smc_104-106-108_en

Christian Xs Vej 201, P.O. Box 1810, DK-8270 Hjbjerg, DenmarkPhone +45 86 27 12 66 . Fax +45 86 27 44 08

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

Reciprocating Compressor

0178-915-EN Rev. 00.02

00.01

0178-910-EN 1

# !"

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

Some of these variants are discussed in this

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

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

UNISAB II Control- and regulating system

Analogue Control System

Thermopump

Water cooled top and side covers

Air cooled top and side covers

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

Coupling

V-belts

Pinion drive

Chain drive

Control

Compressor

Oil pump drive

RefrigerantSerial number

Compressor type

cooling

Drive type

Equipment for parallel operation

SABROE OVUR-type oil separator

Explosion-proof electrical design

Designation

R717 R22 R134a R404A R507 _____

0171

-500

-EN

96.0

6

2 0171-702-EN

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

the function and maintenance of theindividual components;

service schedules;

procedure for dismantling andreassembling of the compressor.

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

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

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

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

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

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

SABROE REFRIGERATION A/S

P.O. Box 1810, DK8270 HjbjergChr. Xs Vej 201, rhus, Denmark

Phone: Telefax: +45 86 27 44 74

+45 86 27 12 66

0178-910-EN 3

!

Specifications for SMC 104-106-108 Mk3 and TSMC 108 Mk3, S-L-E 1. . . . . . . . . . . . . . . Preface 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . List of Contents 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . First Aid for accidents with Ammonia 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . First Aid for accidents with HFC/HCFC 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Protecting the environment 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description of compressor 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Handling of the compressor, areas of application, safety equipment etc. 16. . . . . . . . . . . . . Sound data for reciprocating and screw sompressor units - all types of compressors. 17. Vibration data for compressors - all types 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compressor data for reciprocating compressor 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

4 0178-910-EN

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

Expected discharge gas temperatures 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Servicing the refrigeration plant 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance of reciprocating compressor 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

Heating rods for heating the oil in reciprocating and screw compressors 88. . . . . . . . . . . . . Stop valves pos. 23 and 42 89. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Monitoring cylinder lining insertion 90. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Pressure gauges 93. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Undersize Bearing Diameters for Crankshaft 95. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sundry clearances and check dimensions 96. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0178-910-EN 5

Torque moments for screws and bolts 97. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refrigeration Plant Maintenance 99. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

Selecting lubricating oil for SABROE compressors 113. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Data sheet for listed Sabroe oils 119. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

List of major oil companies 141. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alignment of unit, AMR coupling 143. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fitting and alignment of AMR-type coupling 146. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boring of motor flange for AMR coupling 149. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-belt drive for piston compressor types (T)CMO and (T)SMC 150. . . . . . . . . . . . . . . . . . . . . . Oil Separator OVUR for SMC/TSMC 100 HPC - SMC/TSMC 180 152. . . . . . . . . . . . . . . . . . . Connections on SMC 104-106-108 Mk3, HPC 104S-106S-108S 156. . . . . . . . . . . . . . . . . . . .

Connections on TSMC 108 Mk3 157. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil return in parallel operation for reciprocating compressors 158. . . . . . . . . . . . . . . . . . . . . . . Reciprocating compressors used for air conditioning 161. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water-cooling of reciprocating compressors 162. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure loss in water cooling on SMC/TSMC/HPC compressors 165. . . . . . . . . . . . . . . . Thermo pump cooling of R717 reciprocating compressors 166. . . . . . . . . . . . . . . . . . . . . . . . .

Principle drawings 167. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil cooling with an OSSI or HE8S oil cooler 175. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HFC and HCFC compressors: 175. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling of the intermediate gas on TCMO and TSMC 100 and 180 176. . . . . . . . . . . . . . . . . Ordering Spare Parts 181. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spare parts sets for compressors and units 182. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Compressor block 182. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spare part set for Basic Unit 182. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

List of parts for SMC/TSMC 0661-680. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tools for compressor SMC/TSMC 0661-684. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spare Parts drawing 0661-521/0661-522. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spare Parts drawings (in detail) 0661-520. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piping diagram order specific. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiring diagram order specific. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dimension sketch order specific. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling water diagram order specific. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Foundation order specific. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Positioning of vibration dampers order specific. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 0178-910-EN

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

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.

