Instruction Manual SMC 186-188/TSMC 188

Reciprocating compressor

0178-900 - ENG

04.02

0178-900-EN 1

Instruction manual forSMC 186-188 Mk2 and TSMC 188 Mk2

The SMC/TSMC-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 thisinstruction 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.

Explosion-proof execution

UNISAB II

Analogous

Water cooling (top- and side covers)

Oil cooling (Water-cooled side covers)

Coupling

V-belt

Control

Compressor

Refrigerant

Serial number

Compressor type

cooling

Drive type

Equipment for parallel operation

Oil separator

Designation

R717 R22 _____

0171-500-EN

00.07

2 0178-900-EN

Preface

The aim of this instruction manual is to pro-vide the operators with a thorough knowl-edge of the compressor and the unit and atthe same time provide information about:

S the function and maintenance of the indi-vidual components;

S service schedules;

S procedure for dismantling and reassem-bling of the compressor.

This instruction manual draws attention totypical errors which may occur during opera-tions. The manual states causes of error andexplains what should be done to rectify theerrors in question.

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

this instruction manual to ensure a safe, reli-able and efficient operation of the product asSabroe Refrigeration is unable to provide aguarantee against damage of the product oc-curring during the warranty period as aresult of incorrect operation.

Dismantling and assembly of compressorsand components should only be carried outby authorized personnel to preventaccidents.

The contents of this instruction manual mustnot be copied or passed on to any unautho-rized person without SabroeRefrigerations permission.

Sabroe Refrigerations General Conditionsfor the Supply of Components and SpareParts will apply.

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

0178-900-EN 3

Table of Contents

Instruction manual for SMC 186-188 Mk2 and TSMC 188 Mk2 1. . . . . . . . . . . . . . . . . . . . .Preface 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Table of Contents 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .First Aid for Accidents with Ammonia 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .First Aid for Accidents with HFC/HCFC 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Protecting the Operator as well as the Environment 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Description of compressors SMC 186-188 Mk2, TSMC 188 Mk2 11. . . . . . . . . . . . . . . . . . . .Handling of the compressor, areas of application, safety equipment etc. 13. . . . . . . . . . . . .Vibration Data for Compressors - All Compressor Types 16. . . . . . . . . . . . . . . . . . . . . . . . . . .Sound data for reciprocating and screw compressor units -- all types of compressors 17. .Compressor data for reciprocating compressor 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operating limits 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General operating instructions for CMO/TCMO, SMC/TSMC piston compressors 26. . . . .Starting up compressor and plant 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Stopping and starting-up compressor during a short period of standstill 27. . . . . . . . . . . .Stopping plant for brief periods (until 2-3 days) 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Stopping plant for lengthy periods (more than 2-3 days) 28. . . . . . . . . . . . . . . . . . . . . . . . .Automatic plants 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pressure testing refrigeration plant 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pumping down refrigeration plant 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operating log 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Servicing the reciprocating compressor 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pressure drop test 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removing refrigerant from compressor 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubricating oil 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Lubricating oil requirements 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .General rules for use of lubricating oil in refrigeration compressors 37. . . . . . . . . . . . . . . .Instructions for choosing lubricating oil for refrigeration compressors 37. . . . . . . . . . . . . .Charging refrigeration compressor with lubricating oil 37. . . . . . . . . . . . . . . . . . . . . . . . . . .Changing oil in refrigeration compressor 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Charging the compressor with oil 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Assessing the oil 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Visual assessment 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Analytical evaluation 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Procedure 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .The analysis 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Expected discharge gas temperatures 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Servicing the Refrigeration Plant 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Maintenance of piston compressor 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 0178-900-EN

