safety valve leaky, oropens prematurely.

Check system for any by-pass detectable as awarm connection.

Adjust or repair leaky valves.

11.54

12. Too low suction pressure

Oil in evaporator Draw off oil.12.20

Abnormally low pressure in the refrigeration plant will increase the compression ratioof the compressor with a subsequent risk of damage to the compressor.

The danger of air being sucked into the refrigeration plant also increases at abnor-mally low pressure.

Refrigerant charge on plant insuffi-cient

Bubbles in liquid line sight glassand possibly a warm liquid line

Check refrigerant charge.

Charge plant with refrigerant.

Find and seal any leak.

12.22

Freezing-up of expansion valve(HFC/HCFC plant)

Thaw out expansion valve with hot, wet cloths.

Replace dessicant in drying filter.

12.35

Thermostatic expansion valve haslost charge

Valve fails to open - change valve.12.36

Excessive superheating of suc-tion gas

Regulate expansion valves to higher capacity.12.40

108 0171-231-EN

Compressor has excessive capa-city

Reduce compressor capacity.

Check capacity regulating system.

12.59

Filter in liquid line clogged Check and clean filter in liquid line.12.41

Solenoid valve in liquid line fails toopen

Coil may have blown. Control signal lacking.12.42

13. Oil temperature too low

Too little oil in compressor Top up compressor with oil and investigatecause of oil consumption.

13.15

Oil filter clogged Change filter cartridge13.55

Oil foams in compressor See point 18.13.18

Oil pump defective Repair or replace.13.49

Bearings worn Repair or replace.13.50

14. Excessive discharge pipe temperature

If, after approx. 1 hour’s operation, the discharge pipe temperature is more than10°C higher than indicated in the table, the error may be due i.a. to:

Open by-pass between high andlow-pressure side of compressor,e.g. leaky safety valve

Localize by-pass and remedy any leakages.

14.54

Excessive suction temperature asresult of reduced refrigerant sup-ply to evaporator (extensive su-perheating) owing to insufficientrefrigerant charge.

Check refrigerant charge14.21

Excessive suction temperature asresult of reduced refrigerant sup-ply to evaporator (extensive su-perheating) owing to incorrectlyadjusted liquid regulating valves

Check thermostatic expansion valves14.22

Leaky discharge valves Leaking in discharge valves gives rise to gen-eration of heat.

Change defective valves.

14.52

0171-231-EN 109

15. Too low discharge pipe temperature

Low suction temperature as resultof overflow of liquid refrigerantfrom evaporator

Adjust liquid regulating valve. Increase super-heating.

15.26

16. Excessive oil temperature

During operation, the heat of the compressor crankcase must be 40-70°C. Whenworking with R717 and R22, it may be necessary to supply the compressor with oilcooling.

See point 14.

17. Oil level in crankcase falling

Where HFC/HCFC refrigerants are used, there will be some blending of refrigerantand oil during the initial operating period. It may therefore prove necessary to top upthe oil after initial start-up of the plant.Note:The oil level must always be visible in the oil level sight glass on the compressor.

Filter in solenoid valve or jet in oilreturn line clogged

Oil return pipe must be warm during opera-tions. Clean filter.

17.20

Liquid in suction line and crank-case may cause foaming in oiland thus increase oil consumption

Examine evaporator system and check superheating of suction gas.

17.26

Worn-out piston rings or cylinders Renew piston rings and, if need be, renew pis-tons and cylinder linings.

17.51

Solenoid valve in oil return line de-fective

Coil in solenoid valve defective. - Replace coil. - Electrical control signal lacking.

17.57

110 0171-231-EN

18. Heavy oil foaming in crankcase

Liquid in suction line See 17.26.18.26

Too much refrigerant dissolved inoil

- Before starting compressor, heating elementmust have been on for at least 8 hours in order to boil refrigerant out of oil. During start-up phase, capacity should be con-nected at a slow rate to prevent sudden dropin pressure on suction side with resultant foaming.

- Under normal operating conditions, com-pressor should operate under as stable pressure conditions as possible.

18.61

19. Crankcase sweating or frosting up

Liquid in suction line See 17.26.19.26

Expansion valve sensor misplaced Check positioning of expansion valve sensor -cf. instructions for expansion valve.

19.37

Liquid regulating valve or float val-ve producing too much liquid

Increase superheating on thermostatic expan-sion valve.

19.39

20. Capacity regulation oscillating

Oil foaming in crankcase See point 18.20.18

21. Impossible to bleed plant

Solenoid valve leaky Pinpoint and seal leak, or change leaky com-ponent.

21.43

Defective piston rings Check and replace any defective parts.21.51

Defective discharge valves Check and replace any defective parts.21.52

Defective suction valves Check and replace any defective parts.21.53

0170

-151

-EN

99.0

2

0170-151-EN 111

�� '�� *:��; ��

During the past few years YORK Refrigeration has experienced a number ofproblems with mineral oils, particularly inR717 plants. The problems can be dividedinto two groups:

a: The oil changes viscosityb: The oil decomposes (becomes very black)

The problems have been seen with severalmineral oil brands, often occuring within afew operating hours and resulting in severeconsequences for both compressor andplants.

Following the careful investigation undertak-en by YORK Refrigeration during the pastfew years, it has been decided to introduce arange of synthetic oils which can fulfil the de-mands of modern refrigeration plants.

Mineral oils may continue to be used in re-frigeration plants, providing the lubricatingquality is carefully monitored. For modern,high capacity refrigeration plants, where longlifetime for both lubricants and moving partsis expected, YORK Refrigeration recom-mends the choice of synthetic lubricating oils.

The application areas and specifications forthese synthetic oils can be found in the fol-lowing pages. Installers and/or users are atliberty to choose either YORK Refrigeration’sown or alternative oil brands which fulfil thenecessary specifications.

General

This recommendation only deals with the lu-brication of the compressor. The perfor-mance of the lubricant in the plant (receiver,evaporator, etc.) must, however, also be tak-en into consideration.

Lubricating oils with relatively high viscositiesmust be used to ensure satisfactory lubrica-tion of refrigeration compressors.

To obtain the best lubrication, the oil must:

� Provide the required fluidity at the lowestevaporating temperature encountered inthe plant and at the highest permissibletemperatures in the compressors.

� Provide acceptable fluidity at start-up.

� Provide sufficient oxidation stability (the oilmust be moisture-free when added to thesystem).

� Provide sufficient chemical stability whenused together with the particular refriger-ant.

In addition, the extent to which different re-frigerants dissolve in the oil must be deter-mined, so that the oil return systems, etc. canbe designed to function properly.

Stratification

It should be noted that in certain plants, par-ticularly with HFC and HCFC refrigerants, theoil may stratify into layers in the refrigerantreceivers and evaporators at certain operat-ing conditions and at particular oil concentra-tions.

The Oil recommendation diagrams for SABROE compressors for HFC and HCFCwill indicate the limits for Sabroe oils at whichthis stratification occurs. The oil concentra-tions stated in these diagrams must not beexceeded. This will enable suitable oil rectifi-cation/return systems to be designed to bal-ance with the compressor oil ”carry-over” sothat the maximum concentration is not ex-ceeded. For area A in the diagrams, the max oil con-centration in liquid phase must not exceed

112 0170-151-EN

2%. For the other area, the max. oil con-centration must not exceed 5%. For area B:please contact YORK Refrigeration.

Plants with several different compressortypes/makes

In plants comprising several different inter-connected compressor types and makes, it isstrongly recommended that all compressorsshould use the same type of oil. This is es-sential where automatic oil return systemsare employed.

If it is intended to change the oil from onetype to another, please refer to the Oil chang-ing on SABROE compressors later in thispublication.

Selecting the lubricating oil

There are a number of operating diagramsfor the selection of lubricating oils for Sabroecompressors operating with various refriger-ants. Once the general conditions concern-ing the lubrication of the compressor and oiltype in the plant have been considered, thespecific plant conditions must be takeninto consideration.

Use the Oil recommendation diagrams to se-lect the appropriate oil code number.

The oil code number consists of letters des-ignating the oil type together with the Sabroeviscosity grade number.

Codedesign Oil types

M Mineral oil

A Synthetic oil based on Alkylbenzene

PAO Synthetic oils based on Polyalphaolefin

AP Mixture of A and PAO-oils

E Synthetic ester-based lubricants

In the oil recommendation diagrams for eachrefrigerant and compressor type, it is pos-sible to determine the code number for theoil best suited to the operating conditions.With this code number, it is possible to se-lect the correct Sabroe oil for the application.The marked area on each side of the sepa-rating line in the diagram shows the zonewhere both oils are useable.

Oil types and oil companiesAs a result of the large number of oil compa-nies world-wide that deals in oil for refrigera-tion plants, it is impossible for YORK Refrigeration to test the many differentbrands of oil on the market. It is our experi-ence, however, that some oil brands duringuse can change character and thus no longerfit the specifications given by the companiesat delivery. We have thus experiencedchanges in the specifications as well as inthe formula and performance without havinghad any information about this from the oilcompany. This makes it very difficult forYORK Refrigeration to give a general ap-proval of the various oil brands.

For this reason YORK Refrigeration has, incooperation with a large recognised oil com-pany, developed a series of three oils whichcover most purposes. YORK Refrigerationhas however, also listed a limited number ofoils which can be supplied through YORKRefrigeration. The typical data of these oilscan be found in the Data Sheet for SabroeOils. We suggest you to use these Sabroeoils, which are delivered in 20 litre pails and208 litre drums and can be ordered using theparts no. listed in the List of Oils.

It is of course possible to use similar oils fromother oil companies, and in this connection,

0170-151-EN 113

the Data Sheet for Sabroe Oils may be help-ful.

Please note, however, that YORK Refrigeration has not tested any other oilsthan our own brand, and hence we cannotanswer for the quality, the stability or the suit-ability of other oils for any purposes. The oilcompany in question is thus solely responsi-ble for the quality and suitability of the oil de-livered, and if any problems are experiencedwith these oils in the compressors or in therefrigeration plant, the oil supplier should becontacted directly.

When choosing oils from other oil compa-nies, please pay particular attention to theoil’s effectiveness in the compressor and therefrigeration plant as a whole.