Inhalation1. Move affected personnel into fresh air im-

mediately, and loosen clothing restrictingbreathing.

2. Call a doctor/ambulance with oxygenequipment immediately

3. Keep the patient still and warmly wrappedin blankets.

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

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

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

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

Eye injuries from liquid splashes orconcentrated vapour1. 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.

0170

-008

-EN

96.0

1

0178-910-EN 7

Skin burns from liquid splashes orconcentrated vapour1. Wash immediately with large quantities of

water 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.

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

8 0178-910-EN

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

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. 300C 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.

Inhalation1. 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 injuries1. Force eyelids open and rinse with a sterile

isotonic (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 burns1. Wash immediately with large quantities of

luke warm water to reheat the skin. Continue for at least 15 minutes, removingcontaminated clothing carefully whilewashing.

2. Treat exactly like heat burns and seekmedical advice.

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

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

0170

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0178-910-EN 9

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 0C. Thismeans that liquid refrigerants can be extre-mely harmful if they come into contact withskin or eyes.

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

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

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

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

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

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

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

R717

vol.% 0,1 0,005

vol.% 0,2 0,002

R134a R404A R507 R22

0,10,10,1

R407C

0,1

HCFCHFC

R410A

0,1

Halogenated refrigerants Ammonia

Unit

Time weighted ave-rage during a week

Warning smell

TWA

10 0178-910-EN

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

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

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

Ammonia is easily absorbed by water:At 15C, 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.

0178-910-EN 11

Lubricating oilsRefrigeration 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 plants ves-sels, always collect the used oil in containersmarked waste oil and send them to an ap-proved incinerating plant.

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

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12 0178-910-EN

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

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

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

SABROE

Shop noMax. speed

Test pressureWorking pressureSwept volume

Type Refrigerant

barbar

r.p.m.

T0177093_2

AARHUS DENMARK

m3/h

Year

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

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

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

0178-910-EN 13

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

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

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

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

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

SMC 104 x xSMC 106 x x xSMC 108 x x x xTSMC 108 x x x

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

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14 0178-910-EN

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

Note:

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

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

clearly marked with red paint. The weight ofthe unit is stated on the package as well as inthe shipping documents.During transportation and handling careshould be taken not to damage any of thecomponents, pipe or wiring connections.

Areas of application of the recipro-cating compressorsCompressor types: BFO 3-4-5CMO-TCMO, SMC 100-TSMC 100 Mk3, S, L, ESMC 180-TSMC 180, HPO-HPCIn view of preventing an unintended applica-tion of the compressor, which could causeinjuries to the operating staff or lead to tech-nical damage, the compressors may only beapplied for the following purposes:

The compressor may ONLY be used: As a refrigeration compressor with a num-

ber of revolutions and with operating limitsas indicated in this manual or according toa written agreement with SABROE.

With the following refrigerants:R717 R221 R134a1 R404A1 R410A1 R5071 R6001 R600A1 R2901 LPG1 1) Exempted are the following compres-sors:

SMC-TSMC 100 E (only R717)HPO and HPC (only R717 and R410A))All other types of gas may only be used following a written approval from SABROE.

As a heat pump:

0178-910-EN 15

BFO 3-4-5

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

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

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

The compressor must NOT be used: For evacuating the refrigeration plant of air

and moisture, For putting the refrigeration plant under air

pressure in view of a pressure testing, As an air compressor.

Emergency deviceThe 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 means

of an easily recognizable and visible

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

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

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

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

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

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

T2516273_0

16 0178-910-EN

The temperature of tangible surfacesWhen 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 70C which formetal surfaces may cause your skin to beburnt even at a light touch.

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

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

0170

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0178-910-EN 17

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

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

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

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

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

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

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

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

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

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

Dimensional tolerances are:

3 dB for SAB, SV and FV screw com-pressors5 dB for VMY screw compressors

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

The dimensional values are stated for 100%capacity.