1. If the compressor is operational 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. If the compressor is inoperative 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Top covers 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Mounting top and water covers 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Discharge valve 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cylinder lining with suction valve 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Connecting rod 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. Slide bearing 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. Needle bearing 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Dismanting of needle bearing 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Piston 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Shaft seal 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Crankshaft 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Main bearings 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Compressor lubricating system 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oil pump 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oil pressure valve 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .By-pass valve pos. 24 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oil filter 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Suction filters 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Stop valves 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Unloaded start and capacity regulation on SMC and TSMC 100 and 180 compressors 74Description of unloader mechanism and capacity regulation 74. . . . . . . . . . . . . . . . . . . . . .Pilot solenoid valves 76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Schematic outlines 77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Standard unloaded start and capacity regulation 78. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Schematic drawings 1 78. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Totally unloaded start and capacity regulation 79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Schematic drawings 2 79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Relief cylinders 80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Heating rods, pos. 30 81. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Stop valves pos. 23 and 42 82. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Monitoring cylinder lining insertion 83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. Checking clearance volume 83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. Checking lifting reserve 84. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure gauges 86. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Undersize Bearing Diameters for Crankshaft 88. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Sundry clearances and check dimensions 89. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Torque moments for screws and bolts 90. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Refrigeration Plant Maintenance 92. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operational reliability 92. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pumping down the refrigeration plant 92. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Dismantling plant 92. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tightness testing and pump-down of refrigeration plant 93. . . . . . . . . . . . . . . . . . . . . . . . . .

Trouble-shooting on the Piston Compressor Plant 94. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Selecting Lubricating Oil for SABROE Compressors 106. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Data Sheet for Listed Sabroe Oils 112. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0178-900-EN 5

List of Major Oil Companies 135. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Alignment of unit, AMR coupling 136. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Boring of motor flange for AMR coupling 142. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .V-belt drive for piston compressor types (T)CMO and (T)SMC 143. . . . . . . . . . . . . . . . . . . . . .Oil Separator OVUR for SMC/TSMC 100 HPC - SMC/TSMC 180 145. . . . . . . . . . . . . . . . . . .Connections on SMC 186 - 188 149. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Connections on TSMC 188 150. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oil return in parallel operation for reciprocating compressors 151. . . . . . . . . . . . . . . . . . . . . . .Water-cooling of reciprocating compressors 154. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cooling of the intermediate gas on TCMO and TSMC 100 and 180 162. . . . . . . . . . . . . . . . .Ordering Spare Parts 167. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Spare parts sets for compressors and units 168. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Compressor block 168. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Spare part set for Basic Unit 168. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Complete set of gaskets for SMC/TSMC 0661-640. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spare parts for SMC/TSMC 0661-610. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tools for compressor SMC/TSMC 0661-630. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spare Parts drawing 0661-606 / 0661-607. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spare Parts drawing (in detail) 0661-608. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

Placing of vibration dampers order specific. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 0178-900-EN

First Aid for Accidents with Ammonia(Chemical formula: NH3 - refrigerant no.: R717)

Warning!

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

General

Ammonia is not a cumulative poison. It has adistinctive, pungent odour that even at verylow, harmless concentrations is detectable bymost persons.

Since ammonia is self-alarming, it serves asits own warning agent. This means that noperson will remain voluntarily in concentra-tions which are hazardous. Since ammonia islighter than air, adequate ventilation is thebest means of preventing an accumulation.

Experience has shown that ammonia isextremely hard to ignite and under normalconditions a very stable compound. At ex-tremely high, though limited concentrations,ammonia can form ignitable mixtures with airand oxygen and should be treated with re-spect.

Basic Rules for First Aid

1. Call a doctor immediately.2. Be prepared: Keep an irrigation bottle

available containing a sterile isotonic(0.9%) NaCl-solution (salt water).

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

4. When applying first aid, the personsassisting should be duly protected to avoidfurther injuries.

Inhalation

1. Move affected personnel into fresh airimmediately 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 the patient is conscious and the mouthis not burnt, feed the patient withsweetened tea or coffee (never feed anunconscious person).

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

7. If the patients breathing stops, applyartificial respiration.

Eye injuries from liquid splashes or con-centrated vapour

1. Force the eyelids open and rinse eyesimmediately for at least 30 minutes withthe salt 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 affected areas untilmedical advice is available.

0170-008-EN

96.01

0178-900-EN 7

First Aid for Accidents with HFC/HCFCRefrigerant no.: R134a - R505A - R507 - R22, etc.

Warning!