Pay particular attention to the following as-pects:

� Oil type

� Refrigerant type

� Compressor type

� Miscibility between refrigerant and oil

� Operating data for the compressor

• Discharge gas temperature

• Oil temperatures:

Reciprocating compressors:

Normal oil temp. in the crankcase50-60 °C

Max. permitted oil temperature = Set-ting point for alarm

Min. permitted oil temperatures = set-ting point for alarm - if fitted

Screw compressors:

The oil temperature before injection inthe compressor, but after the oil cooler

Max. permitted oil temperature = set-ting point for alarm

Min. permitted oil temperature = set-ting point for alarm

• Condensing pressure

• Evaporating pressure

� Oil viscosity in the compressor duringoperation and under the influence of:

• Refrigerant type and solubility of refrig-erant in the oil

• Operating temperatures

• Vapour pressure in the oil reservoir

Reciprocating compressor: Suctionpressure and oil temperature in thecrankcase.

Screw compressor: Discharge pressureand gas temperature.

� Compatibility with the neoprene O-rings:the aniline point gives an indication of howthe O-ring material reacts to the oil. At an aniline point less than approximately100°C the material tends to swell, and atan aniline point higher than approximately120°C it tends to shrink.

For this reason it is not recommended tochange oil type from M oil to PAO oil as aleakage may occur if the O-rings are notchanged. YORK Refrigeration thereforerecommends using the Sabroe AP68 oilas it reduces the risk of leaks considerablyin this case.

114 0170-151-EN

YORK Refrigeration can supply a calculationshowing the operating data on request.

Attention is drawn to the following viscositylimits during operation:

� Optimum viscosity range (to be designed for) = 20 to 50 cSt

� Max. permissible viscosity =100 cSt

� Min. permissible viscosity =10 cSt(only applicable to HCFC and HFC undercartain operating conditions: 7cSt)

� Max. permissible viscosity during thestarting of the compressor = 500 cSt

Maximum refrigerant concentration in the oilat running condition: 25% - also if viscosityrequirements are met.

Use of mineral oil

Lately we have experienced a number ofproblems with mineral oil, particularly in R717plants. The problems can be divided into twogroups:

a: The oil changes viscosity within a few operating hours.b: The oil decomposes (becomes very black) within a few operating hours.

The problems have been seen with severaloil brands and have resulted in severe con-sequences for both compressors and plants.

When using mineral oil, it is thus importantthat the plant is monitored very closely, thatoil samples are taken regularly (every1-2,000 hours) and that the condition/colourof the oil is checked on a weekly basis.

YORK Refrigeration therefore recom-mends only to use M oil at moderate oper-ating conditions - cf. the attached oil rec-ommendation diagrams.

YORK Refrigeration is aware, however, thatseveral customers have been using mineraloils for many years without problems. Thosecustomers who wish to continue using miner-al oils in existing, as well as new, compres-sors can do so, providing the compressortype and operating conditions are similar tothe existing ones (excepting the HPC andHPO series compressors).

YORK Refrigeration has therefore decided tomarket a brand of mineral oil which has beentested and found to be suitable for most gen-eral refrigerating purposes.

If another brand of mineral oil is chosen, thespecifications in the data sheet in this recom-mendation should be followed as a guideline.

Mineral oil can be used in refrigeratingplants, providing the lubricating quality iscarefully monitored. For modern, high capac-ity refrigeration plants, in which a long life-time for both lubricant and moving parts isexpected, YORK Refrigeration recommendsusing synthetic lubricating oils.

A benefit of using the synthetic lubricant oil isa much lower oil carry-over to the plant andlonger intervals between oil changes. A better fluidity at lower temperatures alsogives an easier drainage at the cold parts ofthe plant.

How to use the oil recommendation dia-grams:

To determine the code number, first refer tothe Oil recommendation diagram for the re-frigerant and compressor type and then plotthe proposed operating conditions.

0170-151-EN 115

Example (recip. compressors):Refrigerant: R134aCondensing temp. TC +35°CEvaporating temp. TE –3°C

Please observe !Plants may operate at different conditionsfrom time to time, for example at differentevaporating temperatures due to plantvariations or at different condensing tem-peratures due to seasonal changes.By plotting TC and TE in the oil recom-mendation diagram, this example wouldrequire a No 1 oil. If, however, TEchanges at certain times, e.g. from –3 to+7°C, a No 2 oil should be utilised. But, as+7°C is inside the marked area, the No 1oil can be utilised also at this TE.

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By referring to the Oil recommendation tableplaced at the bottom of each oil recommen-dation diagram, it is possible to select thecode number for the appropriate oil type. In

the example above, a oil code number E5can be selected.

E5 �

E9 �

1 2

Code no Area no

In plants which incorporate both screw andreciprocating compressors and where therecommendations indicate the use of differ-ent oil types, please contact YORK Refrigeration for advice.

Changing oil on Sabroe compressors

The oil should never be changed to anothertype without consulting the oil supplier. Nor isit advisable to ”top up” compressors with another oil than the one already used for theparticular plant and compressor.

Mixing different oils may result in operatingproblems in the refrigerant plant and damageto the compressors. Incompatibility betweenthe different oil types may degrade the lubri-cating properties or may cause oil residues toform in the compressor or oil separator or inthe plant. These oil residues can block filtersand damage the moving parts in the com-pressor.

Furthermore, changing the oil from one typeor make to another should only be undertak-en in connection with a careful procedure in-volving the drainage and thorough evacua-tion of the refrigeration plant. Information ona suitable procedure can be obtained fromYORK Refrigeration as well as from a num-ber of oil companies.

116 0170-151-EN

It is imperative that oil is only used from theoriginal container and that both the make andtype complies with the specification for theplant.

Ensure that the original container is sealedduring storage to prevent moisture from theair being absorbed into the oil - many oils,particulary the polyolester oils, are extremelyhygroscopic. Consequently, it is recom-mended that the oil is only purchased in con-tainers corresponding to the amount to beused on each occasion.

If the oil is only partially used, make sure thatit is effectively re-sealed in the original con-tainer and that it is stored in a warm, dryplace. Ideally with nitrogen blanking of the oilto keep the water content below 50 ppm.

Oil drums should, ideally, be ”racked” andmounted with a proper barrel tap to ensurean effective airtight seal.

Oil changing intervals

A list of the recommended intervals forchanging the oil can be found in the com-pressor instruction manual. These are pro-vided for guidance only. The actual intervalbetween oil changes will often be determinedby a variety of operating parameters withinthe plant.

It is strongly recommended to monitor thequality of the oil by carrying out oil analyseswith regular intervals. This will also give agood indication of the condition of the plant.The service can be supplied by YORK Refrigeration or the oil suppliers.

�� "'��,

�� : In case of a new plant. Very suitable.

�� : In case you wish to change from mineral oil

: Max oil concentration in liquid phase at: TE: 2% W

: Max oil concentration in liquid phase: contact YORK Refrigeration

: Min suction temperature –50°C: at TE< –50°C superheating must be introduced.

* : Dry expansion systems only. Flooded systems to be considered individually: contact YORK Refrigeration

SH : Suction gas superheat, K (Kelvin)

: Zone in which both oils are useable

: Calculation must be performed using COMP1

*

:

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0170-151-EN 117

�� $�� '��

Typical data for lubricating oils for Sabroe compressors

Sabroe Viscosity Viscosity Spec. Flash p. Pour p. Anilin Acid no.

code cSt40°C

cSt100°C

Index grav. at15°C

COC°C

°C °Cpoint

mgKOH/g

M1 63 6.4 14 0.91 202 –36 81 0.02

A3 97 8.1 13 0.86 206 –32 78 0.05

AP1 64 9.3 121 0.858 195 –51 121 0.04

PAO3 66 10.1 136 0.835 266 <–45 138 0.03

PAO5 94 13.7 147 0.838 255 <–45 144 0.03

PAO9 208 25 149 0.846 260 <–39 154 0.03

E3

E5Due to the big difference between polyolester-based lubricants from various suppliers, it isnot possible to present typical data for these oils. When using another oil brand than the one

E9 recommended by YORK Refrigeration, please contact the oil supplier to select the correct

E11oil type.

The listed data are typical values and are intended as a guideline only when selecting a similaroil from a different oil company. Data equivalence alone does not necessarily qualify the oil foruse in YORK Refrigeration’s Sabroe compressors.

118 0170-151-EN

List of part numbers for available Sabroe oils

Part no.Oil brand Oil code no.

20 litre pail 208 litre pail

Mobil Gargoyle Arctic 300 M 1 (M68) 1231-264 1231-296

Sabroe Oil A100 A 3 (A100) 1231-263 1231-262

Sabroe Oil AP68 AP 1 (AP68) 1231-257 1231-260

Sabroe Oil PAO68 PAO 3 (P68) 1231-256 1231-259

Mobil Gargoyle Arctic SHC 228 PAO 5 (P100) 1231-282 1231-283

Mobil Gargoyle Arctic SHC 230 PAO 9 (P220) 1231-284 1231-285

Mobil EAL Arctic 68 E 3 (E68) 1231-272 1231-273

Mobil EAL Arctic 100 E 5 (E100) 1231-274 1231-275

Mobil EAL Arctic 220 E 9 (E220) 1231-279

Sabroe H oil E11 (E370) 3914 1512 954 1) 9415 0008 000

1) 18.9 litre pail (5 US gallons)

The oils recommended by the former Stal Refrigeration correspond to the following oils:

Stal Refrigeration oil type Sabroe oil

A Mobil Gargoyle Arctic 300 – M1 (M68)

B Sabroe Oil PAO 68 – PAO 3 (PAO 68)

C Mobil Gargoyle Arctic SHC 230 – PAO 9 (PAO 220)

H Sabroe H oil – E 11 (E 370)

0170-151-EN 119

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Note: YORK Refrigeration recommends that the use of M oils is restricted to moderately loaded compressors andthat the oil quality is monitored carefully via regular oil analyses.

� : In case of a new plant. Very suitable.


120 0170-151-EN

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0170-151-EN 121

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Please observe: PAO 5 oil is the only oil which can be used in the HPO and HPC compressors.


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0170-151-EN 123

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126 0170-151-EN

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0170-151-EN 127

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0170-151-EN 129

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130 0170-151-EN

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132 0170-151-EN

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0170-151-EN 133

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Using the calculating programme COMP1 it is possible to optimize the requirement for suction superheat values (SH) as stated in the diagram. See Oil types and oil companies in this section. Due to the ongoing development oflubrication oils, please contact YORK Refrigeration for an update on the requirement for superheat.




* : Dry expansion systems only. Flooded systems to be considered individually: contact YORK Refrigeration



*

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HLI: Calculation must be performed using COMP1.

