Home

WDanger - coldfrio.com.br

1. The pistons pos 18 are made of aluminium with two hard plated piston rings and one oil scraping 36 342 Single stage Compressors The compressors are equipped with replaceable cylinder liners pos 19A Fig 4 4 which are made of special cast iron and are easy to disman tle for inspection They are honed and surface hardened which makes them very wear resistant Underneath each top cover there are always two cylinders ring ensuring optimum tightness low oil consump tion as well as long life 0178 933 ENG Rev 2005 12 09 04 technical description fm Service manual SMC TSMC 100 Mk4 4 Technical Description Piston Fig 4 5 Suction valve pos 19H which is of the ring plate type is fitted at the top of the cylinder liner and can be removed together with the cylinder liner Discharge valve pos 20 forms the top of the cylinder and is kept in place by a powerful spring pos 21 This spring is also called the safety spring as it enables the complete discharge valve to lift a little at particularly high pressures in the cylinder due to liquid or oil in the compressed gas liquid slugging Thus overloading of the bearings in the connecting rod is avoided The compressor is designed for operation
2. R507 F Operating Limits 122 50 Single Stage Compressor type 104 40 CMO amp SMC T 5 86 30 a 68 20 1 2 50 10 32 0 14 10 4 20 22 30 60 50 40 30 20 10 0 10 20 30 C 76 58 40 22 4 14 32 50 68 86 Evaporating temperature 10111166 2 OIL COOLING 1 NOTE MAX MIN 1500 No CMO20 1 900 1800 At less than 50 capacity 1200 No SMC100S 1 700 1500 At less than 50 capacity SMC100L 1 1200 700 No Top covers Air cooled only 1 When required choose freely between A or B A Water cooled side covers B Built in refrigerant cooled oil cooler with thermostatic expansion valve 126 342 0178 933 ENG Rev 2005 12 09 06 technical data fm Service manual SMC TSMC 100 Mk4 6 Technical Data SABROE TC R507 140 60 Operating Limits 122 50 Two Stage Compressor 5 amp TSMC 5 104 40 86 30 o c 68 20 2 c o 8 50 10 32 0 94 76 58 40 22 14 32 F Evaporating temperature TO111167 1 TYPE AREA RPM OIL COOLING NOTE MAX MIN REQUIRED TCMO20 1800 900 No 1 1200 TSMC100S 5 1800 700 No 1 1 1000 TSMC100L 5 1500 700 No 1
3. 60 50 40 30 20 10 0 10 20 76 58 40 22 4 14 32 50 68 F By using the table which is situated next to the oil recommendation diagram select the recommend ed code number and thus the recommended oil In the example above there are thus 3 possibilities PAO3 AP1 or M1 However M1 is only recom mended for moderately loaded compressors Table 6 22 Code no Area no 1 PAO3 A AP1 A M1 See note Oil Change on Sabroe Compressors Never change to another oil type without contact ing the oil supplier Nor is it advisable to recharge a compressor with another oil type than the one already used for the plant or compressor in ques tion Mixing different oils may result in operating prob lems in the refrigeration plant or damage to the compressor Incompatibility between different oil types may reduce the lubricating properties con siderably and may cause oil residues to form in the compressor oil separator or plant Oil resi 165 342 Service manual SMC TSMC 100 Mk4 6 Technical Data dues may block filters and damage the moving parts of the compressor Changing the oil type or brand should only be done following a thorough procedure involving drainage and evacuation of the refrigeration plant Information on a suitable procedure can be ob tained from Sabroe Refrigeration as well as a number of oil compan
4. The crankshaft pos 16 Fig 4 9 rests in large slide main bearings pos 5 and 6 which are able to absorb both radial and axial loads Both the main bearings and the connecting rod bearings at the large end of the connecting rod are easy to re place in connection with an overhaul of the com pressor and need no additional finishing after re mounting The bearings are available in 0 5 mm undersize to be used for crankshafts that are ground to 0 5 mm undersize during a renovation After having been ground to undersize the crank shaft needs no surface hardening or the like but can be used directly as bearing surface The crankshaft is dynamically balanced for a smooth and vibration free operation and need no further balancing after the above mentioned machining to undersize In the SMC 112 116 compressors the crankshaft is also supported by an intermedi ate bearing pos 49 Fig 4 10 0178 933 ENG Rev 2005 12 09 04 technical description fm Service manual SMC TSMC 100 Mk4 4 Technical Description Fig 4 11 SMC 112 116 and TSMC 116 The oil pump pos 11A Fig 4 14 is built into the compressor and driven by the crankshaft by means of a coupling The oil pump is a self prim ing gear pump which takes the oil from the oil sump through an oil suction strainer in the crank case pos 33A Fig 4 13 and forces it through the full flow
5. 113 4 342 0178 933 ENG Rev 2005 12 09 0178 933 ENGTOC fm Service manual SMC TSMC 100 Mk4 P SABROE Operating Limits Diagrams 114 Direction of Rotation of the 129 Choice of Electric Motor 130 saba Bad BATA bA DTI 130 Starting torque of the compressor ree 132 Moment or Inertia 5255256 aban deer a PE NENG KG ee BAYAD NE 135 Direction of Rotation of Electric Motor 136 Handling of Compressor and 137 Compressor Shaft 138 hee Ee EE KS 140 V belt drive for SMC TSMC 100 142 Transmission Hallo 443 d cera Rex Sneed hase Skee mans eens 142 Power Transmission 2 naa 31 418 1 GLENDA me penne sewed 144 Construction of V Belt Drive 146 cokes ee GEG yaks OSs oe he EET bed et Ks 147 Noise from Compressors and Units 148 Noise Data for Reciprocating Compressors
6. 258 1 Checking clearance volume 1 258 Adjustment is carried out as follows 258 2 Checking lifting reserve 259 Pressure QAUGES REOR RR ORO ELSE PERE EARS ROR EERE 261 Adjustment to other temperature ranges 261 Cleaning and refilling glycerine filled gauges 262 Fitting and alignment of coupling type AMR 263 4 Installation and 4 263 Preliminary installation 264 NA T ITO TI V I 265 Achieving correct centre height 266 Achieving parallel shafts in vertical plane 266 Final installation CARERE howe 266 Refrigeration plant maintenance 267 Operational reliability 267 0178 933 ENG 7 342 Rev 2005 12 09 Service manual SMC TSMC 100 Mk4 Pumping down the refrigeration plant 267 Dismantling plant ee paa
7. 135 Motor DIMENSION issues cerne ern p etre nean NANANA 130 Motor weight emm PO NN 108 Llc 78 Needle bearing o cp 48 d Um 76 BIET 148 Damping Acoustic Noise tuan ma 153 Reverberation Time 2 00 00 000 000000 000 enne nnne nnne nnn 153 Normal Set of tools ccc ri ce E ie 102 Nozzle size een 53 337 342 Service manual SMC TSMC 100 Mk4 338 342 Oil Charging ngaa MAA APA 159 COMSUMPNOM 161 Oil Differential Gut out MP55 AN ee aides 78 Oil Draining Valve E MES 44 Oil Filter SM iP acheter RM ee maa aka khan 41 Oil Level Glass pues can de aves sane ae PA nea 44 Oil Pressure Regulating Valve a estu MA 41 Oil pressure valve 1 E 253 DOSCMPUON 253 DOI VIGO ois tee d bu 253 Oil Pump SMG gar 41 Oil pump 252
8. See uae got GA KG 267 Tightness testing and pump down of refrigeration plant 268 Torques ces had ake BARCA NG ea Foe ae dp otio ifs 268 Ordering spare parts ss eer Ere rbd Sa ais let 269 o BA 271 use the part wa et ioca ro ee ee te we dida 271 Polis list 0662 022 cr ues e EE elata qu E 272 Tools 16F COMpIeSSOr outre etu ese 304 TOOIS TOR compressor 4v xA get teas APA 305 SMC 104 116 Mk3 8 TSMC 108 116 S L E 305 Supplementary tool set for SMC 100 4 307 PAWNS hare nerd re Eee hatte ite afe Do ae 309 SMG 104 106 108 teh Gan Beale eed are 309 TSMC A08 ue toes ae NG ea Serge a eee else ate sve efe cuite cru Sas eek AR 310 SMC 112510 na pag eS Cae be a eee ee eS 311 tie CLE RG EGS Gen we qiie ee 312 Piston cylinder liner and connecting rod
9. HPO CMO HPC SMC 100 SMC 180 UNF 5 16 3 8 5 8 2 1 44 17 N ft Ibf 15 32 130 Nm 20 43 167 General torque moments for bolts not specified in any table Metric thread ISO 8 8 4 5 6 8 10 12 14 16 18 20 22 24 27 0 28 0 53 0 94 2 2 4 1 7 0 11 15 23 30 38 52 68 ft Ibf 2 1 3 9 6 8 16 30 50 80 110 170 220 270 370 490 Nm 2 7 5 2 9 2 22 40 69 108 147 225 295 375 510 670 Metric thread ISO 12 9 4 5 6 8 10 12 14 16 18 20 22 24 27 0 42 0 78 1 4 3 2 6 1 10 16 23 34 44 55 76 100 ft Ibf 3 0 5 7 10 23 44 75 120 160 240 320 400 550 720 Nm 4 1 7 6 14 31 60 98 157 225 385 430 540 745 980 328 342 0178 933 ENG Rev 2005 12 09 21 appendices fm Service manual SMC TSMC 100 Mk4 21 Appendices Fig 21 1 NN 0178 933 ENG Rev 2005 12 09 Bolt on discharge valve HPO HPC HPC SMC 100 SMC 180 Kpm 3 2 7 1 35 ft Ibf 23 52 255 Nm 32 70 344 Oil valves pos 4K 1 4D 1 4E 1 T SMC HPC 100 Kpm 2 5 ft Ibf 18 4 Nm 25 Oil return valve TLT Recom
10. 17 Texts Marked with Caution 17 Safety 19 General Safety Instructions and Considerations 19 Personal Safety GES duse PE Paes 19 Work Area Safety Su ea Reese 19 TOOL JEN 2223452500200 ad meee eee estes 20 Transmission safety EI 20 rs egi 20 ELI MEE 20 Lifting and Carrying Safety 20 Installation and Relocation Safety 21 Set Up and Operation Safety 21 Maintenance Safety 22 Materials Used with this Product 23 First aid for accidents with ammonia 24 MT 24 Basic Fulgs Tor first aid 55365 whe ewe eve ENEA REE EE 24 First aid measures uso iR AYA NAA 24 First aid for accidents with 25
11. 195 Qualification Requirements llis RR III 195 Compressor control systems 195 Operating instructions ORE AMS RE 199 Maintenance Instructions KG RAGE RG LEE NAKAT ERE dE EGRE EE 201 cuve PT TTE 201 Safety HERG DS ED ER SES 201 Maintenance of the Compressor Unit 202 ge T E 202 Sevice ncn casted ca be bee 203 Measures to be taken 205 Visual NSPE CHOM i dia i iea NAAN NGA eek OSA eRe Ga AET NIN ego 206 0178 933 ENG 5 342 Rev 2005 12 09 Service manual SMC TSMC 100 Mk4 General Rules for Use of Lubricating Oil in Refrigeration Compressors 207 Assessing TG ie a ka e oe RN e ECHTE poe Da C e 208 Analytical Evaluation 2 oie c c eee WAV ea de ee Chee Bae ub 208 so Gu e S uel neat rd IUe iid d dede 208 Analysing the Ole suiit HS wii ES se Roue E SE E Bae 208 Limiting Io
12. H TASS NG With the torsionally resistant coupling the oscilla tory weight of the rotor in the electric motor works as a flywheel providing the compressor with a stable and vibration free operation during all kinds of operating conditions and capacity stages Radial flexibility is achieved by means of the inter mediate piece B which together with the two lam inas parcel A creates a cardanic effect In this way the two flanges are able to move a little radi ally in relation to each other thus equalizing minor lateral movements of motor and compressor The compressor unit is delivered with coupling flanges mounted on the compressor and motor 140 342 provided that the motor comes from Sabroe Refrigeration Intermediate piece and par cels with laminas are delivered separately and must be mounted on site Remember that com pressor and motor must be aligned as de scribed in chapter 7 Installation Instructions Intermediate piece B also makes it possible to re move the shaft seal of the compressor without having to move motor or compressor The length C of the intermediate piece Fig 6 34 and the lamina parcels cover a distance after they have been dismantled that makes it possible to dis mount the coupling flange and the shaft seal of the compressor Fig 6 34 Table 6 7 Compressor Distance HPC SMC 104 10
13. MG Rates Reed gre 49 Conversion of TSMC Compressors from Two stage to Single stage 50 Oil Separator Type eae bag Sasa ee ney es Be Reed 51 Model Operation herd ce eR CORR NG Se dote 51 Selecting an Oil Separator hea haw LA wae Sawa DR GWA WE eee XAR Ng wa ee 51 Oil Return to the Compressor SU RR 52 Thermodynamic Liquid Trap TLT 54 Oil Return in Connection with Parallel 56 ico melt T ng cu gk ot Be a 57 System Brids ind Oe eee bt toe etal teed 60 TIC EU D DC ERI EE 62 Capacity Regulation of Compressor 63 Capacity Regulation and Unloading of Compressor 63 Stam Unloading sexa RO eadem ue Adest 65 Regulating Sequences ux Devi da A EATER RIVE RU Ste Pd ved 66 Variable speed drive VSD 1 75 Compressor UNIS saa maban oneri OUR een AR Eee god the Ee 76 Instrumentation eise eu ox dude RR che SA ade es Seka DEN E
14. 152 Reverberation Time 153 Vibration Data for Compressors All Compressor Types 155 Specification of Compressor Materials 156 Pressure Levels for Standard Compressors and Components 157 Charging the Compressor with Oil 159 Oil Consumpllon aCe DERSLER TSS ESI EU RE nr 161 Selecting Oil LORS LEE SEES KA KAY 161 Selecting Lubricating Oil for SABROE Reciprocating Compressors 162 Data Sheet for Listed Sabroe Oils 168 List of Part Numbers for Available Sabroe Oils 169 List or Major Oil Companies eda es eee Rx rA Peg PP TERRE xa nd 173 Selecting Lubricating Oil for SABROE Reciprocating Compressors 174 Oil Changing Intervals Si EEPS 179 Data Sheet for Listed Sabroe Oils 180 List of Part Numbers for Available Sabroe Oils 181 List of Major Oil Companies 194 SOUS oto wee pane clases eee dus ast Sd d talis 195 Safety Precautions
15. 1 C 715 2 C 115 3 C 505 4 C 645 5 A 835 SMC 106 3185 231 Pos No Hose Type L mm 1 C 730 125 335 375 515 C 1100 o O BO N SMC 108 TSMC 108 3185 232 Pos No Hose Type L mm Ce 150 340 255 230 1090 a gt 0178 933 89 342 Rev 2005 12 09 Service manual SMC TSMC 100 Mk4 4 Technical Description Fig 4 67 Cooling of side covers only SMC 104 106 108 112 116 and TSMC 108 116 S b 90 342 Side covers 3185 235 SMC 104 106 108 and TSMC 108 Pos No Hose Type L mm 1 715 2 175 3 230 4 765 Side covers SMC 112 3185 246 Pos No Hose Type L mm SMC 112 1 A 750 2 A 130 3 750 4 220 Side covers 3185 236 SMC 116 and TSMC 116 Pos No Hose Type L mm SMC 116 TSMC 116 740 160 770 2 0 gt gt 215 0178 933 Rev 2005 12 09 04 technical description fm Service manual SMC TSMC 100 Mk4 P 4 Technical Description SABROE Fig 4 68 Cooling of top and side covers SMC 186 188 and TSMC 188 SMC 186 3185 242 Pos no Hose type L 1 815 2 1830 3 605 4 245 5 1165 6 595
16. XXX 112 342 06 technical data fm Service manual SMC TSMC 100 Mk4 6 Technical Data Planning the Machine Room When planning the machine room make sure that there is enough space around the compressor The minimum spacing is indicated below see Fig 6 4 Fig 6 5 and Fig 6 6 SABROE Space 1 500 mm 20 Space 2 400 mm 16 Space 3 SMC 104 106 108 TSMC 108 600 mm 24 SMC 112 116 TSMC 116 1100 mm 437 li Fig 6 4 2 ED IRA Hs TE kag EU Fig 6 5 Compressor Block with Analog System Enough room must be left around the compressor to allow the operating personnel to operate the compressor and carry out service work on the compressor Space should be considered 0178 933 ENG Rev 2005 12 09 Fig 6 6 Compressor Block with UNISAB II System sufficient space to make it possible to take out the crankshaft without dismounting the compressor from the base frame 113 342 Service manual SMC TSMC 100 Mk4 6 Technical Data Operating Limits Diagrams To make sure that Sabroe Refrigeration s custom ers experience a satisfactory compressor opera tion within the specified operating periods be tween the service intervals it is essential that the operating condition
17. 2 E N Z SSSS T 0178 933 ENG Rev 2005 12 09 04 technical description fm Service manual SMC TSMC 100 Mk4 4 Technical Description Start Unloading As already mentioned the compressor cylinders are unloaded when there is no oil pressure on the unloading cylinders This means that when the compressor is stopped i e without any oil pres sure all the unloading cylinders are unloaded and consequently there is no compression resistance during start up This unloading during start up reduces the start ing torque of the compressor considerably Fig 4 42 x SABROE This can be seen from the starting torque curves in chapter 6 Technical Data Solenoid Valves for Capacity Regulation The unloading cylinders are controlled by sole noid valves Fig 4 42 which receive opening and closing signals from a connected regulator This could e g be a programme device or the Sabroe electronic control system UNISAB II as de scribed later in this section under Instrumentation The solenoid control valve is an electromagnetic three way valve which with a dead coil connects the unloading cylinder pos 12 with the crank case the passage of the oil flow from pipe 2 to pipe 3 is open Fig 4 42 If the coil is ener
18. Refrigerant R22 R717 Number of revolutions 1450 rpm Table 6 12 Compressor block LW LP HPO 24 91 76 HPO 26 93 78 HPO 28 94 79 HPC 104 97 81 HPC 106 98 82 HPC 108 99 84 152 342 Table 6 13 Compressor block LW Lp SMC 104 5 95 79 106 5 96 80 SMC 108 5 97 81 SMC 1125 99 82 1165 100 83 SMC 104 L 96 80 SMC 106 L 97 81 SMC 108 L 98 82 SMC 1121 100 83 SMC 1161 101 84 104 96 80 106 97 81 108 98 82 112 100 83 116 101 84 Two stage Ly and L values are measured at the following conditions Evaporating temperature TE 35 C 31 F Condensing temperature TC 35 95 F Refrigerant R22 R717 Number of revolutions 1450 rpm Table 6 14 Compressor block LW LP TSMC 108 5 95 79 TSMC 116 5 97 81 TSMC 1081 96 80 TSMC 1161 98 82 TSMC 108 E 96 80 TSMC 116 E 98 82 0178 933 ENG Rev 2005 12 09 06 technical data fm Service manual SMC TSMC 100 Mk4 6 Technical Data 4 Damping Acoustic Noise in a Machine Room On planning or renovating a machine room atten tion should be paid to the acoustic environment as a minor investment is sufficient to change an acoustically hard room to a noise damped room which is pleasant to work in This is possible to achieve by choosing a sensible noise absorbing material fitted on walls and ceil ing or which is part of the building construction
19. SMC 112 SMC 116 TSMC 116 Shaft end ave 22 os oo ojo kl AI o NG NAB INI MASS 9 9 o o o6 9 9 Shaft end Ts 92 6 19 Shaft end 0 0 Control end SMC 104 SMC 106 SMC 108 TSMC 108 2 f 0 Shaft end Jp Water covers FS i g Right top covers 5 DS ap 8 5 a Left top covers TI 5 20 7 T NL c a 236 342 0178 933 ENG Rev 2005 12 09 13 service instructions fm Service manual SMC TSMC 100 Mk4 13 Service Instructions Discharge valve Fig 13 7 SABROE Pos 20 20E 20C 20A As shown in the above drawing the function of the discharge valve Pos 20 is partly to allow the com pressed gas to pass from the compression cham ber of the cylinder to the discharge chamber be neath the top covers and partly to create a seal from the discharge chamber to the cylinder Furthermore the discharge valve acts as a safety device in the event of liquid refrigerant passing through th