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

General

HFC/HCFC form colourless and invisiblegasses which are heavier than air and smellfaintly of chloroform at high concentrations.They are non-toxic, non-inflammable, non-explosive and non-corrosive under normaloperating conditions. When heated to aboveapprox. 300C, they break down into toxic,acid gas components, which are stronglyirritating and aggressive to nose, eyes andskin and generally corrosive. Besides theobvious risk of unnoticeable, heavy gasesdisplacing the atmospheric oxygen,inhalation of larger concentrations may havean accumulating, anaesthetic effect whichmay not be immediately apparent. 24 hoursmedical observation is therefore recom-mended.

Basic Rules for First Aid

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

2. Adrenaline or similar heart stimuli mustnot be used.

Inhalation

1. Move affected persons into fresh airimmediately. Keep the patients still andwarm and loosen clothing restrictingbreathing.

2. If the patient is unconscious, call a doctor/ambulance with oxygen equipmentimmediately.

3. Give artificial respiration until a doctorauthorizes other treatment.

Eye Injuries

1. Force the eyelids open and rinse with asterile isotonic (0.9%) NaCl-solution (saltwater) or pure running water continuouslyfor 30 minutes.

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

Skin Injuries - Freeze Burns

1. Wash immediately with large quantities oflukewarm 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 electricallyburnt-out hermetic compressors.

0170-009-EN

01.10

8 0178-900-EN

Protecting the Operator as well as the Environment

Warning!

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

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

To this end, many countries have passed leg-islation in an effort to reduce pollution andpreserve the environment. This legislationapplies to all fields of industry, including re-frigeration, and must be complied with.

Be especially careful with the following sub-stances:

S refrigerants

S cooling media (brine, etc)

S lubricating oils.

Refrigerants usually have a natural boilingpoint considerably below 0C. This meansthat liquid refrigerants can be extremelyharmful if they come into contact with skin oreyes.

High concentrations of refrigerant vapoursare suffocating when they displace air. If high

concentrations of refrigerant vapours are in-haled, they will attack the human nervoussystem.

When halogenated gasses come into contactwith open flame or hot surfaces (over approx.300C), they will decompose to produce poi-sonous chemicals, which have a very pun-gent odour, thus warning the personnel oftheir presence.

At 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 willwarn the personnel before the concentra-tions become dangerous.

The following table shows the values for themax. permissible refrigerant content in airmeasured in volume %. Certain countriesmay, however, have an official limit which dif-fers from those stated.

Halogenated refrigerants 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

R407C

0.1

HCFCHFC

R410A

0.1

0178-900-EN 9

Furthermore, it can be said aboutrefrigerants:

HFC/HCFC

S If released to the atmosphere, haloge-nated refrigerants of the type HFC/HCFC(e.g. R22) will contribute to the depletionof the ozone layer in the stratosphere. Theozone layer protects the earth from theultraviolet rays of the sun. Refrigerants ofthe types HFC/HCFC are greenhousegases which contribute to an intensifica-tion of 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.

S 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

S Ammonia is easily absorbed by water:At 15C 1 litre of water can absorb approx.0.5 kg liquid ammonia (or approx. 700litres ammonia vapour).

S 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.

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

CO2S CO2 is a gas which can be discharged into

the open without causing any harm to theenvironment. It must be ensured, how-ever, that the eyes and skin of peopleworking in the proximity of the plant arenot exposed to the discharged CO2 as itcan be extremely cold.

S CO2 is a harmless gas, but in closedrooms it can displace the oxygen and thuscause suffocation.

S CO2 is odourless.

Refrigerant evacuated from a refrigerantplant must 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 incinera-tion 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 to observe the follo-wing:

S Refrigerants must not be released to theatmosphere.

S When purging an R717 plant, use an ap-proved air purger. The purged air mustpass through an open container of waterfor any remaining R717 to be absorbed.The water mixture must be sent to an au-thorized incineration plant.

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

10 0178-900-EN

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 asbeing harmful to nature and they must beused with caution. Be very careful whencharging or purging 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 incineration plant.

Lubricating Oils

Warning!

When charging oil, avoid that your skincomes into direct contact with the oil. Direct

contact with oils may in the long run developallergy attacks. Use therefore always protec-tive equipment - goggles and gloves - whencharging oil.

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.

-- Ester oil

When changing the oil in the compressor ordraining oil from the vessels of the refrigera-tion plant, always collect the used oil in con-tainers marked waste oil and send them toan approved incineration plant.