SH20

SH5

SH25

SH10

SH20

0170-151-EN 135

ÜÜÜÜÜÜÜÜÜÜÜÜÜÜÜÜÜÜÜÜÜÜÜÜÜÜÜÜÜÜÜÜÜÜÜÜÜÜÜÜÜÜÜÜÜÜÜÜÜÜÜÜÜÜÜÜÜÜÜÜÜÜÜÜÜÜÜÜÜÜÜÜ

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Area noCode no

E 5 �

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30

40

50

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Using the calculating programme COMP1 it is possible to optimize the requirement for suction superheat values(SH) as stated in the diagram. See Oil types and oil companies in this section. Due to the ongoing developmentof lubrication oils, please contact YORK Refrigeration for an update on the requirement for superheat.




: Calculation must be performed using COMP1ÜÜÑÑ

SH20

SH5

SH10

SH20

SH30

ÒÒÒÒÒÒÒÒÒÒÒÒÒÒÒÒÒÒÒÒÒÒÒÒÒÒÒÒÒÒÒÒÒÒÒÒÒÒÒÒÒÒ

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(See note)

Note: For the compressors type ”S”, ”Rotatune”, ”SAB 81”, ”SAB 83”, and ”SAB 85” only Sabroe oil H is approved.

136 0170-151-EN

E 3 �

E 5 �

E 9 �

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Using the calculating programme COMP1 it is possible to optimize the requirement for suction superheat values (SH) as stated in the diagram. See Oil types and oil companies in this section. Due to the ongoing developmentof lubrication oils, please contact YORK Refrigeration for an update on the requirement for superheat.







:

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0170-151-EN 137

��60�Screw compressors


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20

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104

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138 0170-151-EN


ŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠŠ



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-20

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-30-70 -60 -50 -40

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86

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50

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0170-151-EN 139

List of major oil companies

The oil from the companies listed below are NOT tested by YORK Refrigeration and are there-fore NOT approved by YORK Refrigeration either. The following list reflects the information pro-vided by the companies themselves. The assessment of durability and suitability of specific oilsfor specific purposes are entirely at the companies’ own discretion. Oils tested and approved byYORK Refrigeration can be found in the ”List of part numbers for available Sabroe oils”.

Oil Oil Types

Company M A PAO AP E

Aral • •Avia •BP • • • •

Castrol • • • •Chevron (UK: Gulf Oil) • • •

CPI Engineering Services • • •DEA • • • •

Elf / Lub Marine 1 • • •Esso/Exxon • • •

Fina • • •Fuchs • • • •

Hydro-Texaco • • • •ICI •

Kuwait Petroleum (Q8) • •Mobil • • • • •

Petro-Canada •Shell • • • •Statoil • •Sun Oil • •

140 0170-151-EN

Notes:

0171

-460

-EN

95.0

3

0178-225-EN 141

*�� % *��

Where the compressor and motor are directlyinterlinked, an AMR coupling is used; this is atorsionally rigid coupling with enough radialand axial flexibility to assimilate small move-ments between the two machines.

In order to ensure compressor and motor along life as well as noise- and vibration-freeoperation, compressor unit and coupling need to be aligned with care. Misalignment ofthe compressor unit or coupling may produce stresses and vibrations which canbe transmitted to the compressor and motorbearings and thus cause major damage.

Vibrations may be caused by the following:

� Distortion between compressor unit andfoundation.

� Distortion between compressor and baseframe.

� Distortion between motor and base frame.

� Strains from pipe connections betweencompressor and plant.

� Misalignment of coupling linking compres-sor and motor.

� Untruth in compressor or motor shafts.

� Untruth in coupling.

� Imperfect balancing of coupling.

� Imbalance in compressor or motor.

The points up to and including coupling align-ment are the responsibility of the fitter settingup the unit. The other points must bechecked by the compressor or motor

manufacturer prior to delivery. The followingsections will deal with the individual pointsconcerning the fitter.

Alignment of unit with foundation

Whenever installing a unit directly onto thefoundation or machine floor, it should standfree of stresses and press down evenly on allsupports.

The unit can be installed in the followingways:

� on vibration dampers

� straight onto a foundation, using founda-tion bolts.

Whichever method is used, the unit must bealigned before hooking the connection pipesup to the installation.

Vibration dampers are supplied as shown atthe top or bottom of drawing T0177040, de-pending whether the compressor unit is in-tended for use on land or at sea.

The purpose of the vibration dampers is todiminish the vibrations from the compressorunit to the foundation. In addition, the marinevibration dampers serve to cushion vibrationsfrom the foundation to the compressor unit,at the same time securing the unit to thefoundation.

It is imperative that the vibration dampers beplaced correctly, as shown in the completeddrawing forwarded to customer or distributor.This drawing is valid only for the unit inquestion .

142 0178-225-EN

Installation on vibration dampers

A2

A1

T0177040_0

2

H

A1

Hmax

A2

1

The vibration dampers supplied are markedwith a code, for instance LM6-60. LM6 indi-cates the size; 60 indicates the rubber hard-ness and is therefore an expression of bear-ing and damping ability.

When using vibration dampers, the machineroom floor is assumed to have the necessarybearing stregth and to be level enough to en-able adjustment of the vibration dampers tobe made within the adjusting measurementsstated on the drawing submitted.

In order for the individual vibration damper tocushion properly, a sufficient load must beimposed. Measure A1 and H in an unloadedand A2 in a loaded set-up, as shown in draw-ing T0177040.

Industrialtype

Marine-type

1 2

Flexion

Height adjustment

A1-A2

min 1,0 min 3,0

with diskssupplied as shown

H = H+12max

max 2,0 max 5,0

The flexion of a damper is adjusted by in-creasing or decreasing the load in relation tothe other supports. The foot can be raised byscrewing the adjusting rod down or insertingmore disks between damper and foot (marinedesign), thereby increasing load and hencealso the flexion.

Once the installation has cooled down, checkduring operation that the flexion of the damp-ers is still correct!

0178-225-EN 143

Installing directly on foundation

When installing a unit directly on a concretefoundation, the foundation should be cast inaccordance with the foundation drawings dis-patched.

When the foundation has been cast - with theholes shown for foundation bolts - and hasset, place the unit in position, allowing it torest on beams levelled at a suitable height sothat the foundation plates are recessedslightly into the foundation.

Check that the foundation plates are rightnext to the base frame. This can be achievedby binding them to the resting surfaces of thebase frame with steel flex.

The concrete cast down around the founda-tion bolts should contain only a small amountof water, so that it can be well tamped aroundthe bolts. Low water content produces nocontraction of the setting concrete.

10-14 days should be allowed to elapse be-fore removing the beams and tightening thenuts for the foundation bolts. Before that, however, remove the steel flexand check that there is no space between thebase frame and the foundation plates. Ifthere is, place shims between the plates be-fore tightening.

Alignment of compressor with baseframe

Check that the entire footing of the compres-sor makes full contact against the milled-offfaces of the base frame.

Perform this check with the bolts loosened. Ifslip occurs at one or more resting surfaces,shim up before tightening. If unaligned, thereis a risk of stresses occurring in the compres-sor frame, which will damage the bearings.

Alignment of motor with base frame

Check the contact faces of the motor againstthe base frame in the same way as for thecompressor.

Stresses from piping connections

In order to prevent stress being transmittedfrom piping connections between unit andplant, pipes must be laid so as not to gener-ate compressive stresses or tensile strains inthe event of expansions or contractions dueto temperature changes. Steel piping ex-pands approx. 1 mm per metre per 100°C.

We recommend that piping be laid as shownin example 2 of the sketch. Example 1 dem-onstrates too rigid pipe laying.

1 2

> 1.5 m

T0177057_0

Final alignment of compressor and motor canbe performed once all piping has been con-nected to the unit.

144 0178-225-EN

Fitting and alignment of AMR-type coupling

Installation and alignment

In principle, alignment involves manoeuvringthe motor so as to make the shaft form anextension of the crankshaft.

Important:Before any work on the coupling, ensurethat the compressor motor cannot bestarted inadvertenly.

T0177120_0/V2

B

C

X

2Z

a

1

Compressor Motor

A

Fig. 1

Compressor

Pos. 1 Pos. 2A

Nm

B

Nm

Verticalmax.mm

Horizontalmin./max.

mmmax.mmmm

HPO/CMO 2

HPC/SMC104-108

SMC112-116

SMC180

225

312 S

350 S

450 S

76,0

103,5

114,5

149,0

147

147

295

34

55

128

275

0,1

0,2

0,2

0,3

0,1/0,2

0,1/0,3

0,1/0,3

0,1/0,4

0,1

0,2

0,2

0,3

AMR type of coupling

DistanceC

nominal*

Torque momentMax. variation measured with a feeler

gauge at a 180° turning of the af coupling

* See Final mounting, pt. 4

0178-225-EN 145

Preliminary installation

� Check tightening of coupling flange oncompressor.

� Tighten 8 coupling bolts securing lamellarsegments to intermediate piece to pre-scribed moment stated in table. It is worth-while doing this before placing the inter-mediate piece in position.

� Mount retaining plate from couplingscreen onto compressor and insert sup-port ring for coupling screen over motorflange.

� Insert coupling intermediate piece. Createspace between flanges either by shiftingentire motor or just motor coupling flange. The intermediate piece should only besecured to the compressor flange. Donot insert the last four bolts in the mo-tor flange until the coupling has beenaligned.As the compressor shaft rotates during thealignment procedure, the motor must turnwith it, as the bolts in the intermediatepiece engage in the free holes in the mo-tor coupling flange.

� Line up motor so that free holes in motorfeet are right over threaded holes in baseframe.

� Shift motor coupling flange to make updistance ”C” in table. See fig. 1.

� Tighten two bolts in coupling hub. On CMO units, the motor flange must becorrectly positioned before putting the mo-tor into place.

� Tighten measuring pin on coupling flangeof compressor, as shown in drawing.

Alignment

Check that the motor with loose bolts standswith all four feet on the base frame. Insertany liner plates needed where there is an airgap beneath the feet. Tauten the bolts slight-ly.

Achieving parallel shafts in horizontal plane

� Turn coupling so that alignment gauge isin upper position. See fig. 1.

� Guide measuring pin (Pos. 2) towardscoupling flange, using a 1.0 mm feelergauge, and fix pin. Remove feeler gauge.

� Rotate coupling 180° and measurechange in distance from measuring pin toflange, using feeler gauges. This changeis called ”x”.