20. ajeipawiaju 2 enjejeduie 3 ainyesaduie ejeipeuuejul 3 ajeipawiaju 3 t 10 10 Jo o Jo ac 2 e1njejeduie eJnje1eduie aunjesadwa c c c c 5 O 44H 3 ZOSH VWrOrH 2 2 7215 5 24H 2 60 197 342 0178 933 ENG Rev 2005 12 09 Service manual SMC TSMC 100 Mk4 9 Settings 198 342 0178 933 ENG Rev 2005 12 09 10 operating instructions fm Service manual SMC TSMC 100 Mk4 10 Operating instructions 10 Operating instructions This chapter is included in the separate manual Operating instructions please consult this manu al if you need information about operating the compressor 0178 933 ENG Rev 2005 12 09 199 342 Service manual SMC TSMC 100 Mk4 10 Operating instructions 200 342 0178 933 ENG Rev 2005 12 09 11 maintenance instructions fm Service manual SMC TSMC 100 Mk4 11 Maintenance Instructions 11 Maintenance Instructions The purpose of this chapter is to describe Dangers resulting from failure to comply with safety precautions when performing maintenance tasks Scheduled maintenance tasks for this equipment and how to carry them out safely When these scheduled maintenance tasks should be performe
21. Adjust liquid regulating valve Increase super heating 16 Excessive oil temperature During operation the heat of the compressor crankcase must be 40 70 C When work ing with R717 and R22 it may be necessary to supply the compressor with oil cooling See 14 17 Oil level in crankcase falling Where refrigerants are used there will be some blending of refrigerant and oil during the initial operating period It may therefore prove necessary to top up the oil after initial start up of the plant Note The oil level must always be visible in the oil level sight glass on the compressor 17 20 Filter in solenoid valve or jet in oil re Oil return pipe must be warm during operations turn line clogged Clean filter 17 26 Liquid in suction line and crankcase Examine evaporator system and check super may cause foaming in oil and thus heating of suction gas increase oil consumption 17 51 Worn out piston rings or cylinders Renew piston rings and if need be renew pis tons and cylinder linings 17 57 Solenoid valve in oil return line de Coil in solenoid valve defective fective Replace coil Electrical control signal lacking 224 342 0178 933 ENG Rev 2005 12 09 12 fault finding instructions fm Service manual SMC TSMC 100 Mk4 12 Fault finding Instructions 18 Heavy oil foaming in crankcase 18 26 Liquid in suction
22. 313 SNA ers i i ree Ha PLAN oe pA ee ae 314 COV EUS a verdure A ar duane AG AN ANG Aa RA gute ees 315 Crankshaft bearings and coupling Ree 316 Bice Aa ce Oe icc 317 Uril adihdq TrATO CV dO tet s ng Sha Sy Ot OG owed d bee sp 318 By pass and service valves 319 Stop valves 320 eena Een tO e kee EG ee E e ERR 321 Thermo PUMP OVET a EAE we eed AA wae AG 322 Analogue control and safety 323 Final Disposal maga tree te cm ee AN 325 General tain a Bo A da Aan ee E A 325 Salety 6 s oo titre aare a a Reet eee ee aed d a 325 Disposal of Machine Parts 325 Disposal of and Refrigerant 325 Disposal of Electrical Components 326 Disposal of Batteries haw aka AD piven KAG erg eod our erra en ea 326 PDT 32
23. 9 1 68 Z8 94 22 69 81 6011 26 8 68 64 Z 69 79 104 OV PEL 001 9 S8 9 v9 EZL 60L 96 v8 4 Z cl 78 BI HO 9 88 GE 291 901 68 jez 99 29 65 evi 88 99 92 89 69 09 691 71 96 116 ZZ 89 19 74 OLL 196 08 89 19 46 69 29 HS 99 Ge COL E8 99 91 eZ 69 99 24 09 011 1801188 8 8 59 eS 87 ZS OC LIL 921 1041169 24 149 99 906 9 00111 06 18 99 8 29 169 IS SIE SP 045 ISE SEL ZLE FOL 971 64 22 99 29 64 081 901 v6 28 CL 64 69 69 49 FOL OV 091 171 90168 9 cL SZ 49 19 49 HS 2916 166 98 BI 79 8896 gi 91 ELL 96 1201114 9 199 24 8046 22 59 FLH 99 227106 kel 05168 99 116 9 89 IS tt LOL V8 69 7 46 7 99 LEL OLL L6 bZ 64 97 9 OV OLL LE 94 19 76 C8 99 lv ZS 02 06 02 01 O 01 5 O 0c Ol 0 5 06 07 OL O 5 OS OZ 01 0 01 5 gt o 22 oO g 20 5 oO
24. Socket cap screw O ring 12 37 x 2 62 3188 009 Gasket kit unloading cylinder 12E 1 Gasket 25 17 x 1 5 12N 1 Gasket for cover TSMC HP only 12R 1 O ring TSMC HP only 12S 1 Gasket 100 x 100 x 2 12L 1 1424 192 Hexagon head screw M10 x 30 Frame for unloading 3184 216 Frame complete Suspension rod Suspension rod Cross piece Cross piece Countersunk screw 3188 034 Service kit unloading frame Benzing ring dia 9mm Benzing ring dia 7mm Lock nut TSMC HP only Spring retainer Spring Washer for bearing cup 3188 009 Gasket kit unloading cylinder Bracket for unloading mechanism 3184 358 Kit assembly bracket for unloading mechanism Bracket with pin Spacing ring Hexagon head screw M6 x 30 Spring washer 0178 933 ENG Rev 2005 12 09 281 342 Service manual SMC TSMC 100 Mk4 18 Part list Compressor SMC Designation Rocker for unloading mechanism 3184 359 Kit assembly rocker for unloading mechanism LP Rocker Bearing for SMC and TSMC LP 3184 360 Kit assembly rocker for unloading mechanism HP 15A 1 Rocker 15B 2 Bearing for TSMC HP Crankshaft all without certificate 16A 1 3121 258 Crankshaft SMC 104S Mk 4 complete 16A 2 3121 262 Cr
25. and side covers Air cooled only 1 Part load operation By pass equipment required to maintain intermediate temperature at minimum load 0178 933 ENG 127 342 Rev 2005 12 09 Service manual SMC TSMC 100 Mk4 6 Technical Data 140 122 104 40 Condensing temperature R407C Operating Limits Single Stage Compressors CMO amp SMC 76 58 40 22 4 14 32 50 68 86 104 10111168 2 Evaporating temperature TYPE AREA RPM OIL COOLING 1 NOTE MAX MIN 1 1800 At less than 50 capacity CMO20 2 900 Yes 3 1500 No 1 1500 At less than 50 capacity SMC100S 2 1200 700 Yes 3 No 1 1200 At less than 50 capacity M SMC100L 2 1000 700 Yes 3 No Top and side covers Air cooled only 1 A B When required choose freely between A or B Water cooled side covers Built in refrigerant cooled oil cooler with ther mostatic expansion valve 128 342 0178 933 ENG Rev 2005 12 09 06 technical data fm Service manual SMC TSMC 100 Mk4 P 6 Technical Data UN SABROE Direction of Rotation of the Compressor The normal direction of rotation for the compres pressor is connected to a combustion motor with sors is anti clockwise when looking at the com a specified direction of rotation pressor from the shaft end In such cases the oil pump must be changed as it F
26. 2G 1 2J 1 Nut M14 2H 1 Staybolt M14x138 SMC HPC 100 Mk4 Side cover air cooled 3A 1 3113 148 Side cover air cooled 3E 1 1424 246 Hexagon head screw M14 x 65 Side cover water coo led 3A 2 3113 265 Side cover with cooling fins SMC 100 Mk 4 3B 1 3113 258 Water cover right SMC 100 Mk 4 3B 2 3113 259 Water cover left SMC 100 Mk 4 3F 1 1424 241 Screwe M14x40 3G 1 3J 1 1432 066 Nut M14 3184 381 Kit assembly staybolts for Side cover Nut M14 Staybolt M14 x 85 SMC 100 HPC 100 Mk 4 3188 119 Gasket kit top side cover SMC 104 Mk4 Gasket for top and side cover Gasket for valve compr 3188 120 Gasket kit top side cover SMC 106 Mk4 Gasket for top and side cover Gasket for valve compr 3188 121 Gasket kit top side cover T SMC 108 Mk4 Gasket for top and side cover O ring Gasket for valve compr 3188 122 Gasket kit top side cover SMC 112 Mk4 Gasket for top and side cover 0178 933 ENG Rev 2005 12 09 273 342 Service manual SMC TSMC 100 Mk4 18 Part list 3188 123 Designation Gasket kit top side cover T SMC 116 Mk4 Compressor SMC Gasket for top and side cover Gasket for valve compr 3188 124 Gasket kit top side water covers SMC 104 Mk4
27. 90 OWS 901 OWS Nouons SPXIYAN 01 OWS 939 H 208 HdWoo SNOILO3NNOO KINO HALYM 8 89 LUNO LETNI HALYM TIVH3AO 9 951 HIONJITIVH3AO V 5 052 WALSASdWNdOWYSHL ZLZH 4218008 4310090110 249 vo 431000 IIO 914434 van NS HOJ O3NNOO LIYVHSYNVHO SNIMVYCHLIM HOS 17139 SNIMVHOHLIM SINTA dOLS ONLLVH3dO HOS DOO 110 342 Service manual SMC TSMC 100 Mk4 6 Technical Data SABROE SMC 100 V belt Driven UNISAB II System ig 6 2 TIVH3AO 0 0 5 HL NJI Sep Sle seek 082 9621 052 713871 NI NOISN3AIG Sec 3SN HLON31419VX3 9101 002 ANY HOLOW DYN OL S3lHVA XVWH HLGIM HLONGT HOLOW 90 969 S99 SOb SOP 006 OEOL SZLL OZOZ WSIE 002 80LOWS D006 BEvLZL 029 Sv9 966 SLZ SEOL OELL SOL 0102 WSLE 00Z 90LOWS ON 088 BePLZL 969 SE9 OSE OFF SZZ 000 9601 89 1 0502 WSLE 00Z vOLOWS HOLOW ON
28. AR dd Deus Mediae 52 Coil for the solenoid valve ci ics cet 53 Float Valve Controlled 56 Parallel Operation aaa RA GAAN 56 Etir 60 Float ValV6 rm acd 58 Sana AA AA 62 Same AA 57 Oil return 02216 51262 2 3 4d nude 5 Solenoid Valve Controlled 52 idest ete ste fa Co deat oett eR NA NA 78 Operating Limits Diagrams toe pere Ree txt io oto tet Peel ae att Reed 114 Operational reliability coco Lotes tet baden ANA deducet iride 267 Ordering Spare Parts cedi te E e ced e prelo xo ule bti tede 269 Parallel Operation ma fes iic eto Ge dtc ofc dee ai cto sf 56 Personal Safety ror te xb INA UNE enero RR an 19 Piston PISTON WINGS NANA aan heavens sean Pech dee eu uq s 243 TYPES E 243 Piston Pin Bearing n e 48 Pistons SM tis dau ege poda aa ada La dad 36 Planning the Machine ROOM i sten doped 113 Plant Maintenance i near Rete t e nna e en e RE ERR RENS ERR 267 Power Transmission x eed enda Aa GH NG 7 144 PrelubricatiOn i secte terree tr ne
29. 146 Motor pulley e 147 V Belts and Pulleys m m GANANG 143 Vessel nam mee 13 Vibration CAYCE Ha I 102 Vibration Data 155 W Warning Texts Marked with Warning aaa aha 17 Warnings in Instructions AA NAA 17 Water ION 92 Water pressure AN 92 We 93 larg me 92 Weight of Electric Motors 108 Work Area Safety maa GAAN 19 0178 933 ENG 341 342 Rev 2005 12 09 Service manual SMC TSMC 100 Mk4 342 342 0178 933 ENG Rev 2005 12 09
30. RUE 235 Mounting top and water covers 236 Discharge valve eese HA BA xx eoe Reset giu Sd e tee dtes 237 POS 20h ces tor er ef ue E day eM Dep Agus 237 Discharge valve types oco hii wee IL el quet pra pagus 238 6 342 0178 933 ENG Rev 2005 12 09 0178 933 ENGTOC fm Service manual SMC TSMC 100 Mk4 P SABROE Dismantling 5 92 2 x NE Kad ek uds Ra iR d 239 ASSSITIDIM S E ERI NA ATA 239 Tightness testing of discharge 239 Service life of discharge and suction valves 239 Cylinder lining with suction valve 240 Extracting cylinder lining 240 Dismantling suction valve 240 Mounting suction valve 240 Inserting cylinder lining 240 Connecting acces REGE 241 Procedure for removing piston and connecting rod 241 Fitting bearings zer cc ioe de 242 Fitting conn
31. Cylinder liner 19 1 3112 085 Cylinder liner with suction valve S amp L LP R717 19A 1 Cylinder liner 5 amp L 19B 1 Unloading ring with pins S amp L 19C 1 Washer dia 8 4 3 x 0 5 19D 1 Spring for unloading ring 19E 1 Tension spring 19F 1 Ring plate 19G 1 Valve spring 19H 1 3132 083 Suction valve retaining plate R717 19J 1 3134 008 Guide ring for discharge valve 19N 1 1413 343 Socket cap screw M6 x 30 19T 1 Gasket 19 2 3112 086 Cylinder liner with suction valve S amp L LP HFC 19A 1 Oylinder liner S amp L 19B 1 Unloading ring with pins S amp L 19C 1 Washer dia 8 4 3 x 0 5 19D 1 284 342 Spring for unloading ring 0178 933 ENG Rev 2005 12 09 tool list fm 18 spare parts list Service manual SMC TSMC 100 Mk4 18 Part list Designation Tension spring Compressor SMC Ring plate Valve spring 3132 095 Suction valve retaining plate HFC 3134 008 Guide ring for discharge valve 1413 343 Socket cap screw M6 x 30 Gasket 3112 087 Cylinder liner with suction valve S amp L HP R717 Cylinder liner S amp L Unloading ring with pins S amp L Washer dia 8 4 3 x 0 5 Spring for unloading ring Tension spring Ring plate Valve spring 3132 08
32. Dismount the filter by turning it counter clockwise Then close purge valve pos 4E 1 Mount the new filter Follow instructions on filter Open shut off valve pos 4K 1 To open the valve completely turn the spindle counter clockwise Then put on cap Open purge valve pos 4E 1 and fill up the filter with oil Evacuate the system of air until oil is running through the branch pos 4F 1 Always check this to avoid air in the plant Close the purge valve pos 4E 1 and put cap Open shut off valve pos 4D 1 open the valve completely turn the spindle counter clockwise Danger Oil filter contains refrigerant under pressure Important Be sure that both valves pos 4K 1 and 4D 1 are completely open at start up The valves in the oil system are replaceable Be fore replacing all preparations concerning open ing of compressor must be carried out in accord ance with the description in this manual 255 342 Service manual SMC TSMC 100 Mk4 13 Service Instructions Fig 13 23 Oil diagram II Sa P 41 1 PDI A ANA u ee 4D 1 9 4 1 v AA 4 1 1 V 6 256 342 0178 933 ENG Rev 2005 12 09 13 service instructions fm Service manual SMC TSMC 100 Mk4 13 Service Instructions Suction filters The purpose of the filters is to collect impurities conveyed from the
33. Polyalkylen Glycol based synthetic oil PAG oil Ester oil E oil See the section Selecting lubricating oil for Sabroe Refrigeration compressors in chapter 6 Technical Data When changing the oil in the compressor or drain ing oil from the vessel of the refrigeration plant al ways collect the used oil in containers marked waste oil and send them to an approved inciner ation plant It is not recommended to re use oil Cooling water systems A Warning The recirculation water system may contain chemicals or biological contaminants including legionella which can be harmful if inhaled or in gested Water systems should only be operated with an effective biological treatment programme Note These instructions only provide general information The owner of the refrigeration plant is responsible for ensuring that all codes regulations and industry standards are complied with 0178 933 ENG Rev 2005 12 09 29 342 Service manual SMC TSMC 100 Mk4 3 Safety Precautions 30 342 0178 933 ENG Rev 2005 12 09 04 technical description fm Service manual SMC TSMC 100 Mk4 4 Technical Description 4 Technical Description The purpose of this chapter is to describe the in tended purpose the physical characteristics and the functions of the unit This chapter is primarily intended for designers service engineers prospective customers sales personnel and personnel undergoing tr
34. Table 6 24 Code no Area no 1 2 E5 A 9 A Oil Change on Sabroe Compressors Never change to another oil type without contact ing the oil supplier Nor is it advisable to recharge a compressor with another oil type than the one already used for the plant or compressor in ques tion Mixing different oils may result in operating prob lems in the refrigeration plant or damage to the compressor Incompatibility between different oil types may reduce the lubricating properties con siderably and may cause oil residues to form in 177 342 Service manual SMC TSMC 100 Mk4 6 Technical Data the compressor oil separator or plant Oil resi dues may block filters and damage the moving parts of the compressor Changing the oil type or brand should only be done following a thorough procedure involving drainage and evacuation of the refrigeration plant Information on a suitable procedure can be ob tained from Sabroe Refrigeration as well as a number of oil companies It is extremely important that the new unused oil is taken directly from its original container and that both the brand and the type correspond to the specifications of the plant 178 342 Make sure that the original oil container is sealed properly during storage so that moisture from the air is not absorbed by the oil Many oils particular ly polyester oils are extremely hygroscopic It is therefore recommended only to buy the oil in con
35. Threaded plug Gasket Seeger ring Spring guide Spring retainer Spring outer Spring inner Benzing ring dia 9 mm Benzing ring dia 7 mm 3135 152 Unloading cylinder complete L 150 S 96 5 Unloading cylinder Piston Pistin rod 150 mm Threaded plug Gasket Seeger ring Spring guide 0178 933 ENG Rev 2005 12 09 Spring retainer 279 342 Service manual SMC TSMC 100 Mk4 18 Part list Designation Spring outer Compressor SMC Spring inner Benzing ring 9 mm Benzing ring dia 7 mm 3135 161 Unloading cylinder complete HP L 82 S 24 5 Unloading cylinder HP Piston Pistin rod 80 mm Threaded plug Gasket Spring guide Spring outer Spring inner Benzing ring 9 mm Cover Gasket Lock nut Socket cap screw O ring 12 37 x 2 62 3135 154 Unloading cylinder complete HP L 107 Unloading cylinder HP Piston Pistin rod 107 mm Threaded plug Gasket Spring guide Spring outer Spring inner Benzing ring dia 9 mm Cover 280 342 Gasket 0178 933 ENG Rev 2005 12 09 tool list fm 18 spare parts list Service manual SMC TSMC 100 Mk4 18 Part list Designation Lock nut Compressor SMC
36. compresosrs refrigerant may be blown out into the open R744 as CO is naturally occuring and harmless in low concentrations Fig 13 1 Fig 13 2 gt gt gt 42 42 X Di Da B X O Water Evacuating pump R717 Note The following instructions apply to the compressor only Servicing of the refrigeration plant is described in a separate section Service the compressor motor according to your own 230 342 instructions For the various scheduled services Sabroe Refrigeration can supply ready made spare part sets which will be helpful in carrying out the scheduled service 0178 933 ENG Rev 2005 12 09 13 service instructions fm Service manual SMC TSMC 100 Mk4 13 Service Instructions Servicing the refrigeration plant During start up as well as operation it must be en sured that the plant is working correctly Compressor and condenser must be able to work satisfactorily safety devices must be intact and the evaporator must function under load Make sure that the desired temperatures are observed the oil pressure and discharge pipe temper ature on the compressor are correct the condenser pressure is not excessively high and the plant works as it is supposed to The service instructions outline some general guidelines for servicing the refrigeration plant with some references to the instruction manual T
37. 42G 1 Gasket Included in Gasket kit 3188 141 42H 1 2313 027 Nut 296 342 0178 933 ENG Rev 2005 12 09 tool list fm 18 spare parts list Service manual SMC TSMC 100 Mk4 18 Part list Pressure Designation and temperature controls Compressor SMC Pressure controls for R717 1373 125 KP 5A 1373 142 KP15A 1373 162 MP 55A 1373 113 KP 1A 1373 132 KP7ABS Pressure controls HFC 1373 123 5 1373 135 KP 15 1373 159 MP 55 1373 103 KP 1 1373 132 KP7ABS Temperature controls 45 1373 043 KP 98 45 1373 044 KP 77 45J 1 1377 171 Phail pocket for temperature controls 45K 1 Gasket Included in Gasket kit 3188 141 Coupling AMR 312S 48F 1 1524 159 Compressor hub for coupling AMR 312 1524 152 Spare part set AMR 312S 48A 1 Disc pack 48B 1 Bolt 48C 1 Bevel washer 48D 1 Lock nut 48E 1 Washer Coupling AMR 350S 48F 2 1524 160 Compressor hub for coupling AMR 350 1524 153 Spare part set AMR 350S Disc pack 0178 933 ENG Rev 2005 12 09 Bolt 297 342 Service manual SMC TSMC 100 Mk4 18 Part list 48C 2 Designation Bevel washer Compressor SMC 48D 2 Lock nut 48E 2 Wa
38. 13 15 Too little oil in compressor Top up compressor with oil and investigate cause of oil consumption 13 18 Oil foams in compressor See 18 13 49 Oil pump defective Repair or replace 13 50 Bearings worn Repair or replace 13 55 Oil filter clogged Change filter cartridge 14 Excessive discharge pipe temperature If after approx 1 hour s operation the discharge pipe temperature is more than 10 C higher than indicated in the table the error may be due i a to 14 21 Excessive suction temperature as result of reduced refrigerant supply to evaporator extensive superheat ing owing to insufficient refrigerant charge Check refrigerant charge 14 22 Excessive suction temperature as result of reduced refrigerant supply to evaporator extensive superheat ing owing to incorrectly adjusted liq uid regulating valves Check thermostatic expansion valves 14 52 Leaky discharge valves Leaking in discharge valves gives rise to gen eration of heat Change defective valves 14 54 Open by pass between high and low pressure side of compressor e g leaky safety valve Localize by pass and remedy any leakages 0178 933 ENG Rev 2005 12 09 223 342 Service manual SMC TSMC 100 Mk4 12 Fault finding Instructions 15 Too low discharge pipe temperature 15 26 Low suction temperature as result of overflow of liquid refrigerant from evaporator