NOTE

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

0178-900-EN 11

Description of compressorsSMC 186-188 Mk2, TSMC 188 Mk2

The SMC 180 and TSMC 180 compressorshave 180 mm diameter pistons, as indicatedby the first digits in the type designation andwith a stroke length of 140 mm. The numberof cylinders in the compressor block is indi-cated by the following digit, where, for exam-ple, SMC 188 is an 8-cylinder compressor.SMC 180 is a one-stage compressor whichcompresses the gas in one single stage.

In the TSMC 188 two-stage compressor, thegas is compressed in two stages at a ratio of1:3 between the number of high- and low-pressure cylinders. Thus, a TSMC 188 has 2high-pressure cylinders and 6 low-pressurecylinders.

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 aSABROE name-plate.

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.

The pistons operate in cylinder linings, whichare inserted in the frame with two cylindersunder each top cover. The suction valves, of

0178-902-EN

96.12

12 0178-900-EN

the ring-plate type, are mounted at the top ofthe cylinder linings. The pressure valves formthe top of the cylinder linings and are kept inposition by a powerful safety spring. Thesafety spring allows the discharge valve unitto rise, providing a greater throughflow aper-ture in the event of liquid strokes in the cylin-der. This prevents any overloading of theconnecting rod bearings.

The crankshaft is supported in slide bearingsable to assimilate both radial and axialforces. The oil pressure for the bearings andthe capacity regulating system is supplied

from 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 186 x x x

SMC 188 x x x x

TSMC 188 x x x

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

0170-119-EN

97.12

0178-900-EN 13

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

Direction of rotation

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

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

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

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

Seen towards shaft end

Handling of compressor and unit

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

Note:

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

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

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

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

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

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

The compressor may ONLY be used:S 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.

S With the following refrigerants:R717 -- R221 -- R134a1 -- R404A1 --R410A1 -- R5071 -- R6001 -- R600A1 --R2901 -- LPG11) 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 beused following a written approval fromSABROE.

S As a heat pump:

14 0178-900-EN

-- 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.

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

The compressor must NOT be used:

S For evacuating the refrigeration plant of airand moisture,

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

S As an air compressor.

Emergency device

The compressor control system must beequipped with an emergency device.

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

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

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

Other demands to the emergency device:

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

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

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

Combustion motors

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

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

Explosion-proof electrical execution

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

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

T2516273_0

0178-900-EN 15

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 compressoris 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.

0170-115-EN

01.01

16 0178-900-EN

Vibration Data for Compressors - All Compressor Types

Vibration data for Sabroe RefrigerationsSabroe reciprocating compressors complieswith: the ISO 10816, standard, Part 6,Annex A, group 4, AB, which fixes max per-missible operating vibrations at 17.8 mm/s.

Vibration data for Sabroe RefrigerationsSabroe screw compressors complies with:ISO 10816 standard, part 1, Annex B,Class III, C, which fixes max permissibleoperating vibrations at 11.2 mm/s.

The measurements are made as illustrated inthe figure below (points A-D).

Pay attention to the following, however:

S Motors comply with EN 60034-14 (CEI/IEC 34-14) Class N.

S When placing the unit on vibrationdampers supplied by Sabroe Refrigeration(additional), the vibrations against thefoundation are reduced by:

-- 85-95% for screw compressor units

-- 80% for recip. compressor units

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

-- motor and compressor have not beenaligned as described in the InstructionManual.

-- the compressor runs at a wrong Vi ratio.This applies to screw compressors.

-- the piping connections have beenexecuted in a way that makes them forcepull or push powers on the compressorunit or transfer vibrations to the unitcaused by natural vibrations or con-nected machinery.

-- the vibration dampers have not beenfitted or loaded correctly as indicated inthe foundation drawing accompanyingwith the order.

0170-114--EN

02.07

0178-900-EN 17

Sound data for compressor units

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 can

be calculated provided that the acoustic dataof the machine room is known.

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

Dimension tolerances are :

1 3 dB for SAB, SV and FV screw com-pressors5 dB for SAB 283 L/E and SAB 355 Lscrew compressors

As to the reciprocating compressors thevalues are stated for the compressor blockonly. The dimensional values are stated for100% capacity.

Fig. 1.1

Fictional frame

Reflecting plane1 meter

Dimensional plane

1 meter

18 0178-900-EN

Note the following, however:

S 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.