� Insert shims of thickness ”y” either underboth front feet or both rear feet, therebytilting motor in direction required. Shimthickness ”y” is calculated using the fol-lowing formula (see drawings):

y = Xb

2 x a•

b

y

� After tightening motor bolts, repeat meas-urement and compare result with values intable under Pos. 2.

146 0178-225-EN

Achieving correct centre height

� Turn coupling so that alignment gaugefaces vertically down.

� Guide measuring pin (pos. 1) towardscoupling flange, using a 1.0 mm feelergauge, and fix pin. Remove feeler gauge.

� Rotate coupling 180° and measure in-crease in distance ”z” from one millimetreusing feeler gauges.

� Then lift motor by placing shims of thick-ness equal to half value of ”z” under allfour feet.

� After securing motor, repeat measurementand compare result with table values inpos. 1 vertical. Remember that the centre-line of the motor shaft must be at least0.05 mm higher than the centreline of thecompressor, corresponding to a minimumof 0.1 mm distance less at the top positionof the alignment gauge.

Achieving parallel shafts in verticalplane

� The motor is now positioned at its correctheight. What now remains is to push andturn the motor at the level on which it isalready lined up.

� Turn coupling so that alignment gaugefaces out to one side horizontally.

� Guide both measuring pins towards coup-ling with a 1.0 mm feeler gauge in be-tween.

� Turn coupling 180° and, using feelergauges, measure deviations from one mil-limetre at both pins.

� Moving and turning motor and repeatingthis measurement, align motor in accord-ance with pos. 1 horizontal and pos. 2 intable. Remember that the motor must befirmly secured during any measurements.

Final installation

� Tighten foundation bolts on motor (seetorque table).

� Fit four bolts into motor coupling flange sothat thin shims are placed between flangeand lamellae, with rounded side facing la-mella. There are no thin shims on cou-plings for CMO and HPO.

� Tighten bolts to torque specified in table.

� Readjust flange distance ”C” so that la-mellae are aligned, by moving motorflange on shaft and fastening motorflange.

� Check alignment of coupling in horizontaland vertical planes for pos. 1 and pos. 2.

� Dismantle measuring pin and tightenscrew to prescribed torque.

� Fit coupling guard.

� Once normal operating temperature hasbeen achieved, double-check couplingalignment.

010-

502-

EN

92.0

3

0171-487-EN 147

:�� *��

T0177131_0 V12

B

MAX. 0.02 mm

MAX. 0.02 mm

A

Unless the necessary data for the motor areknown prior to dispatch, the motor flange forthe AMR coupling will not be supplied inready bored form.

In such case, the motor flange is suppliedprebored and balanced.

Finish-boring is done as follows:

� Secure flange in lathe or jig-boring ma-chine. Observe following tolerances foralignment purposes:

Max. axial eccentricity measured at point A

Max. axial eccentricitymeasured at point B

0.02 mm

0.02 mm

� The bore should then be made to the rele-vant dimensions and to the following toler-ances:

H8 for AMR 312, 350 and 450, H7 for AMR 225.

� Cut keyways. For reasons of balance, coupling AMR312, 350 and 450 must be executed withthe two keyways shown.

� Make the width of the keyway to a toler-ance of H7.

� The keyway must be deep enough to al-low a clearance between parallel keysand hub of 0.2-0.3 mm.

Compressor

Coupling size

Max. bore

Boring tolerance

CMO - TCMO - HPO

AMR 225

60 mm

H7

SMC - TSMC 100 - HPC

AMR 312 - 350

95 mm

H8

SMC - TSMC 180

AMR 450

110 mm

H8

Max. boring diameter:

0171

-469

-EN

95.0

6

148 0171-370-EN

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A�2�� A�2��

If your SABROE compressor is belt driven, V-belts are used with profiles specified in the table below.

Compressor type Belt profileNom. centre

distance15 mm sag

K. max. K.min.kgkgmm

CMO - TCMO 24-26-28

SMC - TSMC 104 - 108

SMC - TSMC 112 - 116

SMC - TSMC 186 - 188

SPB (16 x 13)

SPB (16 x 13)

SPB (16 x 13)

SPC (21 x 18)

700

900

500

1230

11,00

8,00

14,00

9,00

8,00

6,00

10,00

6,50

K

15 mm

C

C/2

T0177084_0

Fig. 2Fig. 1

Fitting V-belts

� Before fitting V-belts, belt pulley tracksmust be carefully cleaned of oil and dirtand checked of any burrs and marks.

� Move motor on slide rails, shorteningcentre distance sufficiently to enable beltsto be mounted without use of force. Beltsmust never be forced over the pulleys, asthe power-transmitting fibres may be dam-aged, reducing their lifetime considerably.

� After mounting V-belts, separate compres-sor and motor again and align by meansof an alignment plate as shown in Fig. 1.

Tracks must be flush and shafts absolutelyparallel.

� To achieve optimal operating conditions,belt tension must be correct. This isachieved as follows:

a) Measure centre distance C as shown inFig. 2.

b) At half centre distance C/2, place a weightweighing K; if necessary, this can hang ina piece of welding flex or suchlike on oneof the V-belts and be moved from belt tobelt.

c) Weight K must be between the minimumand maximum values for the belt drive in

0171-370-EN 149

question, as stated in the table. Tightenbelt drive so that sag is approx. 15 mm forall V-belts.

� A new belt drive always has to be tight-ened to the max. value.

� Run transmission for a few minutes andthen check tension.

� It is important that the tension is inspectedat regular intervals, as stipulated in thesection Servicing the piston compressor.

� When changing worn V-belts, the wholeset should be replaced.

� A set of V-belts must always be within thesame tolerance group.

� Never use belt lubricant.

RememberThe safety guard always be mounted whe-never the belt drive is in operation.

0171

-361

-EN

98.1

0

150 0178-910-EN

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The thermo pump is a compressor coolingsystem for R717 reciprocating compressors.Its purpose is to cool the oil in the crankcaseas well as the compressor discharge gas inorder to lower the temperature in the entirecompressor.

The thermo pump is mounted as a side coveron the compressor and works by pressingrefrigerant under the top covers and into anoil cooler which - depending on the operatingconditions - has been built into the crank-case.

On TSMC compressors only the high pres-sure covers are cooled, and there is no oilcooler in the crankcase.

The thermo pump works under the influenceof the heat coming from the oil in the crank-case, thus regulating its own pump capacity.This means that the thermo pump works at aslow pace whenever the compressor oil iscold, e.g. after start-up of the compressor,but as the oil temperature increases so doespump capacity.

However, the thermo pump will not start untilthe discharge gas temperature of the com-pressor is above 80°C.

The pumping cycle of the thermo pump, i.e. a filling and an evacuation period, lasts be-tween 4 and 8 minutes depending on thenumber of cylinders of the compressor, itscapacity, the oil temperature in the crank-case, and the operating pressure and tem-peratures of the plant. The filling period itselflasts 45 sec.

During a pumping cycle the discharge gastemperature varies as no cooling of the dis-charge gas takes place during the filling period.

Usually, the variation will be +/–10K of theestimated discharge gas temperaturestated in the table of this instruction manual.See table of contents.

However, please notice that under normaloperating conditions the discharge gas tem-perature must not be below the table valueless the variation of approx. 10K .

The important advantage of the thermo pumpis that the refrigerant pumped by the thermopump is led directly into the compressor dis-charge gas and as a consequence has noinfluence on the compressor capacity.

0178-910-EN 151

Principle drawings

SMC 108 TSMC 108

SMC 104 SMC 106

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154 0178-910-EN

Structure of the thermo pumpTogether with the cooling cover, pos. 98Q,the side cover, pos. 98A, forms a pump ves-sel, pos. 98, which is supplied with heat fromthe oil bath in the crankcase. The coolingcover is equipped with cooling fins in order toprovide a satisfactory thermal contact withthe oil.

As illustrated in the principle drawings, thepump vessel has the following three pipeconnections:

� Connection pos. A which is linked to thecompressor suction side and which can beblocked by means of solenoid valve pos.98G. Used to lower the pressure in pumpvessel pos. 98. Part of the pumping cycle.

� Connection pos. B emerges from the re-ceiver or the priority tank and goes right tothe valve block pos. 80 which is of the sa-me type as the one described in the sec-tion on: Solenoid valve controlled oilreturn in this instruction manual.Please, note that the size of orificepos. 80I must be 3.3 mm.

� Connection pos. C is connected to the topcovers and the oil cooler pos. 98T througha number of nozzles pos. 98M.

Filling and evacuation of the pump vessel iscontrolled by two level sensors, pos. 98C,which by means of the control box, pos. 98B,

control the solenoid valves, pos. 98G andpos. 98H, so that they are open and shut si-multaneously. The thermo pump is safe-guarded by the following systems:(See principle drawing)

a: A thermostat built into the control box pos.98B with sensors pos. 98X fitted on thecompressor discharge pipe.

Fasten the sensor to the discharge piperight next to the discharge stop valve bymeans of two clips. Ensure a properthermal contact.

The thermostat is factory set to start upthe thermo pump once the discharge gastemperature is above 80°C.

b: An evacuation system emptying the pumpvessel through solenoid valve pos. 98Vwhenever the thermo pump stops.

Please, notice that the pipe connectionpos. D to the plant evaporating side mustbe made at a spot where there is no riskof the liquid flowing back to the compres-sor. Connection should, f.inst., be made tothe liquid separator or the evaporator.

c: A safety circuit with a non-return valvepos. 98Z that opens for the flow at a pres-sure 3 bar higher in the pump vessel thanthe one in the compressor discharge gasline.

98C98E98F

98Q

T3185085_5

98D

98L

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0178-910-EN 155

Description of pumping cycle

Filling of pump vessel

As soon as the liquid leaves the bottom levelsensor, the control box will activate the sole-noid valves pos. 98H in valve block pos. 80and pos. 98G.

Hereby, solenoid valve pos. 98G opens in thepipe connection to the compressor suctionside and the pressure in the pump vessel de-creases slightly. At the same time solenoidvalve pos. 98H opens and refrigerant liquidstarts flowing to the pump vessel throughpipe connection B.

Evacuation of pump vessel

When the top sensor has registered that theliquid has reached the top level both solenoidvalves will be closed by the control box.

The pressure in the pump vessel now risesas a consequence of the heat impact fromthe compressor oil and - when exceeding thepressure on the compressor discharge side -will make the refrigerant flow through thepipe connections to the top covers and the oilcooler.