39. M M7 AN y 1 9 a 2 0178 933 ENG Rev 2005 12 09 19T 1 19A 1 19M 1 TSMC HP STAGE 19K 1 19C 1 19D 1 19B 1 19E 1 SABROE 313 342 Service manual SMC TSMC 100 Mk4 19 Drawings Shaft seal Drawing no 0662 060 8C 1 8F 1 8D 1 314 342 rere ree 10G 1 G 10D 1 2 7 WI YY 10J 1 10H 1 Baa EN NX Sv 2 LALA 0178 933 ENG Rev 2005 12 09 19 spare parts drawings fm Service manual SMC TSMC 100 Mk4 19 Drawings Covers Drawing no 0662 060 a 2F 1 2G 1 25z 1 2B 1 22A 1 22B 1 22C 1 6E 1 1 1 a lt 37B 1 37A 1 37C 1 0178 933 ENG Rev 2005 12 09 Water cooled version Air cooled version i 2 1 3G 1 3G 1 3D 1 3B 1 SABROE 315 342 Service manual SMC TSMC 100 Mk4 19 Drawings Crankshaft bearings and coupling Drawing no 0662 060 L 36v 0178 933 ENG 316 342 Rev 2005 12 09 Service manual SMC TSMC 100 Mk4 19 Drawings SABROE Oil system Drawing no 0662 060 51 9 21 OWS sued ejeds 64
40. The personnel must also fulfil all national require ments for authorization Main Power Supply Before servicing the compressor switch off the power on the main disconnect switch of the plant To prevent the compressor from starting up inad vertently dismantle the main fuses of the plant Tools and Accessories Servicing the compressor correctly requires a lot of special tools The tools can be ordered from Sabroe Refrigeration Tools set for compressor The tool set comprises the tool set for Mk3 anda supplementary tool set for Mk4 Ver Tool set Description Part of sion Service Manual Spare Parts Manual Mk3 Normal Seedocument Chapter 18 Extended 0061 694 Mk4 Supplementary Seedocument Chapter 18 tool set 0662 061 0178 933 ENG Rev 2005 12 09 13 service instructions fm Service manual SMC TSMC 100 Mk4 13 Service Instructions Servicing the piston compressor Good and careful servicing of compressor and unit is of great importance for their proper func tioning and service life It is therefore recommended that these service in structions be followed Based on the number of operating hours they indicate the service tasks to be carried out The servicing schedules also depend on the speed of the compressor If the compressor is run ning at less than 1200 rpm Sabroe Refrigeration permits extended service intervals However the compressor must always operate within the
41. 153 342 Service manual SMC TSMC 100 Mk4 6 Technical Data Subjective Perception of Noise Damping With reference to table Table 6 15 indicating how the human ear perceives the effect of noise insulation in machine room the following should be noted By investing in a sensible noise insulation of the ceiling of the machine room this usually means reducing the reverberation time by Table 6 15 half in the machine room with a subsequent great subjective effect When using a pre fabricated noise baffle board from Sabroe Refrigeration the sound pressure in the machine room will typically be reduced by 20 dB Naturally this must be considered a great improvement subjec tively perceived Reduction of sound pressure Reduction of the average Subjective perception of by noise insulation of sound pressure level the improved acoustic quality compressor unit by noise insulation of the room dB dB Relative reverberation time 0 0 1 1 0 5 0 9 Insignificant 3 1 0 8 Perceivable 6 2 0 6 Distinct 10 3 0 5 Considerable 20 6 0 25 Very considerable The Sabroe Refrigeration prefabricated Version 2 0 noise baffle board for compressor units 154 342 0178 933 ENG Rev 2005 12 09 06 technical data fm Service manual SMC TSMC 100 Mk4 6 Technical Data Vibration Data for Compressors All Compressor Types Vibration data for Sabroe Refrigeration s Sabroe reciprocat
42. 164 342 e Min permitted viscosity 10 cSt Max permitted viscosity during start up of the compressor 500 cSt e Max refrigerant concentration in the oil during operation 25 also in case the viscosity requirements have been met Use of Mineral Oil As described in the introduction mineral oil in par ticular causes serious problems especially in R717 plants When using mineral oil it is important to monitor the plant closely The condition colour of the oil must therefore be checked on a weekly basis and for each 1 000 to 2 000 operating hours oil sam ples must be taken for further analysis Sabroe Refrigeration recommends therefore only to use M oil under moderate operating conditions see the following oil recommen dation diagrams Sabroe Refrigeration is aware that several cus tomers have used mineral oils for many years without any problems The customers who wish to continue using mineral oil in existing as well as new compressors can do so provided that the compressor type and the operating conditions are similar to the existing ones Sabroe Refrigeration has thus decided to market one brand of mineral oil which has been tested and found suitable for most of the general refriger ation purposes In case another brand of mineral oil is used follow the specifications on the data pages in this recom mendation as a guideline Mineral oil can be used in refrigeration plants pro vided the lubrica
43. 2 In this area the compressor is not allowed to run at a capacity below 50 For higher loads discharge temperature must be checked 0178 933 ENG Rev 2005 12 09 06 technical data fm Service manual SMC TSMC 100 Mk4 6 Technical Data x SABROE TC F C 158 70 R717 o YUP Operating limits 8 sp es Two Stage 5 Compressors 104 40 TCMO amp TSMC 2 s6 30 LI 5 68 20 o O 50 10 32 0 60 50 40 30 20 10 o 76 58 40 22 4 14 32 F TO111161 5 Evaporating temperature rpm TET RUN Cooling e 1 TCMO20 30 5 1800 900 Thermopump or water cooled 2 5 100 1 1 cool S L E 5 1500 700 Thermopump or water cooled 1 and 2 1 750 1 MC 1 4 Water cool TSMC 180 5 1000 50 ater cooled 1 and 2 Thermopump Part load operation High Stage Top covers are cooled by injected refrigerant Oil cooling are included in the system Water cooled Top and side covers are water cooled Oil cooling are included in the system Discharge temperature must not exceed 150 C 302 F at full load and at part load 0178 933 ENG Rev 2005 12 09 1 Depending on the operating conditions and the pressure on the compressor a by pass system may be required 2 Discharge temperature at part load has to be checked 11
44. 7 7 4 Before dismantling side covers empty the crankcase of its oil content Check that the heating rod in the crankcase is de energized 0178 933 ENG Rev 2005 12 09 02 signs and warnings fm Service manual SMC TSMC 100 Mk4 2 Signs and Warnings Warnings in Instructions This section describes warnings used in instruc tions pertaining to Sabroe Refrigeration equip ment Information of importance to the safety of person nel or equipment is given at three levels Warning Caution There is an important distinction between these three levels However as shown below the prin ciple is the same at all three levels Note Information is sometimes given in a Note A Note is used to emphasise information but it is never used for information vital to the safety of personnel and equipment Texts Marked with Danger The example below shows how information vital to the safety of involved personnel is presented AN Danger Risk of electrical shock Always turn off the main switch before servicing the unit Contact with high voltage may cause death or serious injury 0178 933 ENG Rev 2005 12 09 Failure to observe information marked with Dan ger may cause death or serious injury to person nel or even to a third party Texts Marked with Warning The example below shows how information of im portance to the safety of involved pers
45. Discharge valve seat 20B 3 Retatiningplate 20C 1 Ring plate 20E 1 1432 033 Nut 20H 1 1437 066 Lock washer 20G 3 Valve spring 0178 933 ENG Rev 2005 12 09 287 342 Service manual SMC TSMC 100 Mk4 18 Part list Compressor Designation ome 3136 093 Discharge valve LP HFC 3133 028 Discharge valve seat Retatining plate Ring plate 1432 033 Nut 1437 066 Lock washer Valve spring 3136 094 Discharge valve VHP HFC 3133 028 Discharge valve seat Retatining plate Ring plate 1432 033 Nut 1437 066 Lock washer Valve spring 3188 010 Gasket kit pair of cylinder liners SMC 100 Gasket for cylinder liner 0 5mm Gasket for cylinder liner 0 8mm O ring 107 55x3 53 TSMC HP only Gasket dia 163 141 x 0 2mm 3188 027 Service kit ring plates Ring plate Valve spring Ring plate Valve spring 3188 010 Gasket kit pair of cylinder liners SMC 100 3188 098 Kit assembly valve springs 19G 1 20G 1 Valve spring Note for service of compressors equipped with discharge vales of type 3136 094 extra set of 3188 098 must be ordered 21A 1 2142 063 Spring for safety head S amp L 21A 2 2142 064 Spring for safety head E 288 342 0178 933 ENG Rev 2005 12 09 tool list fm
46. SMC 188 TSMC 188 3185 243 Pos no Hose type L mm 1 E 335 2 A 1755 3 535 4 245 5 1175 6 340 Side covers only 3185 244 Pos no Hose type L mm 1 1165 2 245 3 1315 4 410 0178 933 ENG 91 342 Rev 2005 12 09 Service manual SMC TSMC 100 Mk4 4 Technical Description Note The direction of the water flow is indicated in Fig 4 66 The hose sections have been shortened to the lengths indicated from factory In the supply pipe to the water system 50 lenoid valve must be fitted which shuts off the water flow in the refrigerating system when the compressor is not in operation It is recommended however to continue the water cooling for approx 10 minutes after the compressor has been stopped to protect the cooling water hoses against excessive temperatures Dimensions of the inlet and outlet pipes for the cooling water system are indicated in chapter 5 Physical and Connection Data Table of Water Connection 92 342 Necessary Water Consumption To achieve satisfactory distribution of cooling wa ter and hence proper compressor cooling the fol lowing limiting values should be followed Min Water Flow 5 5 litres per hour per kW motor output On water circulation plants greater water flow is recom mended See Fig 4 69 Max permissible inlet temperature 40 C 104 F Min p
47. 13 service instructions fm Service manual SMC TSMC 100 Mk4 13 Service Instructions Alignment Check that the motor with loose bolts is positioned with all four feet on the base frame Insert any liner plates needed where there is an air gap beneath the feet Tighten the bolts loosely Achieving parallel shafts in horizontal plane Turn the coupling so that the alignment gauge is in upper position Guide the measuring pos 2 towards the coupling flange using a 1 0 mm feeler gauge and fix the pin Remove the feeler gauge Rotate the coupling 180 and measure change in distance from the measuring pin to the flange using feeler gauges This change is called x Measure the distance between the motor feet as shown in Fig 13 32 Measure the distance a from the centre of the pin pos 2 to the centre of the motor as illustrated in Insert shims of thickness y either under both front feet or both rear feet thereby tilt ing the motor in the direction required Shim thickness y is calculated by using the following formula see also Fig 13 32 b 2xa Fig 13 32 A Hg taai After tightening the motor bolts repeat the measurement and compare the result with the values in the table below Table 13 2 Maximum variation mm measured with feeler gauge at a 180
48. 20 1 D 50 10 32 0 o 44 10 4 20 22 30 60 50 40 30 20 10 0 10 20 30 C TE 76 58 40 22 4 14 32 50 68 86 Evaporating temperature 10111164 2 OIL COOLING 1 NOTE MAX MIN 1500 No CMO20 1 900 2 1800 At less than 50 capacity 1200 No SMC100S 1 700 1500 At less than 5096 capacity SMC100L 1 1200 700 No Top covers Air cooled design only 1 When required choose freely between A or B A Water cooled side covers B Built in refrigerant cooled oil cooler with thermostatic expansion valve 124 342 0178 933 ENG Rev 2005 12 09 06 technical data fm Service manual SMC TSMC 100 Mk4 6 Technical Data x SABROE TC F 122 50 Operating Limits Two Stage 1041 40 amp TSMC 5 1 a 86 30 2 o c 68 20 c o c 8 50 10 32 0 10111165 1 Evaporating temperature TYPE AREA RPM OIL COOLING NOTE MAX MIN 20 1800 900 No 1 1200 TSMC100S 5 500 700 No 1 1 1000 TSMC 100L 1206 700 1 and side covers Air cooled only 1 Part load operation By pass equipment required to maintain in termediate temperature at minimum load 0178 933 ENG 125 342 Rev 2005 12 09 Service manual SMC TSMC 100 Mk4 6 Technical Data
49. 268 342 given in the separate instruction manual on plant components Note If the oil in the crankcase of the reciprocat ing compressor or the oil separator of the screw compressor has been in contact with the atmos pheric air for any length of time it must be re placed with fresh oil of the same grade and make Torques etc All relevant data and tables regarding torques coupling data etc are specified in chapter 21 Ap pendices 0178 933 ENG Rev 2005 12 09 13 service instructions fm Service manual SMC TSMC 100 Mk4 13 Service Instructions Ordering spare parts When ordering spare parts please state the fol lowing 1 Compressor no All compressors are fitted with an identification plate which states the type and compressor no of the compressor and indicates which refrigerant to use 2 Part no Spare part drawings and part lists inserted in an instruction manual identify spare parts with the fol lowing a Spare part no a reference number which makes it easy to find a part in a drawing and cross reference in the part list or vice versa b Designation of the part c Part no a 7 digit number which refers to Sabroe Refrigeration 5 stocks When ordering spare parts please always state at least the designation and part number If in doubt state the spare part no as well 0178 933 ENG Rev 2005 12 09 x SABROE 3 Forwarding instructions When ordering spare p
50. 317 342 0178 933 ENG Rev 2005 12 09 Service manual SMC TSMC 100 Mk4 19 Drawings Unloading frame cylinder Drawing no 0662 060 b VEL 1 991 1 094 amp pue 4912051 pue OWS 0178 933 ENG 318 342 Rev 2005 12 09 19 spare parts drawings fm Service manual SMC TSMC 100 Mk4 P 19 Drawings N SABROE By pass and service valves Drawing no 0662 060 T 7 F NU Sa EE 2 2 gt 3 9 2 h A bi Omg 5 _ N 5 Ka Q n _ n DT 3 N 0178 933 ENG 319 342 Rev 2005 12 09 Service manual SMC TSMC 100 Mk4 19 Drawings Stop valves Drawing no 0662 060 320 342 0178 933 ENG Rev 2005 12 09 Service manual SMC TSMC 100 Mk4 19 Drawings SABROE Suction filters Drawing no 0662 060 L Hv eBeis MOT OWSL pue OWS L dv sued ejeds 64 b Hve L uve b Wee eDeis M0 OWS L pue OWS 321 342 0178 933 ENG Rev 2005 12 09 Service manual SMC TSMC 100 Mk4 19 Drawings Thermo pump cover Drawing no 0662 060 SE e 98G 1 322 342 0178 933 ENG Rev 2005 12 09 19 spare parts drawings fm Service manual SMC TSMC 100 Mk4 19 Drawings Analogue control and safety equi
51. Mobil Gargoyle Arctic SHC 230 PAO 9 220 H Sabroe H oil E 11 E 370 0178 933 ENG Rev 2005 12 09 169 342 Service manual SMC TSMC 100 Mk4 6 Technical Data R717 single stage reciprocating compressor Codeno Areano 1 PAO 3 A AP 1 X A M1 See note Condensing temperature 76 58 40 22 4 14 32 50 68 F Evaporating temperature Note Sabroe Refrigeration recommends that the use of M oil is restricted to moderately loaded compressors and that the oil quality is monitored carefully via regular oil analyses A Very suitable in case of a new plant x In case you wish to change from mineral oil 170 342 0178 933 ENG Rev 2005 12 09 06 technical data fm Service manual SMC TSMC 100 Mk4 6 Technical Data R717 two stage reciprocating compressors Code Area 1 3 1 1 See note Condensing temperature SABROE 76 58 40 22 4 14 32 50 Evaporating temperature Note Sabroe Refrigeration recommends that the use of M oil is restricted to moderately loaded compressors and that the oil quality is monitored carefully via regular oil analyses Very suitable in case of a
52. O ring 253 59 x 3 53 O ring 266 29 x 3 53 3188 125 Gasket kit top side water covers SMC 106 Mk4 O ring 253 59 x 3 53 O ring 266 29 x 3 53 3188 126 Gasket kit top side water covers SMC 108 Mk4 O ring 253 59 x 3 53 O ring 266 29 x 3 53 3188 127 Gasket kit top side water covers TSMC 108 Mk4 O ring 253 59 x 3 53 O ring 266 29 x 3 53 3188 128 Gasket kit top side water covers SMC 112 Mk4 O ring 253 59 x 3 53 3188 129 Gasket kit top side water covers SMC 116 Mk4 O ring 266 29 x 3 53 3188 130 Gasket kit top side water covers TSMC 116 Mk4 2D 1 O ring 253 59 x 3 53 2D 2 3D 1 O ring 266 29 x 3 53 Oil pump housing 4A 1 3141 178 House for oil pump T SMC 100 Mk 4 3184 350 Kit assembly oil pump housing Allen screw 5 10 Screw M12 x 40 274 342 Male stud coupling 0178 933 ENG Rev 2005 12 09 tool list fm 18 spare parts list Service manual SMC TSMC 100 Mk4 18 Part list Designation Screw 5 x 30 Compressor SMC 3184 351 Kit assembly valves oil pump housing Needle valve Check valve 16 bar 3184 352 Kit assembly Intermidiate bracket Differential pressure control Connector with diode 3184 353 Kit assembly oil pump counter clockwise rotation Oil pump counter clockwise rotation
53. Qil separator 1 gt lt J p T amp Hi Liquid from receiver pe Oil cooler TEA Filter Stopvalve Solenoid valve The filter filters off any dirt particles in the liquid The filter element can be removed and cleaned The stop valve can block the cooling system from the refrigeration plant A thermostat T is connected to the cooling system and its sensor is placed in the oil of the crankcase The thermostat is set to open the solenoid valve whenever the oil temperature exceeds 55 C 131 F In this way it is made sure that the oil heats up quickly and separates as much refriger ant as possible UNISAB II controls the solenoid valve directly based on the measured oil temper ature Booster Compressor As illustrated in Fig 4 61 the pipe pos 1 is taken to the LP side of the compressor This means that the compressor must compress the gas coming from the oil cooler which makes up only a very small part of the compressor capacity 0178 933 ENG Rev 2005 12 09 SABROE The pipe pos 1 on the booster and two stage compressor is led to the IP side as illustrated in Fig 4 62 and Fig 4 63 Thus the compressor ca pacity is not affected by the oil cooling system The liquid supply is regulated by a thermostatic in jection valve of the TEAT type whose sensor is placed on the discharge pipe of the compressor This gives the cooling system two cooling func tions On