S additional equipment such as heat ex-changers, pipes, valves etc. as well asanother motor type can increase the noiselevel in the machine room.

S 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 ones

stated -- e.g. near the compressor andmotor.

S 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.

S by contacting Sabroe Refrigeration youcan have sound data calculated for otheroperating conditions.

Tables for Noise Data

The following tables show the operatingconditions of the compressor during thenoise measurements as well as the appliedrefrigerant.

0178-900-EN 19

RECIPROCATING COMPRESSORS

One-stageEvaporating temperature = --15CCondensing temperature = +35CRefrigerant = R22/R717Number of revolutions = 1450 o/min.

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 = --15CCondensing temperature = +35CRefrigerant = R22/R717Number of revolutions = 900 o/min.

LW LP

SMC 186 101 83

SMC 188 102 84

Compressor block

Two-strageEvaporating temperature = --35CCondensing temperature = +35CRefrigerant = R22/R717Number of revolutions = 1450 o/min.

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 = --35CCondensing temperature = +35CRefrigerant = R22/R717Number of revolutions = 900 o/min.

LW LP

TSMC 188 100 82

Compressor block

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

HPO 24 91 76

HPO 26 93 78

HPO 28 94 79

HPC 104 97 81

HPC 106 98 82

HPC 108 99 84

LW LPCompressor block

20 0178-900-EN

SCREW COMPRESSORSEvaporating temperature = --15CCondensing temperature = +35CRefrigerant = R22/R717Number of revolutions = 2950 o/min.*Number of revolutions = 6000 o/min.

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

SAB 110 SM Mk2 - -SAB 110 SF Mk2 - -SAB 110 LM Mk2 - -SAB 110 LF Mk2 - -SAB 110 LR* Mk2 - -SAB 110 SR* Mk2 - -

SAB 128 M Mk3 100 82SAB 128 F Mk3 104 86SAB 128 R* Mk3 104 86

SAB 128 M Mk4 - -SAB 128 F Mk4 - -SAB 128 R* Mk4 - -

SAB 163 M Mk3 103 85SAB 163 F Mk 3 105 87SAB 163 R* Mk 3 105 87

SAB 163 M Mk4 - -SAB 163 F Mk4 - -SAB 163 R* Mk4 - -

SAB 202 SM 105 86SAB 202 SF 106 87SAB 202 LM 105 86SAB 202 LF 107 88

SAB 283 L 107 87SAB 283 E 108 88

SAB 355 L 109 89

SAB 81 103 84SAB 83 104 85SAB 85 105 86SV 87 106 86SV 89 108 87

Compressor block LW LP

Evaporating temperature = --35CCondensing temperature = --5CRefrigerant = R22/R717Number of revolutions = 2950 o/min.

Compressor unit LW LP

SAB 163 BM 106 88

SAB 163 BF 110 92

0171-496-EN

02.01

0178-900-EN 21

Compressor data for reciprocating compressorCMO 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 and R22 are shown in the following tables, together withthe main data for the compressor.

Compressortype

Number ofcylinders

Bore

mm

Stroke

mm

Max/minSpeed

RPM

Sweptvolumemax 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 8 180 140 1000/450 1283 2900

The maximum speed permitted can be lower than stated here depending on operatingconditions 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

T245400_0/2

Condensingtemperature

Evaporating temperature

1

2

4

3

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

22 0178-900-EN

R717Operating limits

single stagecompressors

CMOSMC 100 S-L

SMC 180

Type

Area rpm Cooling

max min Booster Single and HP-stage compr.

CMO 201--2

1800 900Air-cooled top- and side covers # - or water-cooled

CMO 203-4

1800 900Water-cooled Thermopump or water-cooled

SMC 1001-2

1500Air-cooled top- and side covers # - or water-cooled

SMC 100S-L

31500

700Water cooled Thermopump or water-cooledS-L

4 1200Water-cooled Thermopump or water-cooled

SMC 1801 750

450 Water-cooledSMC 1802-3-4 1000*

450 Water-cooled

# Including refrigerant-cooled oil cooler * 840 to 920 not allowed

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

0178-900-EN 23

R717Operating limits

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 100S-L-E 1-2 1500 700 Thermopump or water-cooled

1)