At the top covers the refrigerant expandsthrough the nozzles pos. 98M directly into thehot discharge gas, with immediate cooling ofthe discharge gas.

The oil cooler (not always required) is aheat exchanger in which the expanding re-frigerant - after cooling of the oil - is taken tothe compressor discharge side.

Once the liquid in the pump vessel has re-turned its lowest level, it is registered by thebottom sensor and the control box opens thetwo solenoid valves for a new pumping cycle.

Capacity regulation of thermo pump

On reducing the compressor capacity it be-comes necessary also to reduce the coolingeffect of the thermo pump. This is done asfollows:

SMC 104-106-108, TSMC 116CMO 24-26-28

The pipe connection from the pump vessel tothe top covers is on its way divided into twopipe lines. In one of these pipe lines a sole-noid valve, pos. 98U, is fitted. This solenoid valve is connected to the thecapacity regulating system of the compressorand closes when the compressor capacityhas been reduced, as indicated in the follow-ing table:

Compressor

capacity

Solenoid valve pos.98U

open closed

50%100%SMC 104

33%100-67%SMC 106

50-25%100-75%SMC 108

50-33%100-83-67%TSMC 116

50-25%100-75%CMO 24

50-33%100-67%CMO 26

50-25%100-75%CMO 28

SMC 112-116

On the SMC 112-116 two thermo pumpshave been mounted as shown on the prin-ciple drawings.

The total capacity of the thermo pumps isadapted to the compressor capacity by a power disconnection of the thermo pump

156 0178-910-EN

positioned at the compressor shaft end andmarked X on the principle drawing.

The disconnection is achieved through theconnection of the thermo pump via terminals5 and 6/7 or 8 to the capacity regulating sys-tem of the compressor. The supply voltage tothe thermo pump must be switched off oncethe compressor capacity has been reducedto the values indicated in the table below.

Compr.

capacity

Thermo pump at compr.

working not working

50-33%100-83-67%SMC 112

50-37-25%100-87-75-63%SMC 116

shaft end

The pipe connections are shown on the prin-ciple drawings on the previous pages.

When the compressor is stopped the currentto the thermo pump is cut off, closing the so-lenoid valves pos. 98H and pos. 98G. At the same time solenoid valve pos. 98Vopens and drains the liquid in the thermopump back to the evaporating side of theplant. See the previously mentioned point b.

Checking the pumping cycle

On dismantling the cover plate on the controlbox four light diodes are made visible (2 green and 2 red ones).One of the green diodes that is connected tothe top level sensor is switched on for a rela-tively short period, i.e. from the moment thesensor has registered the upper liquid leveland until evacuation of the vessel has low-ered the level below the sensor.

Similarly, the other green diode for the bot-tom sensor will only be switched off from themoment the bottom level has been registeredand until the liquid rises once more on fillingof the vessel.

At the bottom level a time lag of a few se-conds has been built in order to prevent thesolenoid valves from clattering in the event ofany lapping in the vessel.

One of the red diodes, LD3, lights up oncethe temperature of the discharge gas risesabove 80°C. The other red diode LD4 lightsup when the relay to the solenoid valves hasclosed.

Functional testing

When stop valve in valve block pos. 80 isclosed the functioning of the pump may betested as follows:

� Roll off the rubber cap on the external partof the level sensors so that the part with-out insulation can be touched with a fin-ger.

NoteIt is quite safe to touch the level sensorsat this point as the voltage is extremelyweak.

� Touching the sensor alters its capacity asif the sensor were surrounded by liquid inthe pump vessel.

By touching the sensors in the order inwhich they are usually surrounded by liquid at increasing liquid level it is pos-sible to check whether the solenoid valvesreceive any voltage and open when thesensors are released.

0178-910-EN 157

Possible sources of error

In case the above tests should reveal thatone or both of the diodes do not light upwhen touched, this may be due to:

1. No voltage to the control box.

2. Loose power connection.

3. Defective control box.(To be replaced by a new one)

In case both diodes switch on and off correct-ly but the built-in relay is not working, replacethe control box.

If the diodes light up and the relay is working,the error may be found in the solenoidvalves:

1. Loose connections to the solenoid valves.

2. Burnt coils in the solenoid valves.

3. Some other malfunction in the solenoidvalves.

If the above-mentioned sources of error arenot present and the thermo pump still fails,the reason may be:

1. Closed stop valve in the liquid line.

2. Clogged filter in the liquid line.

3. Dirt in the solenoid valves.

4. Flash-gas in the liquid supply pipe or liquidshortage.

5. A very low differential temperature be-tween oil and condensing temperature.

6. Clogged nozzles pos. 98M.

Both diodes are constantly lit

If one or both diodes are constantly lit, evenwith no liquid on the sensor, this may be dueto a conductive connection between the innerand the outer part of the level sensor rod.

Outside the side cover the level sensor rod isprotected by O-rings and a protective cappreventing water and moisture from makingcontact.

An oil drop may have slipped inside the sidecover. In this case it is recommended to stripdown the sensor rod and clean the parts. Onmounting make sure that the sensor rod cen-ters in the sensor tube.

If, after remounting, the error persists, thecontrol box must be replaced.

Ensuring liquid to the thermo pump

The thermo pump must always be ensuredliquid from the plant, no matter whether theplant lacks liquid or some other factor pre-vails.

Thus, the thermo pump must also be en-sured liquid during a possible pump down bymeans of the compressor.

In other words: During operation the com-pressor must never be short of cooling.

This safety is achieved by either taking theliquid directly from the receiver, pipe connec-tion B or by building a priority tank into theliquid line of the plant (see drawing). The liquid volume A of the priority vesselmust be minimum 10 litres per thermo pump.

The liquid tube from the priority vessel to thethermo pump must be dimensioned to pre-vent the formation of flash gas along the way.

158 0178-910-EN

Receiver

1

B 2

3B

1

2

3

T0177101_0/4

Priority tank

1: Refrigerant liquid from condenser/receiver2: Refrigerant liquid to evaporator3: Refrigerant liquid reserve for oil coolingB: Refrigerant liquid for oil cooling

Stopping a compressor equipped

with a thermo pump

When the compressor is stopped there must

still be a pilot current on the unit so that the

solenoid valve pos. 98V is kept open until the

pump vessel has been emptied of liquid.

At the same time, stop valve pos. 98Y is kept

open.

Opening of compressor for repair

Pump down of the compressor must take

place with the thermo pump system set out of

function and after the pump vessel has been

emptied as described above.

During pump down close stop valve in valve

block pos. 80 and pos. 98Y.

Cleaning of filter in the liquid

supply line

Pump down the compressor before opening

the filter in the liquid supply line for cleaning.

Power connection

The control box is geared for 3 different voltages: 110V - 50/60Hz

220V - 50/60Hz 240V - 50HZ

The control box contains a terminal strip asshown in the sketch below.

PT100 sensor

GND

GND

Upper level sensor

GND

Terminal 2

K2

K3

M1

N

M2

N

L

N

VS1

230115

Main voltage selector

K1

Lower level sensor

Terminal 1

Terminal 4

Terminal 1

Terminal 1

Terminal 2

K4

0171-370-EN 159

��

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On halocarbonic piston compressors operat-ing in parallel on the same plant, it is impor-tant to regulate the oil return flow to thecrankcases of the compressors so that theyhave the same oil level.

This is achieved by using an oil distributionsystem as described in this instruction.

Each compressor is fitted, via an intermedi-ate piece, with a mechanical float which re-gulates the oil level in the crankcase.

This intermediate piece is mounted betweenthe compressor frame and the oil level glass,as shown in the drawing. This allows visualinspection of the oil level in the crankcase.

T0177089_0/2

Float valve housing

Oil level glass

Pipe connection Vent valvewith float valve

on compressor

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160 0171-370-EN

Schematic diagram

Parallel system,

2

3

4

Oil receiver

Oil separator with

1 1

2

3

4

76

5

9

10

Compressor 1 Compressor 2

Oil separator withAlternative

5

76

9

8

5

11

12

13

Standard

float valve controlled oil return

1. Compressor 8. Float valve for oil separator2. Float valve for parallel operation (1374-005) 9. Oil receiver3. Filter 10. Non return valve, 1 bar4. Stop valve 11. Solenoid valve for driving pressure line5. Oil separator 12. Nozzle dia. 0.4mm for driving pressure line6. Solenoid valve for oil separator 13. Filter for driving pressure line7. Nozzle for oil separator

fitted on unit

Oil chargingHeating cartridge Liquid level glass

solenoid valve controlled oil return

Function

The piping diagram is based on each com-pressor pos. 1 being equipped with an oil separator pos. 5, from which the oil via solenoid valve pos. 6 and nozzle pos. 7, orthrough float valve pos. 8, is conveyed to an oil tank pos. 9.

The nozzle size for pos. 7 is stated in thesection on Oil Separator.

The oil tank pos. 9 must have a volume equalto approx. 50% of the total oil volume to becontained in the compressors. However, it should never be filled more thanhalfway with oil, corresponding to approx.25% of the total oil quantity.

There should be an oil level glass on the oiltank and a heating element to ensure warm,and hence refrigerant free, oil.

From the oil tank, an oil pipe is drawn directlyto the mechanical float pos. 2 controlling theoil level in the crankcase.

From the top of the oil tank pos. 9, a pipe isrouted to the suction side of the plant.

A non-return valve pos. 10 is inserted in thepipe, opening at a differential pressure of 1bar. Note the flow direction. A pressure 1 barhigher than the suction pressure in the plantis thus obtained in the oil tank. This is suffi-cient to pump the oil through the float valvewithout generating any foaming in the floatvalve housings.

Note:After the initial starting up of the float sy-stem, the float housing must be ventilatedin the following way. See drawing of floathousing.

0171-370-EN 161

Unscrew the cap on the vent valve and acti-vate the spring-loaded valve in the branch bypressing it down with a screwdriver or similar.

If the float-valve controlled oil return Pos.8 is used, the oil tank must - in order to main-tain the driving pressure at 1 bar - also be

connected to the discharge side of the plant,as shown in the schematic diagram.

In the pipe connection to the discharge side,mount a 0.4 mm diameter nozzle Pos. 12and a solenoid valve Pos. 11, which must beopen also when only one compressor is op-erating.

0171

-356

-EN

97.0

3

162 0171-370-EN

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Under certain operating conditions – as indi-cated on the diagram on operating limits inthis instruction manual – cooling of the com-pressor oil is required.

On page 1 is stated whether the actual com-pressor has a built-in refrigerant cooled oilcooler.