54. SMC TSMC 100 Mk4 18 Part list 3188 029 Designation Service kit shaft seal Compressor SMC 10D 1 O ring 10E 1 Slide ring steel 10F 1 Slide ring carbon 10G 1 O ring 10J 1 Hexagon head screw M5 x 16 8B 1 Gasket for cover Oil filter 9B 1 2311 075 Nipple 3188 111 Service kit oil change 1C 1 O ring 2C 1 Gasket for top and side cover 9A 1 1517 153 Oil filter Unloading cylinder 3135 149 Unloading cylinder complete L 75 S 21 5 Unloading cylinder Piston Pistin rod 75 mm Threaded plug Gasket Seeger ring Spring guide Spring retainer Spring outer Spring inner Benzing ring dia 9 mm Benzing ring dia 7 mm 3135 150 Unloading cylinder complete L 100 S 46 5 Unloading cylinder Piston 278 342 Pistin rod 100 mm 0178 933 ENG Rev 2005 12 09 tool list fm 18 spare parts list Service manual SMC TSMC 100 Mk4 18 Part list Designation Threaded plug Compressor SMC Gasket Seeger ring Spring guide Spring retainer Spring outer Spring inner Benzing ring dia 9 mm Benzing ring dia 7 mm 3135 151 Unloading cylinder complete L 125 S 71 5 Unloading cylinder Piston Pistin rod 125 mm
55. Table 11 3 Oil level Compressor Difference in oil level 5 of 10mm Type Size corresponds to HPC 100 104 2 litres of oil SMC 100 106 0 5 US gal TSMC 100 108 S L E 112 6 litres of oil 0178 933 ENG Rev 2005 12 09 11 maintenance instructions fm Service manual SMC TSMC 100 Mk4 11 Maintenance Instructions Searching for Leaks Searching for leaks can be carried out in many ways The most frequently used method is to use leak detector After finding a leak a good way to find its exact location is to apply soapy water In case of large leaks divide the system into sec tions by closing the valve to prevent needless amounts of refrigerant from leaking out Proceed as follows to search for leaks Ascertain whether there is a shortage of frigerant by checking the level of the refrig erant in the condenser or the receiver Also check that the measuring equipment is functioning properly and do not give false readings Search for drops of oil at couplings flanged joints valve spindles shaft seals safety valves oil filter and the like Ventilate in advance to remove any gase ous refrigerant from the searching area Check that the required refrigerant pressure is present in the part of the system in ques tion Conduct the search systematically to make certain that all possible sources of leaks are checked Do not forget any of the following
56. The cylinders mentioned are connected directly to the oil system without any solenoid valve as shown in Fig 4 44 This makes it the lowest ca pacity stage on the compressors The standard SMC 100 compressors can be reg ulated with the following capacity stages repre sented by the hatched fields in Table 4 5 0178 933 ENG Rev 2005 12 09 04 technical description fm Service manual SMC TSMC 100 Mk4 4 Technical Description Fig 4 44 Schematic Drawings Standard SMC HP 104 0178 933 ENG Rev 2005 12 09 SMC 112 of SABROE 67 342 Service manual SMC TSMC 100 Mk4 4 Technical Description The electric regulating system should be made in such a way that after start up addi tional capacity cannot be loaded until the mo tor has reached its full torque The recommended run up time is 10 sec The min imum speed according to the operating limit dia gram is 5 sec also applies to variable speed driv en compressors Fig 4 45 illustrates the regulating system in prin ciple The percentages indicate the compressor capacity at every stage When unloading a compressor without extra ca pacity stages the solenoid valves are unloaded in numerical order 1 gt 2 gt gt 4 When loading the order is 4 gt 3 gt 2 gt 1 Note On TSMC 116 compressors the solenoid valves nos 3 and 4 must always be loaded simul taneously as they control both
57. The non return valve in the suction line will also contribute to the pressure drop Normal Evaporating Pressure According to fundamental refrigeration engineer ing principles the refrigerant absorbs heat from the medium that is being chilled 0178 933 ENG Rev 2005 12 09 x SABROE In order for heat to be transferred to the refriger ant it must boil at a lower temperature than the temperature of the medium being chilled in the evaporator A basic rule is thus that the evaporat ing temperature is lower than the temperature of the medium that is being chilled in the evaporator This rule sets a maximum value for the suction pressure Condensing Pressure The terms condensing pressure or high pres sure as used here refer to the pressure that pre vails at the compressor outlet side Usually the pressure is the same at the condenser inlet as at the compressor outlet The only difference is the pressure drop in the line Because of this pressure drop in the line the pres sure is a little higher at the compressor than at the inlet to the condenser The oil separator and stop valve mounted in the discharge line will also con tribute to the pressure drop Normal Condensing Pressure In the condenser the absorbed heat energy in the refrigerant is released to the surroundings The heat energy in the refrigerant is the sum of the heat energy absorbed in the evaporator and the energy supplied to the compressor via
58. 13 service instructions fm Service manual SMC TSMC 100 Mk4 13 Service Instructions 13 Service Instructions The purpose of this chapter is to describe Dangers resulting from failure to comply with safety precautions when performing maintenance tasks Scheduled maintenance tasks for this equipment and how to carry them out safely This chapter is primarily intended for service engi neers UN Danger Risk of injury to personnel and damage to equip ment Always read the safety precautions belong ing to this equipment before start Failure to com ply with safety precautions may cause death or in jury to personnel It may also cause damage to or destruction of equipment Danger Risk of injury to personnel and damage to equip ment In addition to the safety precautions in this 0178 933 ENG Rev 2005 12 09 x SABROE chapter always read the safety precautions be longing to the equipment before changing the set tings Failure to comply with safety precautions may cause death or injury to personnel It may also cause damage to or destruction of the equip ment Safety Measures AN Danger The paragraphs that follow present some impor tant safety considerations for this type of com pressor unit Before starting service work study carefully the general safety instructions regula tions that apply to this series of reciprocating com pressor units Failure to follow these instruc tions
59. 200 730 880 2650 1900 224 817 985 2650 2000 400 250 912 1100 2800 2000 265 976 1166 2800 2000 280 1022 1232 2800 2000 315 1150 1386 2800 2120 335 1273 1474 3000 2120 355 1295 1562 3000 2240 400 1460 1760 3000 2240 SMC 104 108 and TSMC 108 only 0178 933 ENG 143 342 Rev 2005 12 09 Service manual SMC TSMC 100 Mk4 6 Technical Data Power Transmission The number of V belts which must be used to transmit the necessary power from the motor to the compressor which usually corresponds to the nominal capacity of the motor is stated in the fol lowing tables Table 6 10 and Table 6 11 Note To obtain a smooth transmission the number of V belts must be chosen so that the belt drive loads at its maximum as stated in the table The motor pulleys are always delivered with the number of grooves corresponding to the number of V belts which must be used to transmit the maximum power of the motor to the V belt drive in question thus indicating how many V belts must be fitted The compressor pulleys however are only de livered with the number of grooves shown below Thus it may occur that there are more grooves on the compressor pulley than on the motor pulley SMC TSMC 100 The compressor pulleys are always delivered with 4 6 or 8 grooves Table 6 10 Max Power Transmission SMC104 106 108 TSMC 108 Number of
60. 2005 12 09 04 technical description fm Service manual SMC TSMC 100 Mk4 4 Technical Description Table 4 9 Number of Cylinder Working Compressor Type Capacity Ratios LP HP 100 6 2 3 1 TSMC 108 66 4 2 2 1 33 2 4 1 1 100 12 4 3 1 83 10 4 2 5 1 TSMC 116 67 8 4 2 1 50 6 2 3 1 33 4 2 2 1 0178 933 ENG 85 342 Rev 2005 12 09 Service manual SMC TSMC 100 Mk4 4 Technical Description Cooling Systems for Compressors To preserve the optimum lubricating capacity of the oil it may become necessary to cool during compressor operation Depending on the operat ing conditions and the type of refrigerant the plant uses a number of cooling systems are available See chapter 6 Technical Data Operating Limits Diagrams The following standard cooling systems can be delivered for the compressors depending on which type of refrigerant the compressor is oper ating with as well as the compressor type itself Standard Cooling Systems for Compressors 1 R717 a Air cooled top and side covers and refrigerant cooled oil cooler b Water cooled top and side covers c Compressor cooling with thermopump 2 R22 R134a R404A R507 R410A R744 a Air cooled top and side covers b Air cooled top covers and water cooled side covers Air cooled top and side covers and refrigerant cooled oil cooler Description 1 Air cooled Top and Side Covers with Refrigerant
61. 2005 12 09 x SABROE Moreover it is required that the personnel is able to follow a detailed description in English Factory settings for analogous control and safety system appear from Table 9 1 In connection with fault finding in case of irregularities in the opera tion the table should include own settings to make it easier for the supervisor to identify the error in question The same applies to UNISAB II control Compressor control systems Compressors are delivered with an analogue con trol and safety system or the UNISAB II reading safety and capacity regulating system With regard to compressors delivered with the UNISAB II system the system is described in the Operating Manual located in the UNISAB II cabi net Furthermore a UNISAB II Engineering Manual version 2 04 is available This manual describes the control system in more detail Consequently setting of set points etc is not described in this section 195 342 Service manual SMC TSMC 100 Mk4 9 Settings Table 9 1 Pressure and Temperature Settings for Compressor SMC TSMC Analogous control and safety Refrigerant system lt Min setting Max setting 8 gt own setting own setting pe lee ms X X X 24 bar standard Safety valve sii x x X 22 bar special compressor p pa MT xX X X X
62. 37 40 41 42 44 45 56 59 13 Too low oil pressure 12 15 17 18 26 49 50 55 14 Excessive discharge pipe temperature pa F F O Siy BO Bi Ba 97 15 Too low discharge pipe temperature 26 32 39 16 Excessive oil temperature 33 34 35 36 37 40 50 52 17 Oil level in crankcase falling 16 18 20 26 51 57 58 18 Oil foaming vigorously in crankcase 16 26 39 61 19 Crankcase sweating or frosting up 16 18 26 37 39 20 Capacity regulating oscillating 13 15 16 17 18 49 55 56 21 Impossible to bleed plant 10 43 51 52 53 54 60 0178 933 ENG 215 342 Rev 2005 12 09 Service manual SMC TSMC 100 Mk4 12 Fault finding Instructions Table 12 2 Code Cause Code Cause 1 No power master switch not cut in 32 Too much coolant air to condenser 2 Blown fuses loose wiring or connections 33 Water valve closed 3 Electrical voltage too low 34 External pressure equalization on expansion valve closed 4 No control current 35 Expansion valve partly clogged by ice dirt wax 5 Motor protection device activated 36 Expansion valve has lost charge 6 Control current circuit open 37 Expansion valve sensor misplaced 7 Pump fan not started 38 Expansion valve is leaky 8 Welded contracts in motor protection 39 Expansion valve provides too little superheating 9 High pressure cut out ha
63. 933 ENG Rev 2005 12 09 06 technical data fm Service manual SMC TSMC 100 Mk4 6 Technical Data Table 6 6 Max axial untruth 0 02 mm measured at point A Max radial untruth 0 02 mm measured at point B Boring is carried out to the immediate motor shaft diameter with an H8 tolerance Please note that the max boring diameter is 95 mm and that two key grooves must be engraved in the key of the motor shaft in order to maintain balance The width of the key grooves is made with an H7 tolerance and the depth must be such as to cre ate a distance between key and hub of 0 2 0 3 mm Fig 6 32 0178 933 ENG Rev 2005 12 09 x SABROE Fig 6 32 H7 0 2 0 3 H8 Max dia 95 mm As seen in the above drawing Fig 6 31 the cou pling hub is slit up axially and clamped to the mo tor shaft with two screws Read more about the coupling in the following section 139 342 Service manual SMC TSMC 100 Mk4 6 Technical Data Coupling An AMR coupling is used for Sabroe Refrigeration s Sabroe reciprocating com pressors This coupling is resistant to torsional stress but radially and axially flexible Torsional resistance is achieved by a transmission of the ro tational force of the motor through a number of thin laminated steel sheets laminas collected in two parcels disc packs A and fixed on the flanges with screws Fig 6 33 Fig 6 33
64. Evaporating temperature o 76 58 40 22 4 14 32 50 68 86 0178 933 ENG Rev 2005 12 09 06 technical data fm Service manual SMC TSMC 100 Mk4 6 Technical Data R134a two stage reciprocating compressors Code no E5 Area no 1 A Condensing temperature 140 122 104 86 68 50 32 22 40 A Very suitable in case of a new plant 0178 933 ENG Rev 2005 12 09 SABROE 70 60 50 40 30 20 10 0 10 20 30 C 94 76 58 40 22 4 14 32 50 68 86 F Evaporating temperature 185 342 Service manual SMC TSMC 100 Mk4 6 Technical Data R407C single stage reciprocating compressors Code no E3 Area no 1 A Condensing temperature 76 58 40 22 4 14 32 50 68 F Evaporating temperature A Very suitable in case of a new plant 8 Max oil concentration in liquid phase contact Sabroe Refrigeration Min suction temperature 50 C At TE lt 50 C superheating must be introduced 186 342 0178 933 ENG Rev 2005 12 09 06 technical data fm Service manual SMC TSMC 100 Mk4 6 Technical Data R407C two stage reciprocating compressors Code no E3 Area no 1 A A Very suita
65. General 21 5 rcr 25 Basic rules RR cO BALAT 25 Protecting the operator as well as the environment 26 Furthermore it can be said about refrigerants 27 Purging a refrigeration plant 28 Cooling MEd TE OS Ee XX ARS ER RA SEO RS 29 Lubricating ONS eee ANAN beeen ben eee ete ede 29 0178 933 ENG 3 342 Rev 2005 12 09 Service manual SMC TSMC 100 Mk4 Cooling water 5 lt 29 Technical Description chee KALOG BED eed PLS LAG TE EAE 31 Areas of Application of the Reciprocating Compressor Unit 31 Marine application 33 Description of the Compressors Compressor Types 34 Compressor Description xis doses ANG Sb Kada 36 Single stage Compressors 35 uoo ree Kha ERE LK hp teed 36 Two stage Compressors TSMC 100 47 Compressor icine kng Gee aah tere E WERL EU aces atone ts ENSE 47 Piston Fil 5 ess kh oe 48
66. Oil return 80A 1 1372 179 Valve block EVRB 80B 1 1371 037 3 3 mm orifice for mounting in valve block 80C 1 1375 094 TLT valve 80J 1 1372 537 Coil 10W 220 230V 50 60Hz 80J 2 1372 538 Coil 10W 110V 50 60Hz 80 3 1372 539 Coil 10W 240V 50Hz 80J 4 1372 541 Coil 10W 24V 50Hz 1372 089 Strainer kit EVRB block Strainer Gasket 1372 086 Service kit EVRB block Armature tube Armature O ring O ring Gasket 1372 091 Seal kit EVRB block Gasket O ring O ring Gasket Gasket 1371 037 Orifice kit 3 3 mm Gasket Gasket Orifice 3 3 mm 0178 933 ENG Rev 2005 12 09 299 342 Service manual SMC TSMC 100 Mk4 18 Part list Compressor SMC Designation Intermidiate pressure connections TSMC 108 90A 1 3114 095 Mixing chamber with flange TSMC108 90B 1 3115 102 Counter flange for mixing chamber TSMC108 90C 1 3422 100 Intermediate ring 107 88 90F 1 1424 222 Hexagon head screw M12 x 65 90G 1 1424 246 Hexagon head screw M14 x 65 90H 1 1437 026 Spring washer dia 13 2 21 2 x 2 5 90J 1 1437 030 Spring washer dia 14 90K 1 1432 066 Nut M14 Intermidiate pressure connections TSMC 116 90A 1 3114 070 Mixing chamber with flange TSMC116 9
67. R134a R404A R507 Use the same cover mounting as the one de scribed in paragraph 1a In principle the oil cooling system is constructed as illustrated in Fig 4 61 for single stage com pressors in Fig 4 62 for booster compressors and in Fig 4 63 for two stage compressors 101 342 Service manual SMC TSMC 100 Mk4 4 Technical Description Compressor Accessories Following an order the accessories listed below can be delivered for compressors or units Explosion proof instrumentation instead of the standard equipment Explosion proof heating cartridge for oil heating in the crankcase Explosion proof solenoid valves for capacity regulation Vibration dampers to be inserted between unit and machine floor dimen sioned to fit the unit in question Normal set of tools comprising special tools for dismantling and assembling the compressor 102 342 Extended set of tools Besides the normal set of tools this set contains all necessary standard hand tools Spare parts set in various sizes When servicing compressor and unit it is al ways an advantage if you as our customer have some of the most commonly used spare parts at your disposal This enables you or a summoned Sabroe Refrigeration service engineer to carry out the necessary service work without having to spend extra time on getting the spare parts required Spare parts can be delivered as described in the following When contacting
68. Sabroe Refrigeration SH Suction gas superheat K Kelvin Zone in which both oils are useable 0178 933 ENG Rev 2005 12 09 Calculation must be performed using COMP1 179 342 Service manual SMC TSMC 100 Mk4 6 Technical Data Data Sheet for Listed Sabroe Oils Typical data for lubricating oils for Sabroe compressors Sabroe Viscosity Viscosity Spec Flash p Pour p Anilin Acid no code cSt cSt Index grav at COC C C mg 40 C 100 C 15 C NG point KOH g M1 63 6 4 14 0 91 202 36 81 0 02 A3 97 8 1 13 0 86 206 32 78 0 05 AP1 64 9 3 121 0 858 195 51 121 0 04 66 10 1 136 0 835 266 lt 45 138 0 03 5 94 13 7 147 0 838 255 lt 45 144 0 03 9 208 25 149 0 846 260 lt 39 154 0 03 E3 ES Due to the great difference between polyolester based lubricants from various suppliers it is not pos 9 sible to present any typical data for these oils When using another oil brand than the one recommend 11 ed by Sabroe Refrigeration please contact the oil supplier to select the correct oil type E85 The listed data are typical values and are only intended as a guideline when selecting a similar oil from a different oil company Data equivalence does not necessarily qualify the oil for use in Sabroe Refrigera tion s Sabroe compressors 180 342 0178 933 ENG Rev 2005 12 09 06 technical data fm Service manual SMC TSMC 100 Mk4 6