TSMC 1801 750

450 Water cooled 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 conditions

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

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

1

2

0177128_0VIEW

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

Condensingtemperature

Evaporating temperature

C--70--40

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

F

--22

--4

14

32

50

68

86

104

122

140

158

--40

12

3

4

TE

TCC

--30

--20

--10

--60 --50 --40 --30 --20 --10 0 10 20 30 40

0

10

20

30

40

50

60

70

Condensingtemperature

Evaporating temperature

C--70--40

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

F

--22

--4

14

32

50

68

86

104

122

140

158

--40

0177128_0VIEW

4,1

24 0178-900-EN

R22Operating limits

single stagecompressors

CMOSMC 100 S-L

SMC 180

Type Area rpm Oil-cooling Notemax min required 1)

11500

no

CMO2

1500900

noCMO

31800

900At less than 50% capacity

41800

yes1 1000 no

SMC 100 S2 1200

700no

SMC 100 S3 1500

700At less than 50% capacity

4 1200 yes1 Not applicable

SMC 100 L2 1000 no

SMC 100 L3 1200 700 At less than 50% capacity4 1000 yes1-2 Not applicable

SMC 180 3750 450

At less than 50% capacity4

750 450yes

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.

12

3

4

TE

TCC

--30

--20

--10

--60 --50 --40 --30 --20 --10 0 10 20 30 40

0

10

20

30

40

50

60

70

Condensingtemperature

Evaporating temperature

C--70--40

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

F

--22

--4

14

32

50

68

86

104

122

140

158

--40

0177128_0VIEW

5,1

0178-900-EN 25

R22Operating limits

two-stagecompressors

TCMOTSMC 100 S-L

TSMC 180

Type Area rpm Oil-cooling Note

max min required 1)

TCMO1-2 1500

900 noTCMO3-4 1800

900 no

TSMC1 1000

TSMC100 S 2-3 1200 700 yes

2)100 S

4 1500y

TSMC1 Not applicable

TSMC100 L 2 1000 700 yes 2)100 L

3-4 1200700 yes 2)

SMC 1801-2 Not applicable

SMC 1803-4 750 450 yes 2)

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.

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.

0171-461-EN

96.06

26 0178-900-EN

General operating instructions forCMO/TCMO, SMC/TSMC reciprocating compressors

Starting up compressor and plant

S 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

T0177131_0 V15

Cap

To compressor

Optional hand---operated oilpump

Gasket

valve for prelubrication

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.SABROEshand-operated

Estimatedoil quantity

Liters

CMOTCMOHPOSMC 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

S 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.

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

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

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

S Open discharge stop valve at compressor.

S Set capacity regulator to minimum capa-city.

0178-900-EN 27

S 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.

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

S 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.

S Start compressor motor and check suctionand oil pressures.

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

S Open main valve in liquid line.

S 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.

S 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.

S 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.

S 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)

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

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

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

S Cut off power supply to both master andcontrol currents.

28 0178-900-EN

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

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

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

S 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.

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

S Cut off power supply to master and controlcurrents.

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

Automatic plants

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

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

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

-- correct oil charging,

-- automatic oil return,

-- correct oil pressure,

-- suction and condenser pressures,discharge pipe temperature,

-- 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:

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

S air compressor for high pressure;

S 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.

0178-900-EN 29

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

S The test pressure must never exceed thedisign pressure.

S 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

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

S 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.

S 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:

S date of pressure testing,

S person carrying out the test,

S 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 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

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.

30 0178-900-EN

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:

S Evacuate to a pressure lower than 5 mmHg.

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

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

S 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.

0178-900-EN 31

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 temperature

Suction 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 pipeimmediatelybefore compressor

UNISAB II Control Thermometer in discharge pipe

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

0171-462-EN

99.05

32 0178-900-EN

Servicing the reciprocating compressorReciprocating compressors CMO/TCMO, SMC/TSMC100 and SMC/TSMC 180

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 coverhave 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.

0178-900-EN 33

Removing refrigerant fromcompressor

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

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.

34 0178-900-EN

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 valvesCompressor coolingThermopumpSafety automaticsHeating rodV-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 valvesCompressor coolingThermopumpSafety automaitcsHeating rodV-belt driveOil return system from oil separator.