Fictional frame

Reflecting plane

Fig. 1

1 meter

Dimensional plane

1 meter

18 0178-910-EN

Note the following, however:

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

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

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

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

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

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

0178-910-EN 19

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

Compressor block LW LP

CMO 24 84 69CMO 26 86 71CMO 28 87 72SMC 104 S 95 79SMC 106 S 96 80SMC 108 S 97 81SMC 112 S 99 82SMC 116 S 100 83SMC 104 L 96 80SMC 106 L 97 81SMC 108 L 98 82SMC 112 L 100 83SMC 116 L 101 84SMC 104 E 96 80SMC 106 E 97 81SMC 108 E 98 82SMC 112 E 100 83SMC 116 E 101 84

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


SMC 186 101 83SMC 188 102 84

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

TCMO 28 81 66TSMC 108 S 95 79TSMC 116 S 97 81TSMC 108 L 96 80TSMC 116 L 98 82TSMC 108 E 96 80TSMC 116 E 98 82

LW LPCompressor block

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


TSMC 188 100 82

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

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


20 0178-910-EN

SCREW COMPRESSORSEvaporating temperature = 15CCondensing temperature = +35CRefrigerant = 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 81SAB 128 HM Mk2 102 84SAB 128 HF Mk2 106 88SAB 128 HM Mk3 101 84SAB 128 HF Mk3 104 86SAB 128 HR* 102 84SAB 163 HM Mk2 105 86SAB 163 HF Mk2 109 90SAB 163 HM Mk3 103 86SAB 163 HF Mk3 106 87SAB 163 HR* 103 85SAB 202 SM 104 85SAB 202 SF 105 86SAB 202 LM 104 85SAB 202 LF 105 86SAB 330 S 106 87SAB 330 L 106 87SAB 330 E 106 87SV 17 100 83SV 19 101 84FV 19* 101 86SV 24 103 85FV 24* 104 86SV 26 103 85FV 26* 107 85SAB 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 = 35CCondensing temperature = 5CRefrigerant = R22/R717Number of revolutions = 2950 rpm.

Compressor unit LW LP

SAB 163 BM 106 88SAB 163 BF 110 92

Evaporating temperature = 15CCondensing temperature =+35CRefrigerant = R22/R717Number of revolutions = 2950 rpm.


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

Evaporating temperature = 0CCondensing temperature =+35CRefrigerant = R22/R717Number of revolutions = 2950 rpm.


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

0170

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0178-910-EN 21

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

ISO 2372 group C

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

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

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

Ranges of vibration severityExamples of quality judgement

for separate classes of machines

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

0.280.450.711.121.82.84.57.1

11.2182845

71

0.280.450.711.121.82.84.57.1

11.2182845

A

B

C

D

A

B

C

D

A

B

C

D

A

B

C

D

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

Pay attention to the following, however:

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

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

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

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

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

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

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

Jesper Jensen

0171

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22 0178-910-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

TCC

30

20

10

60 50 40 30 20 10 0 10 20 30 40

0

10

20

30

40

50

60

70

T245

400_

0/2

Cond

ensi

ng te

mpe

ratu

re

Evaporating temperature

C70

40

76 58 40 22 4 14 32 50 68 86 104 F94

F

22

4

14

32

50

68

86

104

122

140

158

40

0178-910-EN 23

R717Operating limits

single stagecompressors

CMOSMC 100 S-L

SMC 180

Type Area rpm Coolingmax min Booster Single and HP-stage compr.

12 Air-cooled top- and side covers # - or water-cooledCMO 20

3-41800 900

Water-cooled Thermopump or water-cooled1-2 Air-cooled top- and side covers # - or water-cooled

SMC 100 S-L 31500

7004 1200

Water-cooled Thermopump or water-cooled

1 750SMC 180 2-3 1000 450 Water-cooled

4 900

# Including refrigerant-cooled oil coolerThermopump: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 150C/302F

T245

400_

0/2

TE

TCC

30

20

10

60 50 40 30 20 10 0 10 20 30 40

0

10

20

30

40

50

60

70

Cond

ensi

ng te

mpe

ratu

re


C70

40

76 58 40 22 4 14 32 50 68 86 104 F94

F

22

4

14

32

50

68

86

104

122

140

158

40

24 0178-910-EN



SMC 100 E

Type Area rpm Coolingmax 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

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

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

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

0178-910-EN 25


two-stagecompressors

TCMOTSMC 100 S-L-E

TSMC 180

Type Area rpm Cooling Notemax min top and side

TCMO 12 1800 900 Thermopump or water-cooledTSMC 100

S-L-E 1-2 1500 700 Thermopump or water-cooled 1)1 750 1)TSMC 1802 1000

450 Water-cooled 1)

Oil cooling is always necessary.Thermopump:Only the HP Stage top covers are cooledby a thermo pumpOil cooling included in the systemWater-cooled:Top- and side covers.Oil cooling included in the system.