69. Screw M8 x 30 3188 131 Gasket kit oil pump 3184 354 Kit assembly oil pump clockwise rotation Oil pump clockwise rotation Screw M8 x 30 3188 131 Gasket kit oil pump 3184 182 Kit assembly plugs oil pump housing Plug with gasket 1 4 Plug with gasket 1 8 Plug with gasket 3 8 Plug with gasket 1 2 3188 131 Gasket kit oil pump Gasket 14 5 6 x 1 5 Gasket for oil pump housing Gasket for differential pressure control Gasket 27 21 O ring 82 22 x 2 62 for oil pump house Gasket for oil pump 0178 933 ENG Rev 2005 12 09 275 342 Service manual SMC TSMC 100 Mk4 18 Part list Compressor SMC Designation End cover at pump end 5A 1 3113 266 Bearing cover 5B 1 1424 241 Hexagon head screw M14x40 End cover at shaft seal end 6A 1 3113 124 Bearing cover 6B 1 1424 245 Hexagon head screw M14x60 6E 1 1436 037 Washer 3188 132 Gasket kit end bearing cover T SMC 104 108 Mk4 Gasket 0 3 mm Gasket 0 5 mm Gasket 0 75 mm Gasket 1 00 mm Gasket Gasket for cover 3188 133 Gasket kit end bearing cover T SMC 112 116 Mk4 Gasket 0 75 mm Gasket 1 00 mm Gasket 1 30 mm Gasket 1 50 mm Gasket 1 75 mm Gasket 2 00 mm Gasket Gasket for cover Gasket 34 27 x 1 5 3188 134 Service kit main bearings
70. See spare parts drawing The bearing bushing 17 1 is made of special bronze and is also used in R717 compressors The bearing bushing is used in all SMC compressors and in the low pressure stage on TSMC compressors The needle bearing 17B 2 is 2 mm greater in outside diameter than the above bearing bush and must therefore be fitted in a piston rod bored to the diameter of this bearing The needle bearing has no inner ring but fits the diameter of the gudgeon pin directly If the bearings in connecting rod worn so that the clearance is greater than that prescribed in the table entitled Various clearances and adjustment measurements they must be replaced with new bearings In this connection note that undersized half sections of bearing can be supplied for use in the crankshaft where the journals have been ground to a corresponding undersize See table in section on Diameters for under sized bearings 241 342 Service manual SMC TSMC 100 Mk4 13 Service Instructions Fitting bearings The bearing bushing or needle bearing be squeezed into or out of the connecting rod in a vice or hydraulic press Use softjaws in the vice and use tools which do not damage any components The bear ing bushing must be fitted as shown on the sketch with the lubricating ducts facing sideways Fig 13 10 Note Sleeve to be fitted with lubricating ducts positioned as shown in drawing
71. The strainer pos 33A 1 is made of a wire mesh which can be cleaned See description of the strainer later in this section The shaft seal housing forms a distribution cham ber for the oil The oil pressure in the shaft seal housing is adjusted by means of the oil pressure regulating valve Pos 22 which is mounted in the shaft seal housing The regulating valve can be adjusted from the outside by means of a screw driver Clockwise rotation increases the pressure counterclockwise rotation lowers the pressure Excess oil is returned through a bored channel to the crankcase 0178 933 ENG Rev 2005 12 09 SABROE Fig 13 18 From the shaft seal housing the oil is distributed as follows Through the bored channels in the crank shaft to lubricate main and connecting rod bearings Lubrication of piston pin bearings is done by splash lubrication through a countersunk hole in the top of the connect ing rod the differential oil pressure cut out and the pressure gauge The effective oil pres sure can be read straight off the manometer the suction pressure gauge of the compres sor Through external oil pipes on to the regulat ing cylinders Pos 12 for unloaded start and capacity regulation 251 342 Service manual SMC TSMC 100 Mk4 13 Service Instructions Oil pump Fig 13 19 The oil pump is a gear pump which is run by the crankshaft by means of a guide The oil pump di rection
72. dicate the limits for Sabroe oils where stratification occurs The oil concentrations stated in these dia grams must not be exceeded This makes it pos sible to adjust the oil rectification return systems to the oil consumption of the compressor so that the maximum concentration is not exceeded For area A in the diagrams the oil concentration in the liquid phase must not exceed 2 For the other 0178 933 ENG Rev 2005 12 09 06 technical data fm Service manual SMC TSMC 100 Mk4 6 Technical Data areas the oil concentration must not exceed 5 For area B please contact Sabroe Refrigeration Plants with Several Different Compressor Types Makes In plants where several different compressor types makes are connected it is strongly recom mended to use the same type of oil in all the com pressors This is very important where automatic oil return systems are used If you consider changing the type of oil please read the section Oil Changing on SABROE Com pressors Carefully Selecting Lubricating Oil The correct oil is selected by means of the follow ing diagrams When the general conditions con cerning the lubrication of the compressor have been considered the specific conditions of the plant must be taken into account Use the oil recommendation diagrams to select the correct oil code number The oil code number consists of letters indicating the oil type and viscosity number Table 6 23 Code Oil
73. ing 214 342 Systematic Fault finding Fault finding should be carried out systematically The personnel will often know what the problem is and find the error immediately If the personnel has a thorough knowledge of the unit in question they will often know the cause of the problem If this is not the case consider the situation quiet ly Do not change any settings immediately Spend some time working out a systematic ap proach Operating Condition Experience shows that pressure and temperature variations in a refrigeration system can provide in formation about the refrigeration plant operating conditions In particular the suction and condensing pressure as well as the temperatures of suction and dis charge gases may provide important information as to the operating conditions of the plant Considerable changes in the operating conditions can often be produced by only very small changes in the variable pressure and temperatures Using the following troubleshooting chart it is pos sible to ascertain the cause of and remedy for any operating disturbance Using the Troubleshooting Chart In the following chart each individual error possi bility is indicated by a code number in the left hand column with the error briefly described in the sec ond column The third column states code num bers for the possible causes of the error The code numbers refer to the subsequent chart The section entitled Remedying M
74. sei 960 966 6 092 022 voi Levit 002 2 5 0061 081 091 1 ON ww wa LINN yow 1HOI3M 8 801 OWS 9 X PLLN 901 OWS NOLLONS 8 v0LOWS dO SNOLLO3NNOO ENITT3M 8 9 JUNO L3TNI HALYM WALSAS dWNdOWYSHL 1 4 4315008 431009 10 Z124 471000 10 AE HOJ O3NNOO Service manual SMC TSMC 100 Mk4 SMC 100 Direct Driven UNISAB II System 6 Technical Data Fig 6 3 ONIMVHOH LIM HOS uaria NOLLONS SNOLSId ONIMVHOH LIM HO SAATWA dOLS ONLIVH3dO HOS oO 660 o x fo I MO T38 NOISN3WIG 3SN HLON3T LOVX3 ONY HOLOW 40 OL S3IHVA HLONST IHLGIM TIVH3AO 8 Rev 2005 12 09 0178 933 ENG gt 8 8
75. turning of the coupling Compressor Coupling size Pos 1 Pos 2 Horizontal Vertical max max mm min max mm mm SMC 104 106 108 312S 0 2 0 1 0 3 0 2 SMC 112 116 350 5 0 2 0 1 0 3 0 2 0178 933 ENG 265 342 Rev 2005 12 09 Service manual SMC TSMC 100 Mk4 13 Service Instructions Achieving correct centre height Turn the coupling so that the alignment gauge faces vertically down Guide the measuring pin pos 1 towards the coupling flange using a 1 0 mm feeler gauge and fix the pin Remove the feeler gauge Rotate the coupling 180 and measure the increase in distance z from one millimetre using feeler gauges Then lift the motor by placing shims of a thickness equal to half value of 7 under all four feet After securing the motor repeat the meas urement and compare the result with the ta ble values in pos 1 vertical Remember that the centreline of the motor shaft must be at least 0 05 mm higher than the centreline of the compressor corresponding to a mini mum of 0 1 mm distance less at the top po sition of the alignment gauge Achieving parallel shafts in vertical plane The motor is now positioned at its correct height What remains is to push and turn the motor at the level on which it is already lined up Turn the coupling so that the alignment gauge faces out to one side horizontally Guide both measuring pins towards the cou pling with a 1 0 mm feeler gauge in be tween 266 342 Tur
76. two grooves for HFC HCFC The cylinder lining and suction valve form an inte gral unit which can be dismantled by removing the screws 19N In order to gain access to the cylinder lining or suction valve the top cover spring Pos 21 and discharge valve Pos 20 need to be disassem bled Extracting cylinder lining Rotate crankshaft to position the relevant piston at top dead centre Fit the two T shape extractors 3 from tool kit into threaded holes in guide ring Pos 19J Carefully pull out cylinder lining with suction valve checking that gasket Pos 19K re mains in frame Insert protective plate 5 from tool kit between piston and frame so that the piston can rest on it This will enable piston and piston rings to slide onto the protective plate without being damaged when the crankshaft is turned 240 342 Dismantling suction valve When dismantling the screws Pos 19N the guide ring Pos 19J suction valve stop Pos 19H and ring plate Pos 19F can be removed from the inder lining The paper gasket Pos 19T can be ex pected to disintegrate during dismantling and re quire replacement Mounting suction valve Before reassembling the suction valve make sure that the valve springs Pos 19G are in good condi tion and firmly fixed in their apertures Perform the assembly in reverse order of the one described above Note the following however Change paper gasket
77. 1165 450 4 Start up torque for L models Didgram values x 1 6 Start for E models Diagram values x 2 6 4 400 7 4 350 z 125 8717 55 H R507 55C Di f 300 Torque Nm 100 50 0 250 500 750 1000 RPM min STARTING TORQUE FOR COMPRESSOR SMC TSMC HPC100 0178 933 ENG Rev 2005 12 09 1250 1500 1750 2000 131 342 Service manual SMC TSMC 100 Mk4 6 Technical Data Starting torque of the compressor The motor size is usually selected as described in the previous section With all cylinders unloaded during the starting up phase the motor generally has sufficient starting power in order to bring the compressor at full speed before the cylinders are loaded Read more in chapter 4 Technical De scription Capacity Regulation and Start Unload ing of the Compressor At times however it may be a good idea to com pare the starting torque curve of the compressor Fig 6 21 Motor starters Motor Y starters 132 342 Starting Torque Curve for Electromotors to the starting curve of the motor this information can be obtained from the motor manufacturer Especially when the compressor starts at a plant pressure below normal and when power limiting systems are used to start up the motor e g a Y starter it may be necessary to work out a dia gram as the one shown in Fig 6 21 The
78. 55 TSMC 100 Compressor Oil separator Oil separator Mixing chamber A Equalizing pipe Solenoid valve Intermediate cooler loat valve Liquid subcooling spiral X Oil drain off In the liquid subcooling spiral the refrigerant flow ing from the receiver to the evaporator in the re frigeration plantis cooled The intermediate cooler is dimensioned so that the cooled gas is free of liq uid refrigerant before leaving the top of the inter mediate cooler It is important to check that the float valve is operating correctly and keeping the liquid level constant Frosting of the liquid level pipe on the intermediate cooler indicates the liquid level 0178 933 ENG Rev 2005 12 09 04 technical description fm Service manual SMC TSMC 100 Mk4 4 Technical Description As a matter of precaution a solenoid valve should be used in the liquid line to the float so that it may shut off the liquid flow to the intermediate cooler whenever the system is stopped At regular intervals the intermediate cooler must be drained of oil through the oil drain valve Intermediate Cooling System with Liquid Injection into the Intermediate Discharge Gas R22 and R717 Two stage compressors type TSMC can be equipped with a pipe connection from the LP stage discharge branch to the HP stage suction branch as shown in Fig 4 56 In the pipe connection the warm discharge gas from the LP stage is cooled by injection of liquid ref
79. 6 Technical Data Specification of Compressor Materials The materials to be used for the individual compo nents of the compressors have been selected in view of a long life wear resistance as well as re Table 6 16 the compressors portant componenis sistance to the refrigerants and oils approved for The following table Table 6 16 lists the most im Designation Compressor frame SMC and TSMC Compressor frame HPC 100 Oil pump housing HPC 100 SMC and TSMC 100 Bearing cover pump end HPC 100 SMC and TSMC 100 Water covers 100 SMC and TSMC 100 All other covers SMC and TSMC All other covers HPC Crankshaft HPC 108 Crankshaft all other compressors Connecting rod Piston pin bushing Half section of bearings for Connecting rod Bolts for connecting rod Piston Piston rings and oil scraper ring Piston pin Cylinder liners Suction and discharge valve plates Suction valve retaining plate Safety head spring Main bearings Shaft seal carbon ring Material Cast iron Ductile cast iron Cast iron Ductile cast iron Cast iron Cast iron Ductile cast iron Ductile cast iron Ductile cast iron Ductile cast iron Phosphor bronze White metal on a steel base Cr Mo steel Aluminium alloy Cast iron Cr steel Cast iron w special heat treatment Special steel Ductile cast iron Steel spring White metal on a steel base Special carbon Form EN GJL 250 EN 1561 EN GJS 500
80. 6A seen from the inside of the compressor 250 342 The bearing bushings can be delivered with crankshafts ground to undersize See Spare Parts List The crankshaft for the SMC 112 and 116 and for the TSMC 116 is fitted with a centre bearing This is fitted with four sets of bearing half bushes of the same type as used in the connecting rods The centre bearing housing is made up of two half parts which must be clamped around the crank shaft before this is inserted into the compressor stand The half parts are assembled by means of four screws and guided together with the aid of cylin drical guide pins The bearing housing is prevent ed from rotating by two screws Pos 49F These screws are accessible only when the threaded plug Pos 49H has been removed The screws can be removed using a box wrench NV 17 and crank from the tool set 0178 933 ENG Rev 2005 12 09 13 service instructions fm Service manual SMC TSMC 100 Mk4 13 Service Instructions Compressor lubricating system Fig 13 17 19D je i 15D Ka hk 15A TE e L 15 22 1141 o pr 33A 1 7 The oil pump pos 11A 1 sucks the oil from the crankcase through the strainer The pump press es the oil to the shaft seal housing through a pipe pos 38A
81. 7 EN 1563 EN GJL 250 EN 1561 EN GJS 500 7 EN 1563 EN GJL 250 EN 1561 EN GJL 250 EN 1561 EN GJS 500 7 EN 1563 EN GJS 800 2 EN 1563 EN GJS 700 2 EN 1563 EN GJS 700 2 EN 1563 BS1400 PB1 C Cl 12 9 DIN 898 BS 1490 LM13 BS 1452 W CI7 17Cr3 DIN 17210 EN GJL 250 EN 1561 EN GJS 600 3 EN 1563 54SiCr6 DIN 17221 Shaft seal steel ring Special steel A62P Suction filter Stainless steel wire mesh AISI 316 Oil level glass Glass in steel flange Oil strainer Filter cartridge AISI 304 By pass valve Various steel C75 DIN 17222 Buffer springs Spring steel Gaskets Non asbestos O ring seals CR Rubber standard Compound 2347 156 342 0178 933 ENG Rev 2005 12 09 06 technical data fm Service manual SMC TSMC 100 Mk4 6 Technical Data Pressure Levels for Standard Compressors and Components All components for refrigeration plants which are under the influence of gas pressure must be pres sure tested to prove their strength and tightness The approving authorities determine the test pres sure levels on the basis of various criteria How ever the test pressure requirements can be sum marized into a number of standard pressure levels which in practice meet the requirements set up and which can therefore be approved by most au thorities involved Table 6 17 describes each step from strength test to transport Table 6 18 shows the standard pressure levels used by Sabroe Refrigeration In case of
82. 91 AG 309 342 0178 933 ENG Rev 2005 12 09 Service manual SMC TSMC 100 Mk4 19 Drawings TSMC 108 Drawing no 0662 030 0178 933 ENG 310 342 Rev 2005 12 09 Service manual SMC TSMC 100 Mk4 19 Drawings SABROE SMC 112 116 Drawing no 0662 040 pad fo bf S LZ 1 1 9gg 1 8 E 1 26 5 L 1 ree EN gt N MOM ak NI d 4 j 8 991 Now a 1 386 EM 1 0 00 1 01 jim Sea en Y m 1 40 1 98 sued ejeds 64 311 342 0178 933 ENG Rev 2005 12 09 Service manual SMC TSMC 100 Mk4 19 Drawings TSMC 116 Drawing no 0662 050 0178 933 ENG 312 342 Rev 2005 12 09 19 spare parts drawings fm Service manual SMC TSMC 100 Mk4 19 Drawings Piston cylinder liner and connecting rod Drawing no 0662 060 18B 1 18C 1 20B 1 19N 1 7 e eo que o z o 1 e x E ow W rz lt L O o NS N IN VN Xl Lr T BN LL lA o oa 7 3 5 Z o 1 O or 7152 tO S a SEM
83. EE 228 Qualification Requirements o Rx e EID EO eee Gah eee 228 Main Power oupply cated access dues ey KG NG Mares Gon aw Rare E ect dro es 228 Tools amdJAGGOSSOIIBS s a ewe siete cise gute Es RN 228 Servicing the piston compressor eaaa 229 Pressure drop Test cese vp C Sok esa 229 Removing refrigerant from compressor 230 Servicing the refrigeration plant 231 Maintenance of reciprocating 233 General Sati urs aee eco ripe e Pane de ely deinde qid ite AA 233 Preparation for maintenance 233 PUMP dOWN uice Sud ra Eu qa cd Ed dcs 233 1 If the compressor is 233 2 If the compressor is inoperative 233 Dismantling and assembly 234 Water GOVOIS 222 lt lt face Yaw Vege we ee obere Qa ds dx ume m Rie re 234 Fitting water covers ga obs ES NUR B RU d BRINE RENEE NG Rib Deny aie fd 234 TOP GONG eT Luc TIT ETT 234 Fitting top COVER c ox ses eov NG qe deme oim b REM ea e dur
84. Fitting connecting rod Before fitting the connecting rod in the compres sor stand piston and piston rings must be fitted onto the connecting rod See the following sec tions In addition the two connecting rod bolts Pos 17C must be fitted as shown on the spare parts drawing 242 342 Fit bearing bushes into both parts of necting rod Introduce connecting rod down through top cover opening in frame and manually guide into position on crankshaft Be careful that connecting rod bolts do not leave marks in crankshaft journals Position connecting rod interior through lat eral opening on frame and fit nuts Note The two parts of the connecting rod are numbered with the same number this is only of importance when assembling Parts with different numbers must not be assembled and it is impor tant that the numbers are fitted in the same direc tion as shown in see Fig 13 11 Fig 13 11 Note Stamped number on the same side on assembly Ct 916 916 Tighten nuts Pos 17D alternately with in creasing torque and finish off with torque wrench Torque 4 4 Kpm 43 Nm 0178 933 ENG Rev 2005 12 09 13 service instructions fm Service manual SMC TSMC 100 Mk4 13 Service Instructions Piston The piston is made of aluminium and fitted with two piston rings near the piston top and an oil scraper ring Fig 13 12 Piston Type L Piston Type S There are