As shown in fig. 1 the oil cooling system con-sists of a spiral of smooth steel pipes placedround the oil filter.

Via the cutting ring joints pos. 5, the spiral isconnected to the external pipings, as illus-trated in fig. 2A an 2B.

Connection, pos. B, pipe dimension OD 10mm, emerges from receiver or priority vesseland is conveyed to valve block pos. 80 whichis the same type as the one described in sec-tion entitled: Solenoid controlled oil return ofthis instruction manual. Please, note that nozzle size pos. 80I mustbe 3.3 mm.

4242-087

Fig. 1

Oil cooler

Oilfilter with bracket

Screwed

1349-053Gasket2356-139

2312-022Plug2314-025

Gasket2356-130

5A

5B

4242-080

Pos. 5

connection

Nipple socket

Oil cooling system R22

Fig. 2A

B

1

•

0171-370-EN 163

Oil cooling system R717

Fig. 2B

B

1

•

Connect oil cooling system to the liquid sys-tem of the refrigeration plant where a point atliquid refrigerant is always present, and carryout pipe connection so that no gas bubbleswill occur in the liquid before the expansionvalve.

Pipe dimension is shown on fig. 3 and 4. Apriority vessel may possibly be used as de-scribed under Ensuring liquid supply to Ther-mopump in section Thermopump system forcooling.

Function

The valve arrangement Pos. 1 has a built–instop valve with which the cooling system canbe cut off from the refrigeration plant. The

arrangement also contains a filter that can betaken apart and cleaned as described earlier.

The liquid will pass the solenoid valve whichis electrically coupled to thermostat KP77.This opens the solenoid valve whenever theoil temperature is above 55°C. (See table :Pressure and temperature settings)

Adjustment of liquid flow to the oil coolertakes place through the expansion valvewhich for R22 compressors is a thermostatticexpansion valve with thermo sensor placedon the discharge pipe of the oil cooler asshown in fig. 3.

For R717 it is a thermostatic injection valvewith thermo sensor placed at the compressordischarge branch as shown in fig. 4.

164 0171-370-EN

CMO 2 compressors for R22

3185-133

DN 15

Thermo filter

To evaporator

Oil cooler

Thermostatic

Solenoid valve Pos. 1C

From receiver

HP

LP

expansion valve Pos. 4

Fig. 3

Valve arrangement Pos. 1

OD10

80

CMO 2 compressors for R717

4849-063

Fig. 4

T

OIL P

LP

IP

T

OIL P

Oil cooler

Injection valve

LP

IP

OD10

80

DN 15

Valve arrangement pos. 1

Adjustment

Adjustment of the thermostatic expansionvalve for R22 appears from table: Pressureand temperature settings.

The thermostatic injection valve for R717 isfactory set to begin opening at +75°C dis-charge gas temperature and to be completelyopen at +95°C.

Dismantling oil cooler

In order to facilitate the replacement of oilfilter cartridge, see section on Oil Filter, it isrecommended to dismantle oil cooling spiralas described in the following:

Dismantling: After evacuation of the compressor as de-scribed previously, dismantle the twounion nuts Pos. 5A, after which the cool-ing spiral can be pulled out from thescrewed connections together with the oil filter. See fig. 1.

Mounting: On remounting cooling spiral, counterpressure must be exerted on the outsideon Pos. 5B when tightening union nut Pos.5A. See fig. 1.

0171

-336

-EN

97.0

3

0171-370-EN 165

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Application

The purpose of the oil separator is, under alloperating conditions, to separate the oil con-veyed out of the compressor with the dis-charge gas in order that it may be returned tothe compressor crankcase.

However, with the hot discharge gas some oilis going to leave the oil separator - the so-called oil consumption.

With a normal standard oil separator the oilconsumption will be approx. 35 to 45 ppm(parts per million) for R717 compressors.

The oil consumption is, however, dependenton the discharge gas temperature which atrising temperatures often results in an in-

creased oil consumption. Further, oils with alow flame point can lead to an increased oilconsumption in the R717 compressors.

For HCFC compressors the oil consumptionis of minor importance as the oil normally re-turns to the compressor from the plant.

Your compressor may be delivered with anormal standard oil separator, of which thevarious types are shown in fig. 1, 2 and 3, ora fine filter oil separator as shown in fig. 4.

With due regard to the normal dischargegas temperature and a high flame point thefine filter oil separator separates the oil fromthe discharge gas down to approx. 10 ppm inR717 refrigeration plants.

T0177142_0 V14

Fig. 1

R22 CMO

2 2

L 1L 1

Solenoid valve controlledexecution

Float valve controlledexecution

To compressor housing via

Discharge gas in

To compressor housing Dischargegas in

Dischargegas out

pos. 80valve block

Dischargegas out

166 0171-370-EN

R22-R717 TCMOFig. 2

T0177142_0 V14

Discharge gas out2 2

1 1

L L

Solenoid valve controlledexecution

Float valve controlled execution

Discharge gas out

Discharge gas inDischarge

gas in

To compressorhousing via

To compressor housingvalve blockpos. 80

Fig. 3 Fig. 4

•

M

L

L

D

2

1

1

2

R717 CMOR717 CMONormal standard oil separator Fine filter oil separator

To compressorhousing viavalve blockpos. 80

To compressorhousing viavalve blockpos. 80

0171-370-EN 167

FunctionThe discharge gas from the compressorflows through the oil separator from pos. 1 to 2 and passes through filters in which theoil is separated from the discharge gas. Inthe oil separators fig. 1, 2 and 3 the oil isseparated in a number of rustproof wire-mesh filters which normally need no cleaningand consequently cannot be removed fromthe oil separator.

In the oil separator fig. 4 the oil is sepa-rated, partly in above rustproof wire-meshfilters, partly in a fine filter pos. K, posi-tioned in the upper part of the oil separator.This fine filter may, as shown in fig. 5, be taken out of the oil separator through theflanged joint pos. D. On mounting of the finefilter the nuts pos. E must be tightened even-ly against the plate pos. F and secured withcounter nuts pos. G.

Also make sure that the fine filter is fitted cor-rectly against the intermediate plate pos. H.

Fig. 5

t4241347_1

•

•

K

H

• •

F E

G

•

D

K

2

1

168 0171-370-EN

Oil return to the compressorThe separated oil leaves the oil separatorthrough the connecting branches pos. Land in case of the fine filter oil separator fig. 4 also through branch pos. M. This means that two oil return systems are usedfor the fine filter oil separator.

The oil flow from the connecting branchespos. L and M can be regulated by the fol-lowing systems:

� Solenoid valve controlled oil return

� Float valve controlled oil return

a: Solenoid valve controlled oil return

As illustrated in fig. 6 the oil is conveyed from

the oil separator through the screwed con-

nections pos. 80A and 80B. Fig. 6 pos. also

shows that pos. 80A is of such a length that it

pierces the base plate by approx. 10mm.

In this way any dirt particles may be collected

on the bottom of the oil separator instead of

being returned with the oil to the compressor.

Fig. 6 ��

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Valve block pos. 80C, shown in fig. 7, con-

sists of a stop valve pos. 80D, which is

closed and opened by turning of the spindle.

This valve may be dismantled by unscrewing

the big union nut from the valve block.

On refitting the nut, tighten it with 60 Nm.

From the stop valve the oil passes filter pos.

80E, which can be removed by dismountingcover pos. 80F. The filter can be cleaned in acleansing fluid and blown clean with com-pressed air.

On remounting tighten the cover with atorque of 60 Nm. Remember gasket pos.80G.

0171-370-EN 169

60 Nm

A

80H

80J

1,4 Nm

80M

80P

10 Nm

80Q

80I

80L 50 Nm

80

B

60 Nm

80E80G

80F

Fig. 7

80N

80K

80D

After the oil has been cleaned, it flows to thesolenoid valve pos. 80H, which is alwaysclosed at compressor standstill.

During start-up of the compressor, the sole-noid valve can be kept closed for 20 to 30mins. by means of a time relay, available asan additional equipment. This prevents anyrefrigerant from entering the compressor.

The seat of the solenoid valve pos. 80I alsoacts as a nozzle that regulates the oil flowback to the compressor.

Select the nozzle size on the basis of table 8.We recommend not to use a bigger nozzlesize than prescribed. In order to replace thenozzle the compressor must first be depres-surized. Next, dismantle coil pos. 80J andarmature tube pos. 80P. The nozzle is screwed into the valve blockand, on remounting, use gasket pos. 80Q for the nozzle and gasket pos. 80L for thearmature tube. Tighten with the prescribedmoments of 10 and 50 Nm – see fig. 7.

On mounting the coil keep it in place byusing hand screw pos. 80N and O-ring pos.80K and 80M.

R717 One stage compr.

CMOMk 2 100 180

Num

ber

of c

ylin

ders 4

6

8

12

16

0.6

0.6

0.6

0.6

0.6

0.6

0.6

0.6

0.6

0.6

0.6

Booster compr.

CMOMk 2 100 180

0.6

0.6

0.6

0.6

0.6

0.6

0.8

0.8

0.8

0.8

0.8

Two stage compressor

TCMOMk 2 100 180

LP HPLP LP HP LP HP

0.6 1.0 0.60.6 0.8

0.60.8

HFC/ One stage compr.

CMOMk 2 100 180

4

6

8

12

16

0.6

0.6

0.6

0.6

0.6

0.6

0.8

0.8

0.8

0.8

0.8

Booster ompr.

CMOMk 2 100 180

0.6

0.6

0.6

0.8

0.8

0.8

1.0

1.0

1.0

1.0

1.0

Two stage compressor

TCMOMk 2 100 180

LP HPLP LP HP LP HP

0.6 0.80.6

0.6

HCFCSMC SMC SMC SMC

TSMC TSMC

TSMC TSMC

SMC SMC SMC SMC

Fig. 8

Num

ber

of c

ylin

ders

170 0171-370-EN

b: Float valve controlled oil return

Fig. 9

To the compressor

��

For the oil separators shown in fig. 1 and 2the float valve is built into the oil separator.After the oil separator has been depressu-rized, this valve can be removed by disman-tling of the bottom cover.

As to the oil separator types as shown in fig.3, drain the separated oil from the float valvepos. C, as outlined in fig. 9, once the valvespos. A and B are open. At a rising oil level

the float valve will open and lead the oil backto the compressor crankcase.

The filter pos. D and the float valve can becleaned by dismantling the threaded nippleon the stop valve housing and removing thecover on the float housing after the valvespos. A and B are closed and the pressure inthe compressor equalized to atmospheric.