Part-load operation:1)

Depending on the operating conditionsand the presure on the compressor a by-pass system may be required.

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

0177

128_

0 VI

EW 3

,1

TE

TCC

30

20

10

60 50 40 30 20 10 0 10 20 30 40

0

10

20

30

40

50

60

70

Cond

ensi

ng te

mpe

ratu

re


C70

40

76 58 40 22 4 14 32 50 68 86 104 F94

F

22

4

14

32

50

68

86

104

122

140

158

40

TE

TCC

30

20

10

60 50 40 30 20 10 0 10 20 30 40

0

10

20

30

40

50

60

70

Cond

ensi

ng te

mpe

ratu

re


C7040

76 58 40 22 4 14 32 50 68 86 104F94

F

22

4

14

32

50

68

86

104

122

140

158

40

0177

128_

0 VI

EW 4

,1

26 0178-910-EN

R22Operating limits


CMOSMC 100 S-L

SMC 180

Type Area rpm Oil-cooling Notemax min required 1)

1 no2

1500noCMO

3900

At less than 50% capacity4

1800yes

1 1000 no2 1200 noSMC 100 S3 1500

700At less than 50% capacity

4 1200 yes1 Not applicable2 1000 noSMC 100 L3 1200 700 At less than 50% capacity4 1000 yes

1-2 Not applicableSMC 180 3 At less than 50% capacity

4 750450

yes

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

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

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

thermostatic expansion valve.

TE

TCC

30

20

10

60 50 40 30 20 10 0 10 20 30 40

0

10

20

30

40

50

60

70

Cond

ensi

ng te

mpe

ratu

re


C70

40

76 58 40 22 4 14 32 50 68 86 104 F94

F

22

4

14

32

50

68

86

104

122

140

158

40

0177

128_

0 VI

EW 5

,1

0178-910-EN 27

R22 Operating limits


TCMOTSMC 100 S-L

TSMC 180


1-2 1500TCMO

3-4 1800900 no

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

4 15001 Not applicable

TSMC 2 1000 2)100 L3-4 1200

700 yes 2)

1-2 Not applicableSMC 180

3-4 750 450 yes 2)





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

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

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

28 0178-910-EN

R134a Operating limits


CMOSMC 100 S-L

Type Area rpm Oil-cooling Notemax min required 1)1200 no

1-21500 At less than 50% capacityCMO1500

900no

31800 At less than 50% capacity

1 1000 no2 1200 noSMC 100 S

1200700

no3

1500 At less than 50% capacity1 Not applicable2 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.



T017

7128

_ V8

,1

TE

TCC

30

20

10

60 50 40 30 20 10 0 10 20 30 40

0

10

20

30

40

50

60

70

Cond

ensi

ng te

mpe

ratu

re


C70

40

76 58 40 22 4 14 32 50 68 86 104 F94

F

22

4

14

32

50

68

86

104

122

140

158

40

80 176

0178-910-EN 29

R134a Operating limits


TCMOTSMC 100 S-L


1-2 1500 1)TCMO 283 1800

900 1)

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

3 15001 Not applicable

TSMC 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.

T017

7128

_0 V

8,1

TE

TCC

30

20

10

60 50 40 30 20 10 0 10 20 30 40

0

10

20

30

40

50

60

70

Cond

ensi

ng te

mpe

ratu

re


C70

40

76 58 40 22 4 14 32 50 68 86 104F94

F

22

4

14

32

50

68

86

104

122

140

158

40

30 0178-910-EN

R404A Operating limits


CMOSMC 100 S-L

Type Area rpm Oil-cooling Notemax min required 1)1200 no

11500 At less than 50% capacityCMO 201500

900no


1 1000 noSMC 100 S 1200 700 no


1 1000 noSMC 100 L

2 1200700

no





2742

63.1

Rev

. 0

TE

TCC

30

20

10

60 50 40 30 20 10 0 10 20 30

0

10

20

30

40

50

60

Cond

ensi

ng te

mpe

ratu

re


C70

76 58 40 22 4 14 32 50 68 86 F94

F

22

4

14

32

50

68

86

104

122

140

0178-910-EN 31

R404A Operating limits


TCMO TSMC 100 S-L


1 1)TCMO 282

1800 900 1)

TSMC 1 1200 1) 2)100 S 2 1500

700 1) 2)