85. Ib kg Ib kg Ib kg Ib kg Ib IEC 160L 102 225 80 176 78 172 120 265 IEC 180M 190 419 1738 381 98 216 100 220 135 298 IEC 180L 210 462 188 414 128 282 110 243 184 406 IEC 200M 240 529 165 364 IEC 200L 265 584 235 518 190 419 170 375 260 573 IEC 2255 309 681 205 452 290 639 IEC 225M 355 783 340 750 240 529 235 518 388 855 IEC 250S 455 1003 335 739 IEC 250M 480 1058 445 981 360 794 340 750 395 871 IEC 280S 625 1378 570 1257 460 1014 445 981 475 1047 IEC 280M 680 1499 630 1389 515 1135 490 1080 565 1246 IEC 315S 875 1929 900 1984 720 1587 850 1874 IEC 315M 945 2083 940 2072 730 1609 785 1731 1000 2205 IEC 315L 1050 2315 1200 2646 830 1830 1050 2315 IEC 355S 1500 3307 IEC 355M 1790 3946 1600 3527 855 1885 IEC 355L 2095 4619 1750 3858 1510 3329 IEC 355L LA 1900 1550 3417 LB 2150 108 342 0178 933 ENG Rev 2005 12 09 06 technical data fm Service manual SMC TSMC 100 Mk4 6 Technical Data Compressor Capacity Compressor capacity is calculated by means of the COMP 1 program in the Sabroe Match Master suite of programs Alternatively contact your local dealer who can help dimensioning the compressor Dimension Sketches of Compressor Block As standard execution the compressor block can be delivered with either an analog display and safety system i e with pressure gauges pres sure sentive and thermostats or with a UNISAB II 0178 933 ENG Rev 2005 12 09 system with display and safety faciliti
86. Piston with pin and rings S 18A 1 Piston pin 18B 1 Piston ring 18C 1 Oil scraper ring 18D 1 Seeger ring dia 40 18 2 3124 052 Piston with pin and rings L 18A 1 Piston pin 18B 1 Piston ring 18C 1 Oil scraper ring 18D 1 Seeger ring dia 40 18 3 3124 065 Piston with pin and rings E 18A 1 Piston pin 18B 1 Piston ring 18C 1 Oil scraper ring 18D 1 Seeger ring dia 40 3188 028 Service kit pair of piston rings Piston ring Oil scraper ring 3188 090 Service kit half section bearings Half section of bearing Lock nut 3188 089 Service kit Piston pins LP Bushing for piston pin Bolt for connecting rod 0178 933 ENG Rev 2005 12 09 Piston pin 283 342 Service manual SMC TSMC 100 Mk4 18 Part list Designation Seeger ring dia 40 Compressor SMC 3188 030 Service kit pair of connecting rod bearings LP 3188 090 Service kit half section bearings 3188 089 Service kit Piston pins LP 3188 097 Service kit piston pin HP Needle rollar bearing Bolt for connecting rod Piston pin Seeger ring dia 40 3188 031 Service kit pair of connecting rod bearings HP Half section of bearing Lock nut 3188 097 Service kit piston pin HP
87. SPNO 37 43 Stop 45 37 Suction Ru 37 Special unloading O ama AA TAGA 70 Standard AA 67 Start Unloading te er eae 65 udi e 49 jp owe 83 jc oreet 83 Unloading c 68 BIOCK 47 Intermediate pressure 48 Needle bearing 48 Piston Pin Beanng 48 Water AA AA a 93 Description of Compressor Types 22 2 NA GANAN 34 Description of Pumping Cycle 97 Determining the Intermediate Pressure 4444222 22 84 Dimension GA 109 Direction ec c 129 136 Direction of Rotation of Electric Motor 4 2 22222 136 335 342 Service manual SMC TSMC 100 Mk4 Discharge GasTemperatures 197
88. Table 6 13 The measured value will normally lie somewhere between the stated Lp and Ly values 2 2 In machine rooms with a number of compressors the total sound pressure level can be calculated by adding AL read on the curve in Fig 6 45 to the sound pressure value for the unit with the highest sound pressure 150 342 Fig 6 45 Curve for adding of logarithmic levels Difference L L dB Example 1 With two compressors in the same room Compressor 1 Lp 81 dB A Compressor 2 86 dB Difference 5 dB A Total sound pressure level Lp 86 1 2 87 2 87 dB Example 2 In case two compressors have the same sound pressure level e g 86 dB A the difference will be 0 total sound pressure level Lp 86 3 89 cB Example 3 With a number of compressors in the same room the sound pressure level is calculated by miner of the curve Fig 6 46 as follows 0178 933 ENG Rev 2005 12 09 06 technical data fm Service manual SMC TSMC 100 Mk4 6 Technical Data Fig 6 46 3 compressors 52 61 dB 57 5 62 6 63 dB 6 compressors 48 54 61 62 62 58 dB 55 0 62 0 po 65 0 66 7 L m 67 2 67dB 2 3 It is essential that during a potential check meas uring to carry out more than one sound pressure measuring e g by measuring in fields as shown in Fig 6 44 as a few local measures may result in incorrectly high measured values
89. and returns the oil to the crankcase 56 342 The pipe connection with valve B acts as a pres sure equalizer between the two vessels The float can be dismantled for servicing Oil Return in Connection with Parallel Operation If several compressors are running in parallel on the same refrigeration plant it is expedient to ad just their oil level in the crankcase by means of an automatic system This is particularly necessary in the case of HFC and HCFC plants in which the oil is returned to the compressors with the suction gas as it is not distributed evenly on all the com pressors However also in modern automated R717 refrig eration plants an automatic oil equalizing system can contribute to greater reliability thus reducing the daily inspection tours The following passages A B and C include a de scription of the three systems most commonly used The following passages describe each of the three systems in general For more detailed infor mation please contact Sabroe Refrigeration 0178 933 ENG Rev 2005 12 09 04 technical description fm Service manual SMC TSMC 100 Mk4 4 Technical Description x SABROE System A System A is used where two or more compres Principle diagram Fig 4 33 is an example of a sors are working in parallel and where either HFC plant with two compressors working in parallel on HCFC or R717 is used as the refrigerant It is a the same suction and discharge line con
90. and washers pos 24E 24B 5 T 254 342 0178 933 ENG Rev 2005 12 09 13 service instructions fm Service manual SMC TSMC 100 Mk4 13 Service Instructions Strainer All oil to the compressor lubricating system is fil tered through a strainer pos 33A 1 which is mounted in the crankcase As shown in Fig 13 22 the strainer is a unit con sisting of a 100 stainless primary filter anda shield covering half the filter Fig 13 22 Strainer Oil filter After oil pump and strainer the oil is further filtered in a full flow filter pos 9A The filter element is a disposable filter and must be replaced with a new one when the filter capacity is used up The filter element pos 9A is a unit consisting of a 13 p filter Replacement of the filter is carried out as described in the following see also oil diagram Fig 13 23 Stop the compressor Close shut off valve pos 4 1 Remove the cap and turn the spindle clockwise Close shut off valve pos 4D 1 Remove the cap and turn the spindle clockwise Open purge valve pos 4E 1 Remove the cap and turn the spindle counterclockwise 0178 933 ENG Rev 2005 12 09 SABROE Bleeding ensures pressure equalizing of the filter element before it is changed The filter element be removed when there is no longer any oil running from the branch pos 4F 1
91. any way during operation The guard is marked with a sign A When mounting the coupling guard make sure that it is not in contact with any rotating parts For correct torque see the Service Instructions sec tion After 20 hours check to see if tightening up is required Check the coupling guard for correct tightening cracks or other defects every 5000 hours A Do not start the compressor until the coupling guard or belt drive is mounted correctly Before performing any kind of work on the coupling make 20 342 sure that the compressor motor cannot start up unintended When performing service where the motor is dis mantled from the base frame follow the instruc tions for coupling alignment in the Installations In structions section Belt drive The belt guard is not designed to resist unintend ed load and is therefore marked with a warning sign No step When the belt guard is mounted it should be checked after 20 hours whether tight ening up is required Check the belt guard for cor rect tightening cracks or other defects every 5000 hours Lifting and Carrying Safety Contact Sabroe Refrigeration if you have any questions or if you are not sure about the proper procedures for lifting and carrying Before lifting or carrying a compressor unit or oth er parts determine the weight and size by means of e g tags shipping data labels marked infor mation or manuals Use power hoists or other mechan
92. assembling parts should generally be fitted in the same posi tion from which they were taken and should therefore be marked as they are removed Further they should be thoroughly cleaned checked and lubricated prior to being reassembled Water covers Dismantling water covers The water covers may be dismantled even with pressurised compressor as the water covers are mounted with four independent nuts Always make sure however that the compressor cannot start while the water covers are being dismantled To dismantle the water covers first shut off the water supply Also to avoid scalding when dis mantling make sure that the water temperature inside the system does not exceed 70 C 158 F First remove the hoses connecting the individual water covers Then loosen the four nuts A on top of each water cover and the water covers can be lifted away If the water cover sticks to the top cov er underneath loosen it with a blow from a soft hammer on the side Fig 13 3 M 2 5 234 342 Fitting water covers Before assembling the water cover check that the o ring gaskets are not damaged If so they must be replaced Also thoroughly clean the o ring groove and the gasket surface on the top c
93. be dismantled without re moving the top covers and depressurizing the compressor the pipe system and the inner faces of the water cover can easily be cleaned of any impurities It is fairly easy to build this water cooling system on an air cooled compressor Note however that the air cooled side covers must be replaced with covers with cooling fins on the inside This may be seen by comparing Fig 4 60 with Fig 4 65 88 342 Fig 4 64 Water cooled Top Cover M Note Do not use sea water as cooling water on top covers Fig 4 65 Water cooled Side Cover Mounting of Cooling Water Hoses On delivery of the compressor the cooling water covers are mounted but they are not connected with water hoses These are delivered separately to avoid damaging the hoses and connecting branches during transportation and mounting The cooling water hoses are mounted as shown in the drawing which is delivered with the compres sor A copy of this drawing can be seen in Fig 4 66 0178 933 ENG Rev 2005 12 09 04 technical description fm Service manual SMC TSMC 100 Mk4 P 4 Technical Description SABROE Fig 4 66 Mounting of water hoses on top and side covers Cooling of top and side covers SMC 104 106 108 and TSMC 108 SMC 104 3185 230 Pos Hose Type mm
94. before operating the compressor unit Failure to follow safety in structions may result in serious personal injury or death Important The safety precautions for this Sabroe Refrigeration compressor have been pre pared to assist the operator programmer and maintenance personnel in practicing good shop safety procedures Operator and maintenance personnel must read and understand these precautions completely be fore operating setting up running or performing maintenance on the compressor unit These precautions are to be used as a supple ment to the safety precautions and warnings in cluded in All other manuals pertaining to the compres sor unit b Local plant and shop safety rules and codes 0178 933 ENG Rev 2005 12 09 SABROE c National safety rules regulations and direc tives General Safety Instructions and Considerations Personal Safety Owners operators set up maintenance and service personnel must be aware that constant day to day safety procedures are a vital part of their job Accident prevention must be one of the principal objectives of the job regardless of the activity involved Know and respect the compressor unit Read and carry out the prescribed safety and checking pro cedures Make sure that everyone who works for with or near you fully understands and more importantly complies with the following safety precautions and procedures when operating this compre
95. class B 90K approx 10 continual overloading of the motor will be acceptable in connection with the nominal effect As mentioned previously all compressors are as standard completely unloaded during the start up phase This reduces the power consump tion of the compressor considerably as may be seen from the starting torque curve Fig 6 20 As standard the SMC 100 can only be capacity regulated in steps of two cylinders which is usual ly satisfactory If required extended unloading can be ordered when the order is placed or it can be mounted at a later time For more information on this subject see chapter 4 Technical Description Extended unloading of the Compressor 0178 933 ENG Rev 2005 12 09 06 technical data fm Service manual SMC TSMC 100 Mk4 6 Technical Data The starting torque for compressors with extend ed unloading appears from Fig 6 22 and Fig 6 23 Please note that moment of inertia is not included in the diagrams Further pay attention to the fact that the motor should reach its maximum torque before the non adjustable cylinders are put into operation SABROE The maximum time for reaching minimum rpm TSMC 100 750 rpm is 5 sec and nominal speed should be reached after max 10 sec For more information on this see chapter 4 Tech nical Description Capacity Regulation and Un loading of the Compressor Fig 6 20 Starting torque at 0 load 500
96. compressor Selecting an Oil Separator As the velocity through the oil separator affects the ability of the oil separator to separate the oil from the discharge gas a series of oil separators of different sizes has been designed A special type of oil separator with a very low oil carry over is available on request 51 342 Service manual SMC TSMC 100 Mk4 4 Technical Description Oil Return to the Compressor The oil separated in the oil separator is usually conveyed directly back to the compressor crank case by means of the differential pressure be tween the pressure of the oil separator and that of the crankcase PE As the return of gas from the discharge side to the suction side will have a negative effect on the plant it is desirable to lead only the separated oil back to the crankcase This is controlled by using a thermodynamic liquid trap TLT combined with a reliable solenoid valve which blocks the system at standstill Furthermore it makes it possible to delay the opening of the oil return after start up and thus allowing condensed refrigerant if any in Fig 4 26 Solenoid Valve Controlled Oil Return Oil separator the oil separator to evaporate and not be led back to the crankcase For plants which do not allow solenoid valves a reliable float valve controlled system can be deliv ered at an additional price A Solenoid Valve Controlled Oil Return As illustrated in the drawing Fig 4 26 the oil
97. cylinders are called short blocks whereas compressors with 12 and 16 cylinders are called long blocks Short Block bM O EO O O o Long Block iif Single stage compressors are designated SMC S has 80 mm piston stroke and is which is an abbreviation of SABROE Multi cylin used with all approved refrigerants der Compressor As for the two stage compres sors the letter T has been added to indicate Two stages has a 100 mm piston stroke and is used with all approved refrigerants has a 120 mm piston stroke and is used only in connection with R717 The compressor has 50 more capacity than type S Further the compressors can be delivered with the following three strokes designated S L or E respectively 34 342 0178 933 ENG Rev 2005 12 09 04 technical description fm Service manual SMC TSMC 100 Mk4 4 Technical Description The operating limits including number of revolu tions depend on the compressor type and refrig erant As the extension of the operating limits is an 7 SABROE ongoing process please make sure that the dia gram in question is the latest revision before mak ing a conclusion Below are given some examples of type designations of the compre
98. dirt Congestion due to iron oxides Congestion due to copper oxides o N D O N Inadequate refrigerant charge Below information is given about ways of keeping contaminants out of the refrigerating system and at the same time facilitating day to day supervi sion of the refrigeration plant Pumping down the refrigeration plant Before dismounting any parts of the refrigeration plant for inspection or repair pump down must be carried out 1 Open suction and discharge stop valves compressor 2 Close liquid stop valve after condenser receiver so that liquid refrigerant can be col lected in the tank Any solenoid valves in the liquid line should be opened by force ad justing the thermostat to its lowest position so that the liquid line can be bled of refriger ant Adjust any constant pressure valves to bring evaporator pressure down to atmos pheric pressure 3 Start up the compressor Adjust regulating system to lower suction pressure 0178 933 ENG Rev 2005 12 09 4 Keep a close eye on the suction pressure gauge When the suction pressure is equal to at mospheric stop the compressor and quickly shut off the discharge stop valve Shut off any stop valve in the oil return line 5 If the receiver has an extra stop valve in the feed line this can be closed practically the entire refrigerant charge will then remain shut off in the receiver Note The receiver must not be overfille
99. effect The boiling point for CO is 78 5 at 1 013 bar CO is an odourless non toxic non inflam mable gas At concentrations higher than 5000 ppm the gas can be dangerous for hu mans The gas is heavier than air and will thus be concentrated on the lowest level of the room in case of a leak In closed rooms the gas can displace oxygen and cause suf focation Refrigerant evacuated from a refrigeration plant must be charged into refrigerant cylinders intend ed for this specific refrigerant If the refrigerant is not to be reused return it to the supplier or to an authorized incineration plant Halogenated refrigerants must never be mixed Nor must R717 ever be mixed with halogenated refrigerants 27 342 Service manual SMC TSMC 100 Mk4 3 Safety Precautions Purging a refrigeration plant If it is necessary to purge air from a refrigeration plant make sure to observe the following Refrigerants must not be released into the atmosphere exept When purging an R717 plant use an ap proved air purger The purged air must pass through an open container of water for any remaining R717 to be absorbed The water 28 342 mixture must be sent to an authorized incin eration plant Halogenated refrigerants cannot be ab sorbed by water An approved air purger must be fitted to the plant This must be checked regularly by use of a leak detector Note The occurrence of air is usually an indica