0171

-339

-EN

93.1

1

Thread Pressure Pressure Air-cooled/ Air-cooled Booster Thermo-Pos. RG frame/ connect. water- with built-in with pump Normal appilication

(INCH) cover max. cooled oil-cooler oil-cooler

A 11/4 Suction Suction + + + + Heating rod

B 3/4 Suction Suction + + + + Oil charging valve

C 1/2 Suction Suction Plugged Plugged Plugged Plugged Applicable for thermostat KP 98 oil temp.

D 1/2 Suction Suction Plugged + + Plugged Thermostat KP 77

E 3/4 - 3/8 Suction H-pressure Plugged + + Plugged Inlet to built in oil cooler

F 3/4 - 3/8 Suction H-pressure Plugged + + Plugged Outlet from built in oil cooler

G 1/2 H-pressure H-pressure Plugged Plugged Plugged Plugged Applicable for KP 98

H 1/4 H-pressure H-pressure + + + + Equalizing pressure for pressure gauge

and pressure switch

J 3/8 Suction H-pressure Plugged + Plugged + Return from oil cooler/equalizing from

Thermopump

K 1/4 H-pressure H-pressure - - - + Injection from Thermopump

L 1/4 Suction Suction + + + + Suction pressure to pressure gauge and

pressure switch

M 3/8 Suction - Plugged Plugged Plugged - Available

N 1/4 Suction - + + + + Oil return from oil separator

O 1/4 Oil Oil + + + + Oil pressure to pressure gauge and

pressure switch

P 1/4 L-pressure H-pressure - - + + Return from oil cooler (Booster)

R 1/4 H-pressure H-pressure - - - + Liquid supply to Thermopump

S 1/4 H-pressure H-pressure - - - + Equalizing to suction side from Thermo-

pump

1 LP-suction stop valve + Is present on compressor block unit and used for

2 LP-discharge stop valve - Not present on compressor block

A B M R F S E O D C J

T0177142_0 V6

H N G L 1 2 K K K K,P

OLHGC

(OPT) KP15

MP55

only for CMO

0178-225-EN 171

�� 3#��

Thread Pressure Pressure Air-cooled/ Air-cooled Thermo-Pos. RG in frame/ connect. water- with built-in pump Normal application

(INCH) cover max. cooled oil cooler

A 11/4 Suction Suction + + + Heating rod

B 3/4 Suction Suction + + + Oil charging valve

C 1/2 Suction Suction Plugged Plugged Plugged Applicable for thermostat KP 98 oil temp.

D 1/2 Suction Suction Plugged + Plugged Thermostat KP 77

E 3/4 - 3/8 Suction H-pressure Plugged + Plugged Inlet to built-in oil cooler

F 3/4 - 3/8 Suction H-pressure Plugged + Plugged Outlet from built-in oil cooler

G 1/2 H-pressure H-pressure Plugged Plugged Plugged Applicable for thermostat KP 98

H 1/4 H-pressure H-pressure + + + Equilizing pressure for pressure gauge

and pressure switch

J 3/8 Suction - Available

K 1/4 H-pressure H-pressure - - + Injection from Thermopump

L 1/4 Suction Suction + + + Suction pressure to pressure gauge and

pressure control switch

M 3/8 Suction - Plugged Plugged - Available

N 1/4 Suction - + + + Oil return from oil separator

O 1/4 Oil Oil + + + Oil pressure to pressure gauge and

pressure switch

P 1/4 I-pressure H-pressure - + + Return from oil cooler/equalizing from Thermopump

R 1/4 H-pressure H-pressure - - + Liquid supply toThermopump

S 1/4 H-pressure H-pressure - - + Pressure equalizing from Thermopump

T 1/4 I-pressure I-pressure + + + Intermediate pressure to pressure gauge

U 3/8 H-pressure H-pressure + + + By-pass outlet

V 3/8 I-pressure H-pressure + + + By-pass inlet

X 1/2 H-pressure H-pressure + + + TEAT injection valve

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

A B M R F S E G O D C J

T0177142_0 V6

X H N L T V 3 1 U 2 P K

OLHGC

(OPT)

T

KP15

MP55

172 0178-225-EN

Connections on TCMO 28

0171

-333

-EN

97.0

3

0178-225-EN 173

B�� $� ��

��

#��

The piston compressor can be cooled withwater on the top and side covers, the coolingrequirement being dependent on the operat-ing conditions and the refrigerant on whichthe compressor operates.

See page 1 for details.

Water cooling is obtained by mounting an ex-tra cover (water cover) Pos. 2K/3K on theoutside of top and side covers with the inter-vening gaskets Pos. 2L and 3L and 2P/3P inbetween.

Tighten top and water covers with the boltsPos. 2C, which are longer than the bolts forthe air-cooled version.See the Spare-parts list at the end of this in-struction manual for details.

For water cooling of the side covers, only aspecial finned side cover Pos. 3A is used to-gether with a water cover Pos. 3K and a gas-kets Pos. 3L and 3P. These are also listed inthe spare-parts list.

The water cover, together with the cover onwhich it is mounted, forms a ducting systemin which the water is channelled back andforth and effectively cools the top or side cov-er. By virtue of their large surface area, the

cooling fins on the interior of the side coverPos. 3A provide excellent cooling of the oil inthe crankcase.

When dismantling top or side covers with wa-ter covers, it is a good idea first to dismantlethe topmost covers on the compressor. Inaddition, you should ensure that the two cov-ers are kept tight against the intervening gas-ket. This will prevent water flowing into thecompressor block.

Fitting cooling water hosesWhen supplied, the compressor is not fittedwith cooling water hoses or appurtenant as-sembling parts. These are provided loose.This avoids damage to the parts in transit. Fitthe cooling water hoses as shown in the fol-lowing drawing, corresponding to the specifi-cation enclosed with the delivery.

Please note:� The direction of water throughflow is

shown by arrows on the drawing.

� The hose length is indicated opposite therespective Pos. nos. on the drawing.

� The hoses must not be in contact with theframe, covers, discharge pipe or similarcomponents.

In the supply pipe to the water system a solenoid valve must be fitted which shuts off the water flow inthe refrigeration system at compressor standstill.

However, we do recommend to continue the water cooling for approx. 10 mins after the compressor hasbeen stopped as this protects the cooling water hoses against excessive temperatures

174 0178-225-EN

1

5

5

1

5

6

T0177142_0 V7

2

34

1

32

3

4

32

4

3Pos. A mmCMO 28 & TCMO 28

CMO 26

CMO 24

123456

365610150205230590

Pos. A mm

12345

370

Pos. A mm

12345

465520410260550

705275190575

2

Pos. A mm

12

710590

1

CMO 24-26-28

HPO 28

HPO 26

HPO 24

Mounting of hoses for cooling water

The flow direction of the water is indicated by

arrows on the sketch. The length of the hose

is indicated by A-measures in the table. The

hoses must not touch frame, discharge pipes

or similar.

Max. permissible inlet temperature: +40 °C

Min. permissible inlet temperature: +10 °C

Max. permissible outlet temperature: +55°C

Max. permissible temperature rise frominlet to outlet on the compressor: 15°C

Minimum water consumption is 5.5 litres perkW motor power.

0178-225-EN 175

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CMO 24HPO 24

CMO/TCMO 28HPO 28

CMO 26HPO 26

Volumetric flowV(l/hour)

Pressure lossp (mVS)

0171

-348

-EN

91.0

6

176 0171-370-EN

��

�� 16��16��16�

When the CMO or SMC compressor is usedfor air conditioning, you can choose to controlthe compressor capacity by means of one ortwo KP1 pressure cut-outs.

CMO compressors are all controlled by threesolenoid valves. When these are to be con-trolled with pressure cut-outs, cut-out A mustbe connected in parallel with solenoid valvesnos. 1 and 2. Cut-out B must be connectedwith solenoid valve no. 3.

The SMC 108 must be connected in thesame way as CMO.

The SMC 106 is controlled by two solenoidvalves, where pressure cut-out A must beconnected to solenoid valve no. 1 and cut-outB to solenoid valve no. 2.

The SMC 104 is controlled by a solenoid val-ve to be connected to pressure cut-out A.Only one cut-out is to be used for the SMC104.

If the compressor features a solenoid valvefor totally unloaded start, this must not be

connected to any of the above pressurecut-outs.

Pressure cut-out A must be set to a close ata pressure approx. 0.5 bar higher than thesetpoint for cut-out B.

A third cut-out, the low-pressure cut-out,must be set to break at a pressure equal tothe lowest evaporator temperature that canoccur, however, never lower than started insection Pressure and temperature settings.At this temperature, the compressor muststop. This control form provides the followingcapacity stages:

Capacity in %Capacity stage 1 2 3

CMO 24 100 50 25CMO 26 100 50 35CMO 28 100 50 25SMC 104 100 50 –SMC 106 100 66 33SMC 108 100 50 25

AB 2

1

13

2

SMC 106 SMC 108

2

3

2

4

1

1

AB

3

A

2 1

1

SMC 104

1 2 3

CMO

A B

0171

-359

-EN

97.0

3

0171-370-EN 177

�� $� ��

�� 166 �� 1�6

At two-stage operation it is necessary to coolthe discharge gas from the LP stage before itenters into the HP stage. This intermediatecooling is done with the systems describedbelow, depending on the type of refrigerantused.

Common for these intermediate cooling sys-tems is the fact that they must cool the inter-mediate pressure gas sufficiently and, at thesame time, ensure that no liquid is admittedinto the HP stage, as liquid can produce li-quid stroke in the HP cylinders and result inwear to the moving parts. It is important,therefore, to check the systems as indicatedbelow.

Intermediate cooling system withintermediate cooler type DVEA,R717

The two-stage R717 plant may consist of twocompressors, one low pressure compressor(LP) and one high pressure compressor (HP)as illustrated in fig. 1. The plant may alsoconsist of two-stage compressors as shownin fig. 2.

In both cases the compressors are con-nected to an intermediate cooler in which thewarm gas from the LP-stage is cooled downbefore it flows on to the HP-stage.