TSMC 1 1000 1) 2)100 L 2 1200

700 1) 2)




2742

63.3

Rev

. 0

TE

TCC

0

10

20

60 50 40 30 20 10 0

30

40

50

60

Cond

ensi

ng te

mpe

ratu

re


C7010

76 58 40 22 4 14 32 F94

F

32

50

68

86

104

122

140

14

32 0178-910-EN


single stagecompressors CMOSMC 100 S-L


1 1200 no2 1500 At less than 50% capacity

CMO 202 1500

900no

3 1800 At less than 50% capacity1 1200 no

SMC 100 S 2 1200 700 no3 1500 At less than 50% capacity1 1000 no

SMC 100 L2 1200

700no





7426

3.2

Rev.

0

TE

TCC

30

20

10

60 50 40 30 20 10 0 10 20 30

0

10

20

30

40

50

60

Cond

ensi

ng te

mpe

ratu

re


C70

40

76 58 40 22 4 14 32 50 68 86 F94

F

22

4

14

32

50

68

86

104

122

140

40

0178-910-EN 33



TCMO TSMC 100 S-L

Area rpm Oil-cooling NoteType

max min required 1)1 1)TCMO 282

1800 900 1)

TSMC 1 1200 1) 2)100 S 2 1500

700 1) 2)

TSMC 1 1000 1) 2)100 L 2 1200

700 1) 2)




2742

63.4

Rev

. 0 TE

TCC

0

10

20

60 50 40 30 20 10 0

30

40

50

60

Cond

ensi

ng te

mpe

ratu

re


C7010

76 58 40 22 4 14 32 F94

F

32

50

68

86

104

122

140

14

34 0178-910-EN

R407COperating Limits

one-StageCompressor type

CMO & SMC


1 1500 noCMO 2 900 At less than 50% capacity

31800

yes1 1200 no

SMC 100 S 2 1500 700 At less than 50% capacity3 1200 yes1 1000 no

SMC 100 L 2 1200 700 At less than 50% capacitySMC 100 L 3 1000 yes

1 NOT APPLICABLESMC 180 2 At less than 50% capacity

3 750450

yes





Cond

ensi

ng te

mpe

ratu

re


TE

30

20

10

0

10

60 50 40 30 20 10 0 10 20 30

20

40

50

30

60

TC

76 58 40 22 4 14 32 50 68 86 F94

F

22

4

14

32

50

68

86

104

122

140

T245411_0 view 2

C70

C

0171

-461

-EN

96.0

6

0178-910-EN 35

Starting up compressor and plant Before the initial start-up of the compres-

sor following a lengthy stand-still period ofseveral months, the compressor must beprelubricated. Hereby, the bearings arelubricated and the oil system filled upwith oil before the compressor is set run-ning.Carry out the prelubrication by connect-ing the oil pump to the prelubricatingvalve which in the more recent SMC-TSMC-HPC compressors is connected tothe shaft seal housing pos. 6A and on theCMO-TCMO-HPO to the cover pos. 86Hor 87K. As prelubricating pump we recom-mend SABROEs 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

LitersCMOTCMOHPOSMC 104106-108TSMC 108HPC

SMC 112-116TSMC 116SMC 186-188TSMC 188

appr. 25

appr. 35

appr. 45

appr. 50

2.5

3.5

4.5

5.0

oil pump

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

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

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

Check correct setting of safety auto-matics on compressor.

Open discharge stop valve at compressor.

Set capacity regulator to minimum capa-city.

36 0178-910-EN

In order to avoid excessive pressure re-duction in the compressor on startup, 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 ofstandstillBefore 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 a

few minutes before stopping the plant.

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

Stop condenser cooling, pumps, fans andany compressor cooling.

Cut off power supply to both master andcontrol currents.

0178-910-EN 37

Stopping plant for lengthy periods(more than 2-3 days) Shut off main valve after receiver and

pump 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 put

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

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

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

air compressor for high pressure;

nitrogen.

ImportantThe plant compressors must not beused to pressurize the plant.Water or other fluids must not be usedfor pressure testing.

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

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

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

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

38 0178-910-EN

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

The test pressure must never exceed thedisign pressure.

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

HP side: 24 barLP side: 17.5 bar

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

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

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

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

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

date of pressure testing,

person carrying out the test,

comments.