100. if the inspected parts must be replaced In other words these sets tell the service techni cian what to bring to the inspection 0178 933 ENG Rev 2005 12 09 11 maintenance instructions fm Service manual SMC TSMC 100 Mk4 11 Maintenance Instructions Measures to be taken The following sections describe the measures which must be taken They include information about tools materials preparations and imple mentation Noise and Vibration No special requirements are imposed regarding equipment and materials Inspect the unit and check that there is no abnormal noise and vibra tion Listen for any knocking or other abnormal noise caused by poorly clamped pipes or faulty valves Evaporating Pressure and Condensing Pressure No special requirements are imposed regarding equipment and materials Check on the operator s panel or manometers that the pressures comply with what is set forth in the specifications issued for the reciprocating compressor unit in question and that they are within the permissible operating ranges Evaporating Pressure The terms evaporating pressure and suction pressure refer to the pressure on the suction side of the compressor Usually the pressure is the same at the evaporator outlet as at the compressor inlet The only differ ence is the pressure drop in the line Because of this pressure drop the pressure at the evaporator outlet is a little higher than at the compressor
101. loaded cone The spring pressure is adjusted by turning an adjusting screw at the valve end Use a screw driver for this purpose Turning right clockwise raises the oil pressure turning left counterclockwise lowers the pres sure Fig 13 20 Locking screw 22A 0178 933 ENG Rev 2005 12 09 x SABROE Adjustment Oil pressure 4 5 bar The oil pressure can be read off the suction pres sure gauge or on UNISAB II On more recent compressor models the adjusting screw may be locked by means of an M6 pointed screw see Fig 13 20 which must be loosened before adjustment can take place Service Since the oil pressure valve is not subject to any appreciable wear or soiling it should not be disas sembled during routine services In the event of a malfunction the complete valve should be replaced 253 342 Service manual SMC TSMC 100 Mk4 13 Service Instructions By pass valve pos 24 The compressor is equipped with a built in me chanical by pass valve see Fig 13 21 which secures it against any inadvertent excess pres sure if the electrical safety equipment fails The by pass valve safeguards against any excess pressure between the discharge and suction sides of the compressor If the by pass valve is released the compressor must be stopped immediately and the cause es tablished The by pass valve is supplied ready set and sealed in accordance with
102. loosen it with a blow from a soft hammer on the side while keeping the four nuts fitted This is important because of the powerful spring pressure beneath the top cover After dis mantling the four nuts unscrewing them nately the top cover can be removed Fitting top cover Before fitting the top cover the long plug must be fitted into the relief cylinder Also check that the gasket D is intact and if necessary that the clearance volume and lifting reserve have been adjusted as described later in these instructions If the gasket D needs to be replaced at all the graphitized side must face the compressor frame Place the top cover loosely on top of the springs Pos 21 using the four staybolts as guides Before 0178 933 ENG Rev 2005 12 09 x SABROE tightening the four nuts C on the staybolts all screws must be mounted by hand Tighten the top cover firmly first with the four nuts mentioned above then with the remaining screws Finally cross tighten all the screws and nuts to the pre scribed torque in the following sequence Fig 13 5 Ap O 4D o 7 1 3 5 11 9 115 13 16 14 6 6 the top cover has been fitted remove the long plug and insert the short plug The top cov ers must be mounted as shown in the following chart 235 342 Service manual SMC TSMC 100 Mk4 13 Service Instructions Mounting top and water covers Fig 13 6
103. maintenance presented in the following instructions Maintenance can be divided into three groups 1 Daily Maintenance This consists of visual inspections When fa miliar with the normal noise and vibration of the unit compare each day s performance with previous observations Make compari sons with the available diagrams etc to make certain that the operating data lie with in the permissible ranges e Inspect the compressor unit and check that both noise and vibration are normal e Enter the observed operating data into the operations log see Table for Moni toring Operation in chapter 10 Operat ing Instructions Check that all operating values are within the permissible rang es Compare them with previous values to detect trends If necessary submit a report so that a closer check can be made e Check the oil level in the oil separator Screw compressor unit e Check the oil level in the compressor Reciprocating compressor unit e Check oil pressure e Check the refrigerant charge 202 342 e Search for leaks if there is even the slightest suspicion that there may be a leak Conducting a manual check right at the compressor unit itself is always the best way to check for a leakage of oil and or refrigerant b leakage of cooling water or brine c abnormal vibrations e Donotwait for the monitoring equipment to issue an alarm Searching for leaks is explained in greater detail later in this chapt
104. new plant x Incase you wish to change from mineral oil 0178 933 ENG Rev 2005 12 09 171 342 Service manual SMC TSMC 100 Mk4 6 Technical Data R717 HPO and HPC reciprocating compressors Code no PAO 5 Area no 1 A Condensing temperature 22 4 14 32 50 68 86 104 122 F Evaporating temperature Note Please observe PAO 5 oil is the only oil which can be used in the HPO and HPC compressors Very suitable in case of a new plant 172 342 0178 933 ENG Rev 2005 12 09 06 technical data fm Service manual SMC TSMC 100 Mk4 6 Technical Data List of Major Oil Companies The oil from the companies listed below are not tested by Sabroe Refrigeration and are therefore not ap proved by Sabroe Refrigeration The following list includes the information provided by the oil companies The oil companies are responsible for the information concerning the durability and suitability of their oils for specific purposes Oils tested and approved by Sabroe Refrigeration are included in the List of Part Numbers for Available Sabroe Oils Oil Types Oil Company M A PAO AP E Aral Castrol Chevron UK Gulf Oil CPI Engineering Services Elf Lub M
105. oil changing intervals Improved viscosity at low tem peratures facilitates furthermore drainage at the cold parts of the plants How to Use the Diagrams in the Oil Recommendation To find the correct code number select refrigerant and compressor type in the oil recommendation diagram Then insert the estimated operating con ditions in the diagram Example reciprocating compressors Refrigerant R134a Condensing temperature TC 35 C Evaporating temperature TE 3 C Note Sometimes plants operate under different conditions e g different evaporating tempera tures due to variations in the plant or different condensing temperatures as a result of seasonal changes By inserting TC and TE in the oil recom mendation diagram the recommended area is found In this case it is oil area 1 If TC should change e g from 3 C to 7 C use oil area 2 As 7 C is within the marked area oil area 1 can however also be used at this TE 0178 933 ENG Rev 2005 12 09 SABROE Fig 6 53 122 68 50 Condensing temperature o N A 50 40 30 20 10 58 40 22 4 14 32 50 68 86 Evaporating temperature By using the table which is situated next to the oil recommendation diagram select the recommend ed code number and thus the recommended oil In the example above an oil with code number E5 can be used
106. or V belt pulley as described in the following The coupling flange or the V belt pulley is fixed by means of a cone clamping system Fig 6 30 yy Boring of Hub The coupling flange or the pulley is usually mounted on the compressor shaft on delivery of compressor units On delivery of compressor blocks where the cus tomer prefers to bore the hub himself the follow ing procedure should be observed It is recommended to use the types of coupling as stated for SABROE compressors If the neces sary data is not known on delivery of the compres sor the coupling flange for the motor will be deliv ered pilot bored and the boring must be completed on site 138 342 Coupling Types AMR 312 for SMC 104 106 108 and TSMC 108 HPC 104 106 108 AMR 350 for SMC 112 116 and TSMC 116 Just like the flange to the compressor the motor coupling flange has been duly balanced from fac tory This makes special demands on the accura cy of the boring procedure Boring Procedure The coupling flange is fixed in a lathe or a fine bor ing machine by tightening the outer diameter C of the flange Fig 6 31 Fig 6 31 Coupling Flange to Motor Shaft A fd Max 0 02 mm Alignment must be kept within the values stated in Table 6 6 0178
107. order to increase the oil level 10 mm is indicated in the table Table 6 20 0178 933 ENG Rev 2005 12 09 Fig 6 50 Oil level glass Table 6 20 Oil level Compressor Difference in oil 4 level of 10 mm Type Size corresponds to 104 SMC HPC 106 2 litres of oil 108 0 5 US gal TSMC 108 112 SMC 116 6 litres of oil 1 6 US gal TSMC 116 A manually operated pump connected to the oil charging valve pos B can be used for the first as well as the following oil charges See chapter 5 Physical and Connection Data Note On HPC 100 compressors with R717 and R744 the pressure must be relieved before oil charging 159 342 Service manual SMC TSMC 100 Mk4 6 Technical Data Fig 6 51 Manually Operated Oil Pump Optional hand operated oilpump 5 Gasket 71 k EH i gt 0177131 0V 160 342 0178 933 ENG Rev 2005 12 09 06 technical data fm Service manual SMC TSMC 100 Mk4 6 Technical Data Oil Consumption In refrigeration compressors there will always be a minor oil consumption which means that a little oil is bound to follow the warm discharge gas out of the compressor In order to separate this oil an oil separator is nor mally used The separator is built into the dis charge pipe right next to the co
108. ratio for single stage compressors This is described in detail in chapter 6 Technical Data Operating Lim its As mentioned previously all compressor types in the SMC 100 and TSMC 100 series with a few exceptions are built up of the same components and with the same facilities However the TSMC 100 compressors deviate on the following points Compressor Block The interior of the compressor block is construct ed with suction chambers for both low pressure and high pressure stages The pressure in the crankcase is the same as the suction pressure of the LP stage 47 342 Service manual SMC TSMC 100 Mk4 4 Technical Description Piston Pin Bearing In the SMC and TSMC low pressure stages the piston pin bearing consists of slide bearings pos 17B Fig 4 21 In the connecting rods of the high pressure stage a needle bearing pos 17B 2 has been fitted This is because HP pistons on two stage compressors as opposed to single stage and LP pistons are often subject to uni di rectional force Fig 4 22 TSMC cylinder liner 48 342 Fig 4 21 TSMC 100 Cylinder Liner Complete 17B TSMC HP 17B TSMC LP Similarly an O ring pos 19M is used to seal the intermediate pressure chamber from the crank case in which there is evaporating pressure 0178 933 ENG Rev 2005 12 09 04 technical description fm Service manual SMC TSMC 100 Mk4 4 Technical Descrip
109. sensor kit 4 conductor 1 2 thread 3 Notes 1 Not used for compressors 0178 933 ENG Rev 2005 12 09 2 Only used forHPO HPC compressors 3 With 1 2 1 4 nipple cutting ring and instruction 303 342 Service manual SMC TSMC 100 Mk4 18 Part list Tools for compressor The SMC 4 compressor tool set comprises the tool set for Mk3 and a supplementary set for Mk4 The tool set for Mk3 MG NNNM m T0177095_0 1 2 304 342 0178 933 ENG Rev 2005 12 09 tool list fm 18 spare parts list Service manual SMC TSMC 100 Mk4 18 Part list Tools for compressor SMC 104 116 Mk3 amp TSMC 108 116 Mk3 Type S L E Line no A600 Normal set tools set no 3183 109 Line no A601 Extended set tools set no 3183 110 Line no A602A Tools for coupling SMC 104 108 Line no 602 Tools for coupling SMC 112 116 Line no A603 Tools for alignment of coupling Line No Designation Dimen part No 600 601 A602 A603 sion A B 1 1 Clamp with screw compr type S and L 3183 144 4 4 1 2 Clamp wi
110. shaft end V belt driven 4 36 31 37 15 37 84 41 59 4280 37 32 38 22 39 05 43 68 46 41 38 69 40 29 40 74 46 75 49 41 compressor with shaft pulley No of V belts 6 33 35 34 18 3487 38 62 3983 3435 35 25 3608 40 71 43 44 35 72 37 32 37 77 43 78 46 44 Profil SPB 8 42 26 43 09 43 75 47 53 48 74 43 25 44 16 44 99 49 62 52 35 44 63 46 22 46 67 52 68 55 34 Direct driven com 6 22 7 05 7 74 13 28 14 49 7 22 8 12 8 95 15 37 18 10 860 1019 10 64 18 43 21 09 pressor with com plete AMR coupling 0178 933 ENG 135 342 Rev 2005 12 09 Service manual SMC TSMC 100 Mk4 6 Technical Data Direction of Rotation of Electric Motor Sometimes the motor is equipped with specially designed ventilation wings to reduce the noise level These motors have a specified direction of rotation which must be considered when con necting them to a compressor If the motor is con nected by means of a coupling it must rotate clockwise when looking at it from the shaft end Fig 6 24 Fig 6 24 If the motor is connected by means of a V belt pul ley the direction of rotation should be as follows 136 342 SMC 104 106 108 and TSMC 108 Anti clockwise Fig 6 25 Fig 6 25 SMC 112 116 and TSMC 116 Clockwise Fig 6 26 Fig 6 26 Note The driving part of the V belts must always be closest to the bas
111. system Emergency stop mounted when installing the unit UNISAB II control system Th cO stop lj 2 TF Sy L NISUS fl les Safety during Service Before dismantling or servicing a compressor or unit attention should be paid to the following points Read the Safety Precautions in chapter 3 before opening the compressor and other parts of the refrigeration plant Make sure that the motor cannot start in advertently It is recommended to remove all main fuses 16 342 Switch off all electric components on the compressor unit before the disman tling servicing Make sure that there is neither overpressure nor any refrigerant in the part to be disman tled Close all necessary stop valves Use gloves and safety goggles and make sure to have a gas mask ready for use Use the prescribed tools and check that they are properly maintained and in good working condition In explosion proof areas use tools especially suited for this specific purpose When dismantling the top covers attention should be paid to the considerable spring force beneath the covers When the screws are loosened the cover must lift itself from the frame as described in the instruction manual Fig 2 6 Springs Top cover
112. tainers whose size correspond to the amount to be used In case all of the oil is not used make sure that the rest of the oil is sealed in the original container and stored in a warm dry place It is recommend ed to charge nitrogen to keep the water content below 50 ppm Ideally oil containers should be equipped with a barrel tap to ensure an effective airtight seal 0178 933 ENG Rev 2005 12 09 06 technical data fm Service manual SMC TSMC 100 Mk4 6 Technical Data Oil Changing Intervals A list of the recommended oil changing intervals is included in the instruction manuals of the com pressors This list is for guidance only The actual oil changing intervals are often determined by a number of operating parameters in the plant Oil recommendation diagram symbols Incase of a new plant Very suitable In case you wish to change from mineral oil x SABROE It is strongly recommended to monitor the quality of the oil by performing oil analyses on a regular basis This will also give an indication of the con dition of the plant This service can be supplied by Sabroe Refrigeration or the oil supplier Max oil concentration in liquid phase at 2 W x Max oil concentration in liquid phase contact Sabroe Refrigeration Min suction temperature 50 C At TE lt 50 C superheating must be introduced Dry expansion systems only Flooded systems to be considered individually contact
113. the main fuses are dismantled If any tool is required to remove a guard cover bracket or any basic part of this compressor place the Main Disconnect Switch in the OFF position and lock it in the OFF position If possible post sign at the disconnect switch indicating that main tenance is being performed Dismantle main fus es to the unit 22 342 Danger HIGH VOLTAGE Before working on any electrical circuits place the Main Disconnect Device of the compres sor unit in the OFF position and lock it Dis mantle the main fuses to the compressor unit Unless expressly stated in applicable Sabroe Refrigeration documentation or by ap propriate Sabroe Refrigeration Field Service Representative do NOT work with the electri cal power ON If such express statement or advice exists work with the electrical power ON should be performed by a Sabroe Refrigeration Field Service Represent ative The customer and subsequent transfer ees must make sure that any other person per forming work with the electrical power ON is trained and technically qualified FAILURE TO FOLLOW THIS INSTRUCTION MAY RESULT IN DEATH OR SERIOUS PERSONAL SHOCK INJURY When maintenance is to be performed in an area away from the disconnect and the switch is not locked tag all start button stations with a DO NOT START tag Adequate precautions such as warning notices or other equally effective means must be taken