LP

MT

MT HT

CT

LP

HP

Suction

Fig. 1

•

••

•

•

Oil drain off

Intermediate

Oil separatorEqualizing pipe

Float valve

Oil separator

coolerLiquid subcooling

spiral

filter

CMO, SMC 100/180 compressor

Oil drain off

Intermediate

Liquid subcooling

HP

Float valve

Equalizing pipe

Suction filter

TCMO, TSMC 100/180 compressor

Oil separatorOil separator

CTLP IP

IPLP

cooler

Fig. 2

spiral

In the intermediate cooler, the liquid level ofR717 is regulated by the float valve and thedischarge gas from the LP stage is cooled bybubbling up through the refrigerant from thedistributor at the bottom of the intermediatecooler.

178 0171-370-EN

In the liquid subcooling spiral, the refrigerantflowing from the receiver to the evaporatorside of the refrigeration plant is cooled. Theintermediate cooler is dimensioned so thatthe cooled gas is free of liquid refrigerant be-fore leaving the top of the intermediate cool-er. It is important to check that the float valveis functioning correctly and keeping the liquidlevel constant. Frosting of the liquid levelpipe on the intermediate cooler indicates theliquid level.

In order to avoid violent foaming of the liquidin the intermediate cooler, the compressorshould run for a few minutes after start-up atthe lowest capacity stage to stabilize plantpressures. Capacity can then be increasedstage by stage at suitable time intervals.

Make sure that the equalizing pipe on the in-termediate cooler has been connected. Theequalizing pipe safeguards against backflowof liquid from the intermediate cooler to theLP stage of the compressor, when the com-pressor is not working.

At regular intervals, the intermediate coolermust be drained of oil through the oil drainvalve.

Intermediate cooling system withliquid injection into the intermedi-ate discharge gas, R22 and R717

Two-stage compressors can be equippedwith a pipe connection from the LP stage out-let branch to the HP stage suction branch asshown in fig. 3.

In the pipe connection the hot discharge gasfrom the LP stage is cooled by injection of

liquid refrigerant into the intermediate pipe.This is achieved with the following systems 1and 2:

1: Intermediate cooling with thermostaticexpansion valve type: TEA (R717) or TEX (R22)TCMO and TSMC 100/180

TCMO and TSMC

CT

LP HPIP

IPLP

LP

Opt.

Fig. 3

•

B•

80

•

TEA or TEX

•

Mixing chamber

Oil separator

Suction filter (opt.)

In the system in fig. 3 the liquid refrigerantconveyed to the intermediate pipe is regu-lated by a thermostatic expansion valvetype TEA (R717) or TEX (R22) with a sen-sor placed on the intermediate pipe close tothe HP stage.

A valve block pos. 80 is built into the liquidsystem.

Connection, pos. B, pipe dimension OD 10mm, emerges from receiver or priority vesseland is conveyed to valve block pos. 80 whichis the same type as the one described in sec-tion entitled: Solenoid controlled oil return ofthis instruction manual.

Please note:that nozzle size pos. 80I must be 3.3 mm.

0171-370-EN 179

It is essential to make sure that the inter-mediate cooling system functions correctly inorder to prevent too much liquid refrigerantfrom being injected into the IP gas.

Too much liquid refrigerant may impede theevaporation of the liquid before the IP gas issucked into the HP stage of the compressor.This may result in liquid hammer and wearand tear on moveable parts.

The expansion valve must be adjusted to su-perheat the intermediate gas at a temper-ature not below 10 K.

This is done by measuring the pressure andthe temperature of the intermediate gas be-fore it enters the compressor to the HPstage. (For this purpose SABROE hasmounted an empty sensor pocket. To ensurean exact measurement the pocket can befilled with oil before the thermometer isintroduced).

Compare the measured values with thecurves in fig. 4. For any given intermediatepressure the temperature must be close tothe curve, but never below.

XX

4��

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4�

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4

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° temperature HP suction side

R717

R22

X X

• •X

X

X

XX

X

Fig. 4

Intermediate pressure (bar)

Position the sensor of the expansion valve onthe intermediate pressure pipe immediately

before the HP-stage suction filter. The sensormust be fitted on the side of the pipe and in-sulated as shown in fig. 5

�#

�

.��

/��

��

Note:

� The necessary superheat of 10 K is in-cluded in the curve, fig. 4.

� An exact measurement of the temperaturecannot be read until after a stabilisationperiod which is not under 5 minutes forR22 and not under 15 minutes for R717.

� Before the initial adjustment of the valve itmust be adjusted to its highest level tomake sure that the superheat is above 10K. Do this by turning the spindle 20 turnsclockwise for R717 and 2.5 turns for R22.The superheat can now be regulated onthe basis of measurements and the curvesin fig. 4.

� The valve for R717 changes the super-heat 0.5 K per rotation of the adjustingscrew. The valve for R22 changes the su-perheat 4 K per rotation. By turning the adjusting screw clockwisethe superheat is increased. By turning thescrew anti-clockwise the superheat isreduced.

� SABROE has adjusted the valve to 10 Ksuperheat.

180 0171-370-EN

2: Intermediate cooling with thermostaticinjection valve type: TEAT (R22)TCMO and TSMC 100/180

Different systems are applied for TCMOand TSMC 100/180 as described below insections A and B.

Fig. 6

�

From receiver

To evaporator

Liquid tank 4L

$"

/"!"

Suction filter

�+"��

Oil separator

TEAT

80

Liquid subcooler

A: TCMO

As illustrated in fig. 6 the intermediate gas iscooled by injecting refrigerant into the lowpressure stage pressure chamber in thecompressor. The liquid is thoroughly mixedwith the hot discharge gas by means of thedistributor pos. 83A as may be seen fromfig. 7.

Fig. 7

83A

•

For sub-cooling of liquid to the evaporatorsthe injected liquid first passes a liquidsub-cooler, mounted on the compressor.The liquid injection is controlled by a TEATvalve.

B: TSMC 100/180

From receiver

Mixing chamber

Oil separator

To evaporator

Liquid supply

T

CT

HESI

A

LP HPIPIPLP

LP

Fig. 8�+"��

TEAT

On TSMC 100 and 180 plants, the intermedi-ate cooling system can be designed as illus-trated in fig. 8, in which the intermediate cool-ing is carried out by a thermostatic injectionvalve of the TEAT type, and in which the sub-cooling takes place in a HESI heat exchang-er.

0171-370-EN 181

Adjusting the TEAT valve:

For both systems, A and B, the following applies: The sensor of the TEAT valve is placed in asensor pocket at the discharge branch of thecompressor, and a proper thermal contact isobtained by means of the heat conductingcompound.

The solenoid valve is opened by the KP77thermostat whenever the temperature of thepressure pipe is above 55°C.

It is important to make sure that the interme-diate cooling system functions correctly andthus prevent too much refrigerant from beinginjected into the intermediate pressure gas.

Excess refrigerant may lead to the liquid be-ing unable to evaporate before the intermedi-ate pressure gas is sucked into the HP stageof the compressor and may thus cause liquidstrokes and wear to the moving parts.

When supplied, the TEAT valve is factoryset to the following regulating temperatures:

Refrigerant Regulating temp.

R22

R717 75 C°

75 C°

Before using the valve, the regulating tem-perature must be changed to the same valueas the discharge gas temperature indicatedin the table Anticipated discharge gas tem-peratures in this instruction manual.

Adjustments are made by rotating the regu-lating spindle clockwise, 5 turns for every10K of temperature increase.

Example:

Regulating temperaturefactory setting 75°C

Estimated dischargegas temperature

IT = –10°CCT = 35°C 96°CSuperheat = 20°C

Refrigerant R22

Adjustment

96 – 75 x = 10.5 revolutions510

Under all circumstances, the regulating tem-perature of the valve must be raised at least10K, corresponding to 5 revolutions (clock-wise).

When the plant has stabilized and the com-pressor is working at 100% capacity, the val-ve must be readjusted to the same value asthe discharge temperature with the Antici-pated discharge gas temperature in the table,within -5K to +10K. (In the example, 91°C <96°C < 106°C)

At reduced compressor capacity, the dis-charge gas temperature may rise somewhat;under these circumstances it should bechecked that the discharge gas temperaturedoes not exceed the Set point for the KP98.

0171

-466

-EN

94.0

5

182 0178-925-EN

��

When placing an order for spare parts,please state the following:

1. Shop No.

All compressors are fitted with an identifica-tion plate, which states the type and shop no.of the compressor and indicates what refrig-erant is to be used.

2. Part No.

Spare parts drawings and parts lists insertedin an instruction manual identify spare partswith the following:

a) Spare part no. – which is a referencenumber to facilitate finding a part in thedrawing and cross-referencing in the partslist or vice versa.

b) Designation of the part.

c) Part no. – a 7-digit number which refers toSABROE’s stores.

When you order spare parts, please alwaysadvise at least the designation and part num-

ber. If you are in any doubt, add the sparepart no. too.

3. Forwarding instructions

When ordering spares, please advise the for-warding address, and the address to whichthe invoice should be sent. If appropriate,please state the name of your local bank, theway in which you want the goods transportedand required delivery date.

4. Classification certificate

If you require a certificate from a Classifica-tion authority, please mark the order appropriately, as the inspection and issuingprocedures take extra time and incur extraexpenses.

5. Quotation No.

If a quotation no. has been given during earli-er correspondence, please refer to this whenplacing your order – it will help us to identifyand execute your order quickly.

0171

-941

-EN

97.0

3

0171-941-EN 183

��

��3�� 3�� 166 � ��3�� 1�6

On servicing compressor and unit it is alwaysan advantage if you, as our customer, havesome of the most commonly used spareparts at your disposal. This enables you or asummoned SABROE service engineer tocarry out the necessary service work withouthaving to spend extra time on procuring thespare parts needed.

Spare parts are obtainable in sets as men-tioned in the following.By contacting SABROE’s local representa-tive it is possible to receive a list of the sparepart sets recommended by SABROE.

Compressor block

� Standard spare part setContains a suitable selection of O-rings as well as valve ring plates and valvesprings.

� Extended spare part setFurther to the parts included in the stan-dard spare part set this set contains acylinder lining and discharge valve as wellas an extended number and types of gas-kets and fittings.

� Certificate spare part setFurther to the parts from the extendedspare part set this set contains a majornumber of components and wearing partsselected by the classification societies.

� Special spare part setThis is a more compehensive set than theextended spare part set as almost all O-rings and gaskets are included and forthe most wearing parts the number ofparts has been extended.

Spare part set for Basic Unit

� Standard spare part setThis is a set consisting mainly of O-ringsand gaskets for some of the componentsincluded in the unit.

� Certificate spare part setFurther to the parts from the standardspare part set this set contains other com-ponents selected in accordance with therequirements of the classification soci-eties.

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