3.4 For heat pump operation, inspect:Valve seatsCylinder liningsPistons, 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

0178-900-EN 35

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 valvesOil cooling systemWater cooling system for any deposits and cloggingThermopumpSafety automaticsHeating rodV-belt driveCoupling and alignmentOil return system from oil separatorValve seatsCylinder liningsPistons, gudgeon pins and gudgeon pin bearingsPiston and oil scraper ringsUnloading mechanismSeal for tightness

4.4 Change:Suction and discharge valve ring platesV-belts

4.5 Finish off with a pressure drop test.

No.

4

22500 15000

5.1 Check V-belt drive

5.2 For heat pump operation, inspect:Valve seatsCylinder liningsPistons, gudgeon pins and gudgeon pin bearingsPiston and oil scraper rings.

Change:Suction and discharge valve ring plates.

5

36 0178-900-EN

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 valvesOil cooling systemWater cooling system for any deposits and cloggingThermopumpSafety automaticsHeating rodV-belt driveCoupling and alignmentValve seatsCylinder liningsPistons, gudgeon pins and gudgeon pin bearingsPiston and oil scraper ringsUnloading mechanismSeal for tightnessOil pump and driveCheck valves.

6.4 Change:Suction and discharge valve ring platesV-beltsHalf-sections of bearing for connecting rod(does not apply to CMO compressors)

6.5 Finish off with a pressure drop test.

60000 40000 Major overhaul; contact SABROE Refrigeration

37500 25000 As for service no. 5

45000 30000 As for service no. 4

52500 35000 As for service no. 3

7

8

9

10

Then repeat scheduled services from no. 3 inclusive.

0178-900-EN 37

Lubricating oil

Lubricating oil requirements

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

General rules for use of lubricatingoil in refrigeration compressors

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

S Use grade of oil originally prescribed forcompressor.

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

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

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

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

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

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

Instructions for choosinglubricating oil for refrigerationcompressorsThe 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

38 0178-900-EN

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.

0178-900-EN 39

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.

40 0178-900-EN

Charging the compressor with oil

Compressor

Type Size

Volume of oilin 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 table illus-trates, how many litres of oil a drop in theoil level of 10 mm is approximately equalto.

T0177162_0

Compressortype size

10 millimeterdifference 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.

0178-900-EN 41

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 -- 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 customersSABROE 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:

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

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

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

Procedure

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

S 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.

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

42 0178-900-EN

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

the results of the analyses approach thesevalues. 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 @ 40C cSt ASTM D 445 66 76 53 64 74 51 100 115 80TAN *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 D1500

report report report

Pentane Insolubles W% MM 490(5m)

-- 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

0178-900-EN 43

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

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

S 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.

S 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

96.04

Pressure and temperature settings for SABROEcompressor types SMC-TSMC and CMO-TCMO

Safety valveon the compressor

High and intermediate

Low-pressure

Oil pressure cut-out

Discharge pipe

Oil thermostat

Thermostat forcompressor cooling

Injection valve for

By-pass valve

Oil pressure

Refrigerant

22 bar (special)

24 bar (standard)

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

3,5 bar

regulating valve

HP

IP

MP 55

* 120* 150

CCKP 98

KP 98 C80C55KP 77

Thermo valve forcompressor cooling

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

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

CC

TEAT

PMC +CVC

C45C75

CC-15

4.5 bar

x x x x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

*

**

**

12 bar

cut-out

cut-out

thermostat

safety valve setting.KP 5(KP15)

KP 1(KP15)

Safetyequipment

Controlequipment

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

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

SMC - TSMC - CMO2 - TCMO2CMO4 0.8-1.2 bar

SMC - TSMC - CMO2 - TCMO2CMO4

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 10C superheatAdjust to min 10C superheat

T(E) XTEA

R22

R134a

R404A

R507

Set to a pressure with saturation temp.

temperature.C lower than the lowest evaporating5

R717

x

xx

x

x

x

x

x

x

x

x

x

x

44 0178-900-EN

0170-105-EN

96.02

0178-900-EN 45

Expected discharge gas temperatures

Suction gas superheat C

Condensing temp. C

HFC-H

CFC

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

5371

91110

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

CDischargegas

temp.C

C

C

Condensing pressure

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

5371

91110

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