Pumping down refrigeration plantFollowing 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 100C. 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

5101520

6,639,14

12,7317,80

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

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

ImportantNever use the refrigeration compressorto evacuate the plant.

0178-910-EN 39

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

It is recommended to carry out evacuation asfollows:

Evacuate to a pressure lower than 5 mmHg.

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

Repeat evacuation to reduce pressure toless than 5 mm Hg.

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

40 0178-910-EN

Operating log

In order to keep tabs on the operating stateof the refrigeration plant, it is recommendedthat 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 motorsconsumption in amps.

Oil level sight glassin compressor

UNISAB II Control

Compressor pressure gauge UNISAB II Control

Observation Measuring point Measurement unit

Date and timeTime

Suction pressure

Oil pressure

Oil temperatureSuction gas temp.

Discharge gas temp.

Recharding of oil oncompressor

Discharge pressure

Compressor pressure gauge UNISAB II Control Compressor pressure gauge UNISAB II Control

Thermometer in suction pipe immediately

before compressor UNISAB II Control Thermometer in discharge pipe

immediately after compressor but before oil separator

UNISAB II Control

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

0171

-462

-EN

99.0

3

0178-910-EN 41

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

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

S The following must therefore be checkeddaily:

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

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

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

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

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

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

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

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

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

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

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

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

42 0178-910-EN

1. Run compressor at lowest capacity 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.

R22Evacuating pump

42

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

Water

R717

42

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

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

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

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

0178-910-EN 43

Operatinghours

< 1200 rpm

Operatinghours

> 1200 rpmActivity

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.

3.2 Clean suction filter.3.3 Check that following function correctly:

Solenoid valves Compressor cooling Thermopump Safety automaitcsHeating rodV-belt drive Oil return system from oil separator.

3.4 For heat pump operation, inspect: Valve seats Cylinder linings Pistons, gudgeon pins and gudgeon pin bearingsPiston and oil scraper rings.Change suction and discharge valve ring plates.

3.5 Finish off with a pressure drop test.

7500 50003

44 0178-910-EN

Operatinghours

< 1200 rpm

Operatinghours

> 1200 rpmActivity

15000 10000

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

4.2 Clean suction filter.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 drive5.2 For heat pump operation, inspect:

Valve seats Cylinder linings Pistons, gudgeon pins and gudgeon pin bearings Piston and oil scraper rings.Change:Suction and discharge valve ring plates.

5

0178-910-EN 45

OperatingHours

< 1200 rpm

OperatingHours

> 1200 rpmActivity

30000 20000

No.

6

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

6.2 Clean suction filter.6.3 Check following:

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

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


60000 40000 Major overhaul; contact SABROE Refrigeration

37500 25000 As for service no. 5



7

8

9

10

Then repeat scheduled services from no. 3 inclusive.

46 0178-910-EN

Lubricating oil requirementsAbove 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 compressorsS Only fresh, clean refrigeration machine oil

may be charged. Oil tapped from theevaporator system in an ammonia plantmust not be reused in the compressor.

S Use grade of oil originally prescribed forcompressor.

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

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

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

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

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

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

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

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

0178-910-EN 47

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

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

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

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

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

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

S Avoid getting air or other impuritiessucked into compressor.

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

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

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

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

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

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

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

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

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

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

S Dismantle side covers.

S Replace oil filter cartridge with a new one.

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

S Reassemble side covers.

S Charge to correct level with fresh, cleanrefrigerator oil according to SABROEs oilrecommendations.

S Connect heating cartridge.

48 0178-910-EN

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

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

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

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

0178-910-EN 49

CompressorType Size

Volume of oil in crankcase

Litres

BFO

CMOTCMO

SMC 100TSMC 100

Mk 3

SMC 180TSMC 180

345

242628

104106108112116

186188

1,545

141618

2628304750

8090

4 13

S-L-E

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

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

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

S type of refrigerant

S refrigerant charge (volume)

S size of plant

S temperature range in which refrigerationplant is to operate.

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

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

T0177162_0

Compressortype size

10 millimeter difference in

oil levels equals

SMC /TSMC100S-L-ESMC /TSMC180

CMO/TCMO

242628

~1 litre of oil

104106108

~2 litres of oil

112116 ~6 litres of oil

186188 ~6 litres of oil

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

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

50 0178-910-EN

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

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

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

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

S be clear and shiny

S not contain any visible particles

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

If you dont 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

smc_104-106-108_en

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