114. the LP and the HP cylinders Further the TSMC compressors can as standard equipment be totally unloaded as described in the following Total Unloading Besides the standard equipment as described in the previous passage the compressor can be fit ted with a solenoid valve marked S optional Fig 4 45 68 342 The TSMC compressors however are always equipped with this S solenoid valve The S solenoid valve makes the total unloading of the compressor possible i e the compressor idles at 0 capacity The S solenoid valve must never however be part of a normal capacity reg ulation as the compressor will heat up excessively during a lengthy operating period at 0 capacity The S solenoid valve must therefore only be used as follows When total unloading is required until the motor has reached its maximum torque When a refrigeration plant has sudden brief operational stops for a short time and com pressor stop is not required In this case the compressor must not be allowed to run for more than 5 minutes at 0 capacity If the compressor is equipped with a refrigerant cooled oil cooler type OOSI R717 or OOKH HFC HFCF and liquid refrigerants are available so that the cooling system can operate idling is allowed for up to 30 min utes The regulating sequence can be seen from the schematic drawings in Fig 4 45 Capacity Stages The SMC 100 compressors can be regulated with the following capacity stage
115. threaded plug is fitted while the top cover is being mounted Remember to put in the normal plug pos 12D once the top cover has been tightened 0178 933 ENG Rev 2005 12 09 13 service instructions fm Service manual SMC TSMC 100 Mk4 13 Service Instructions Pressure gauges The analog instrumentation on the compressor in cludes two pressure gauges one that measures the discharge pressure on the compressor and one combined suction and oil pressure gauge These pressure gauges are filled with glycerine which both attenuates the deflections of the indi cators and lubricates the gauge works However a fluctuating ambient temperature has an influence on the volume of the glycerine warm glycerine takes up more space than cold glycer ine which can affect the measuring accuracy of the gauge Furthermore it is essential that no ex cess pressure can possibly occur in the gauge housing as this involves a risk of explosion of the housing Both these considerations have been effectively solved in the gauges by a combination of internal temperature compensation and the so called blowout safety device which is fitted in the back plate of the pressure gauge housing Adjustment to other temperature ranges A balancing screw at the rear of the instrument is firmly tightened at a temperature of 20 C the nor mal ambient temperature If ambient temperatures change considerably thus requiring a general shift in th
116. to prevent electrical equipment from being activated electrically when maintenance work is being per formed When removing electrical equipment place number or labelled tags on those wires not marked If wiring is replaced be sure it is of the same type length size and has the same current carrying capacity 0178 933 ENG Rev 2005 12 09 03 safety precautions fm Service manual SMC TSMC 100 Mk4 3 Safety Precautions Close and fasten all guards shields covers plates or doors securely before power is recon nected An electrician must analyse the electrical system to determine the possible use of power retaining devices such as capacitors Such power retaining devices must be disconnected discharged or made safe before maintenance is performed Working space around electrical equipment must be clear of obstructions Provide adequate illumination to allow for proper operation and maintenance 0178 933 ENG Rev 2005 12 09 x SABROE Materials Used with this Product Always use Sabroe Refrigeration original spare parts Please note the type of refrigerant on which the compressor operates as well as the precautions that need to be taken as described in the following sections First aid for accidents with ammonia First aid for accidents with First aid for accidents with HC First aid for accidents with CO Protecting the operator as well as the environment 2
117. using cutting tools e g angle grinder or flame cutter during the dismantling process as pipes or the like will contain oil residue which may ignite Refrigerant residue does also involve a great risk as HFC and HCFC refrigerants will develop toxic gasses when heated Make sure that there are no air traps as heating will result in a pressure rise Disposal of Machine Parts When dismantling the plant it is important to sort the parts to be disposed of Compressor frame containers etc belonging to the category of iron and metal scrap must be delivered to an approved scrap dealer complying with the prevailing rules and regulations of the individual country Disposal of Oil and Refrigerant Oil and refrigerant must be delivered for destruc tion or regeneration at a receiving station for haz ardous waste including used oil filters The re ceiving station must comply with the prevailing rules and regulations of the individual country 325 342 Service manual SMC TSMC 100 Mk4 20 Final Disposal Disposal of Electrical Components Electrical and electronic products e g wiring panels hardware etc must be delivered to a re ceiving station approved to handle electronic waste The receiving station must comply with the prevailing rules and regulations of the individual country 326 342 Disposal of Batteries Used batteries from e g the backup of the compu ter control must be delivered for destruction at a receivi
118. 0 07 0 07 0 11 Main bearing journals 54 5 0 09 59 5 0 09 54 5 0 09 79 5 0 09 79 5 0 09 134 014 o Connecting rod 0 025 0 035 0 0 0 015 E bearing journals 95 5 002 9 002 7 194 20060 o T 0 010 Intermediate journals 79 5 0 029 Bushing and bearing valves can be supplied for all above journals 0178 933 ENG 331 342 Rev 2005 12 09 Service manual SMC TSMC 100 Mk4 21 Appendices 332 342 0178 933 ENG Rev 2005 12 09 0178 933 ENGIX fm Service manual SMC TSMC 100 Mk4 P SABROE Index A Accidents with quie ic OO SS 24 Accidents with aeS 25 Air Cooled Top and Side 101 Air Cooled and Side Covers and Refrigerant Cooled Oil Cooler 101 Air Cooled Top Covers and Water Cooled Side Covers 101 140 Reading ME een ere NAN ee 77 LOG VS a 129 a etu ad ee 327 Area of 36 licct isse aa 31 B Bearings Main 249 Boring of HUD T 138 inde M 29 elie Cf iue Coon dn uS AA 49 By pass Valv
119. 00 SMC 100 SMC 180 CMP 1 TCMO 2 TSMC 65 TSMC 100 TSMC 100 TSMC 180 TCMO 1 4 10 cyl 12 16 cyl CMO 4 HPO HPC Mk 1 amp Mk2 Main bearinas manufactured 0 08 0 08 0 08 0 08 0 08 0 14 9 max 0 20 0 20 0 20 0 20 0 20 0 35 Connecting rod manufactured 0 08 0 08 0 08 0 10 0 10 0 14 bearings max 0 15 0 15 0 15 0 20 0 20 0 30 Piston pin manufactured 0 04 0 04 0 04 0 04 0 04 0 09 bearings max 0 10 0 10 0 10 0 10 0 10 0 20 Parallel to manufactured 0 18 0 18 0 20 0 20 0 20 0 25 5 piston pin max D Al right angles manufactured 0 11 0 11 0 11 0 15 0 15 0 35 to piston pin max 0 30 0 30 0 30 0 40 0 40 0 90 If the maximum value has been exceeded replace the parts Crankshaft end play min 0 30 0 30 0 40 0 40 0 75 0 95 max 0 55 0 55 0 55 0 64 1 00 1 20 The end play can be adjusted by means of the gasket under the bearing cover The gasket is available in the following thicknesses 0 3 0 5 0 75 1 0 1 3 1 5 1 75 and 2 0 mm Piston ring gap min 0 25 0 25 0 25 0 33 0 33 0 66 max 1 00 1 00 1 00 1 30 1 30 1 50 The piston ring gap must be measured with the ring placed in the cylinder liner Dimensions of crankshaft bearing journal 0 06 0 06 0 06 0 07 0 07 0 11 Main bearing journals 55 0 09 60 0 09 55 0 09 80 0 09 80 0 09 135 0 14 Connecting rod 0 025 0 040 0 0 0 015 bearing journals 55 5050 9 9059 9 gox 9 coo 99 195 000 Intermediate journals 80 0 010 0 029 0 06 0 06 0 06
120. 01 introduction fm Service manual SMC TSMC 100 Mk4 Manual for SMC and TSMC Mk4 S L E The SMC TSMC reciprocating compressor can be fitted with a range of equipment depending on the function and requirements it is expected to meet Some of these variants are discussed in this man ual even if they are not featured on your particu lar unit The variants featured on the unit are marked with in the following diagram with the compres sor number stated below Compressor type swch tswclL sly Ll 1040 1064 1084 noli Compressor R717 R22 U R134a LL R404A R507 other Control UNISAB II control and regulating system Analog control system Compressor Thermopump Water cooled top and side covers Air cooled top and side covers Oil cooling water cooled side covers Oil cooling OOSI OOKH Drive type Coupling V belts Explosion proof electrical design Equipment for parallel operation SABROE OVUR oil separator 0178 933 ENG Rev 2005 12 09 1 342 Service manual SMC TSMC 100 Mk4 1 Introduction 1 Introduction The purpose of this manual is to provide the oper ating personnel with a thorough knowledge of the compressor as well as information about The function and maintenance of each component Service schedules This manual describes the compressor and its component parts as well as sa
121. 0B 1 2331 051 Counter flange for mixing chamber TSMC116 90C 1 3422 111 Intermediate ring 148 116 90F 1 1424 108 Hexagon head screw M16 x 75 90G 1 1424 104 Hexagon head screw M16 x 55 90H 1 90J 1 1437 027 Spring washer 3188 023 Gasket kit intermidiate connection TSMC 108 O ring 82 14 X 3 53 O ring 98 02 X 3 53 O ring 91 67 X 3 53 Gasket 18 10x1 5 O ring 91 67 X 3 53 3188 024 Gasket kit intermidiate connection TSMC 108 90D 1 O ring 113 89 x 3 53 90E 1 O ring 120 24 X 8 53 90L 1 O ring 132 94 x 3 53 90 1 Gasket 18 10x1 5 Oil cooling Oil cooler HFC 4242 038 Oil cooler OOKH HFC Oil cooler R717 300 342 0178 933 ENG Rev 2005 12 09 tool list fm 18 spare parts list Service manual SMC TSMC 100 Mk4 18 Part list 4242 029 Designation Oil cooler OOS R717 SABROE Compressor SMC 3184 378 Kit assembly oil cooling type HFC R717 Adapter for oil cooler Cyl skrue M6x40 kv 12 9 DIN912 Gevind nippel Prop med rand 1 4 RG Plug 3 8 3188 140 Gasket kit oil cooling O ring 25 07 x 2 62 Gasket 025 17 Gasket 032 27 Gasket 927 21 Gasket 020 13 O ring 21 82 x 3 53 92 1371 301 Expansion valve TX 2 92 1371 339 Nozzle no 01 for T2 TE2 valve 92 1371 026 Expansion valve
122. 100 compressors have the following values Table 64 Moment of Inertia for SMC HPC TSMC 100 Compressors Type SMC 100 S 80 mm stroke SMC 100 L 100 mm stroke SMC 100 E 120 mm stroke No of cylinders 4 6 8 12 16 4 6 8 12 16 4 6 8 12 16 SMC TSMC 100 HPC 100 4 6 8 Compressor with 0 154 0 189 0 218 0 376 0427 0 196 0 234 0 269 0 464 0 579 0 254 0 321 0 340 0 593 0 705 free shaft end V belt driven 4 1 529 1 564 1 593 1 751 1 802 1 571 1 609 1 644 1 839 1 954 1 629 1 696 1 715 1 968 2 080 compressor with shaft pulley No of V belts 6 1 404 1 439 1 468 1 626 1 677 1 446 1 484 1 519 1 714 1 829 1 504 1 571 1 590 1 843 1 955 Profil SPB 8 1 779 1 814 1 843 2 001 2 052 1 821 1 859 1 894 2 089 2 204 1 879 1 946 1 965 2 218 2 330 Direct driven com 0 262 0 297 0 326 0 559 0 610 0 304 0 342 0 377 0 647 0 762 0 362 0 429 0 448 0 776 0 888 pressor with com plete AMR coupling Table 6 5 Moment of Inertia Ib ft2 for SMC HPC TSMC 100 Compressors Type SMC 100 S 80 mm stroke SMC 100 L 100 mm stroke SMC 100 E 120 mm stroke No of cylinders 4 6 8 12 16 4 6 8 12 16 4 6 8 12 16 SMC TSMC 100 HPC 100 4 6 8 Compressor with 3 66 4 49 5 18 8 93 10 14 4 66 5 56 6 39 11 02 13 75 6 03 7 62 8 08 14 09 16 75 free
123. 11 ed by Sabroe Refrigeration please contact the oil supplier to select the correct oil type E85 The listed data are typical values and are only intended as a guideline when selecting a similar oil from a different oil company Data equivalence does not necessarily qualify the oil for use in Sabroe Refrigeration s Sabroe compressors 168 342 0178 933 ENG Rev 2005 12 09 06 technical data fm Service manual SMC TSMC 100 Mk4 6 Technical Data List of Part Numbers for Available Sabroe Oils Oil brand Oil code no Part no 20 litre pail 208 litre barrel Mobil Gargoyle Arctic 300 M1 M68 1231 264 1231 296 Sabroe Oil A100 A3 A100 1231 263 1231 262 Sabroe Oil AP68 AP 1 AP68 1231 257 1231 260 Sabroe Oil PAO68 P68 1231 256 1231 259 Mobil Gargoyle Arctic SHC 228 5 P100 1231 282 1231 283 Mobil Gargoyle Arctic SHC 230 9 P220 1231 284 1231 285 Mobil EAL Arctic 68 E3 E68 1231 272 1231 273 Mobil EAL Arctic 100 E5 E100 1231 274 1231 275 Mobil EAL Arctic 220 E9 E220 1231 279 Sabroe H oil E11 E370 3914 1512 954 1 9415 0008 000 FUCHS DEA Reniso C85E E85 85 1231 304 2 1 18 9 litre pail 6 US gallons 2 10 litre The oils recommended by the former Stal Refrigeration correspond to the following oils Stal Refrigeration oil type Sabroe oil A Mobil Gargoyle Arctic 300 M1 M68 B Sabroe Oil PAO 68 PAO 3 PAO 68
124. 12 bar so that the compressor stops ata High and intermedi KP5 ate pressure cut out KP15 XIX X X X lower than the safety 5 1 Set to a pressure with saturation Low pressure cut out KP15 X X temp 5 K lower than the lowest Ead evaporating temperature z Oil pressure cut out MP55 X X X X X 3 5 bar m Discharge pipe ther KP98 120 C mostat X 150 C Oil thermostat KP98 X X X xX X 80 C Thermostat for com KP77 55 pressor cooling Thermo valve for E Normally set at 4 su perheat compressor cooling Change to min 10 superheat E 5 Factory setting 45 See NB 5 E 9 injection valve for in X X Factory setting 75 C See 5 5 termediate cooling X Set at min 10 superheat z TEA X Setat min 10 C superheat xX X 25 c By pass valve PMC CVC X 15 o P Oil filter differential KZD4 M3 x 20bar pressure Oil pressure regulat 4 5 bar ing valve Factory setting be adjusted if required to a breaking point 20 C higher than the highest normal discharge pipe temperature Adjust the TEAT valves so that the expected discharge pipe temperature 5 C 10 C is achieved at 100 compressor capacity Increase the opening temperature 10 C by turning
125. 1543 SMC108E 8 120 679 770 1698 SMC112E 12 1018 1300 2866 SMC116E 16 1357 1400 3086 TSMC108S 6 LP 2 HP 80 339 775 1709 TSMC116S 12 LP 4HP 679 1400 3086 5 TSMC108L 6LP 2 HP 100 424 775 1709 TSMC116L 12LP 4HP 848 1400 3086 TSMC116L 6LP 2 HP 120 509 800 1764 TSMC116E 12LP 4 HP 1018 1450 3197 1 LP Low pressure cylinder HP High pressure cylinder 2 Permitted max speed varies with operation conditions and refrigerant See the Operating Limit Diagrams 106 342 0178 933 ENG Rev 2005 12 09 06 technical data fm Service manual SMC TSMC 100 Mk4 6 Technical Data Table 6 2 Weight of Compressor Units Compressor Type Direct driven Belt driven Remarks Kg Ib Kg Ib SMC 104 830 1830 880 1940 SMC 106 925 2039 970 2138 SMC 108 990 2183 1030 2271 SMC 112 1660 3660 1820 4012 SMC 116 1400 3086 1920 4233 TSMC 108 1060 2337 1130 2491 Excl intermediate cooler Incl in TSMC 108 1400 3086 1410 3109 termediate cooler TSMC 116 1900 4189 2080 4586 Excl intermediate cooler Incl in TSMC 116 2350 5181 2530 5578 termediate cooler The weight is exclusive of electric motor 0178 933 ENG Rev 2005 12 09 107 342 Service manual SMC TSMC 100 Mk4 6 Technical Data Table 6 3 Weight of Electric Motors Sizes MOTOR TYPE SHORCH LEROY SOMER IP 23 IP 54 PLS LS FLS kg
126. 18 spare parts list Service manual SMC TSMC 100 Mk4 18 Part list Oil pressure valve Designation Compressor SMC 3184 362 Kit assembly oil pressure valve Oil pressure valve Gasket Hexagon head screw M12 x 35 22B 1 Gasket included in Gasket kit 3188 141 Oil charg ing valve 3184 363 Kit assenbly oil charging valve 2412 585 Oil charging valve Threaded reduction nipple Socket Gasket Nut Gasket Male stud coupling Gasket Bend 3188 138 Gasket kit oil charging valve Gasket 19 14 Gasket 18 10 Gasket 34 27 23 Packing gland By pass valve 24 1 3137 033 By pass valve dia 20 22 bar 24 2 3137 010 By pass valve dia 20 24 bar 24 3 3137 046 By pass valve dia 28 14 bar 24 4 3137 007 By pass valve dia 28 22 bar 24 5 3137 009 By pass valve dia 28 24 bar 0178 933 ENG Rev 2005 12 09 289 342 Service manual SMC TSMC 100 Mk4 18 Part list 3188 020 Designation Gasket kit by pass valve 20 Compressor SMC O ring 44 0 X 3 53 O ring 56 74 X 3 53 3188 019 Gasket kit by pass valve 28 24B 2 O ring for cylinder 24C 2 O ring 66 27 X 3 53 24D 1 1424 168 Skrue M8x25 Kv 8 8 24E 1 1437 023 Washer DIN 127
127. 2 4 Likewise pay attention to the fact that the meas ured values stated for a certain unit should com prise a complete unit incl compressor motor oil 0178 933 ENG Rev 2005 12 09 separator etc which have all been covered by the measuring grid Thus on assessing the measure results it is es sential to know the extent of the measured surface area in the surrounding measuring grid 2 5 If the compressor is working at part load this will generally lead to higher measured values than the ones indicated in the tables 151 342 Service manual SMC TSMC 100 Mk4 6 Technical Data 3 How to Check Sound Data 3 1 The only correct method is the measuring of sound power Ly on the site itself and this requires the setting up of a measuring grid as well as the use of sound intensive equipment 3 2 If using sound pressure L meters only an addi tional measuring of the reverberation period of the room will be required This makes it possible to find a theoretical value of the emitted sound power provided that the background noise is too low to be of any importance Noise Data for Reciprocating Compressors Single stage Ly and L values are measured at the following conditions Evaporating temperature TE 5 C 5 F Condensing temperature TC 35 C 95 F Refrigerant R22 R717 Number of revolutions 1450 rpm Heat Pump Evaporating temperature TE 20 C Condensing temperature TC 70 C
128. 24F 2 2469 002 Intermediate piece Stop valves 25 1 2414 073 Complete stop valve DN 50 25 2 2414 069 Complete stop valve DN 65 25 8 2414 070 Complete stop valve DN 100 25 4 2414 048 Complete stop valve DN 125 25AV 1 2333 053 Intermidiate flange 3184 364 Kit assembly welding nipple 65 65 Counter flange 65 Welding nipple dia 65 Screw for counter flange M10x40 3184 365 Kit assembly welding nipple 100 65 Counter flange 100 Welding nipple dia 65 Screw for counter flange M12x50 3184 366 Kit assembly welding nipple 100 80 Counter flange 100 Welding nipple dia 65 Screw for counter flange M12x50 3184 367 Kit assembly welding nipple 100 100 Counter flange 100 Welding nipple dia 100 290 342 Screw for counter flange M12x50 0178 933 ENG Rev 2005 12 09 tool list fm 18 spare parts list Service manual SMC TSMC 100 Mk4 18 Part list 3184 368 Designation Kit assembly welding nipple 125 125 Compressor SMC Counter flange 125 Welding nipple dia 125 Screw for counter flange M16x65 2314 065 Threaded plug 3 4 3184 369 Kit assenbly stop valve 50 65 Screw bonnet valve M10 x 25 Front part for cone Rear part for cone Screw for valve cone Threaded
129. 3 Suction valve retaining plate R717 3134 008 Guide ring for discharge valve O ring 107 55 x 3 53 1413 343 Socket cap screw M6 x 30 Gasket 3112 088 Cylinder liner with suction valve S amp L HP HFC Oylinder liner S amp L Unloading ring with pins S amp L Washer dia 8 4 3 x 0 5 Spring for unloading ring Tension spring Ring plate Valve spring 3132 095 Suction valve retaining plate HFC 3134 008 Guide ring for discharge valve 0178 933 ENG Rev 2005 12 09 O ring 107 55 x 3 53 285 342 Service manual SMC TSMC 100 Mk4 18 Part list 1413 343 Designation Socket cap screw M6 x 30 Compressor SMC Gasket 3112 081 Cylinder liner with suction valve E LP R717 Cylinder liner E Unloading ring with pins E Washer dia 8 4 3 x 0 5 Spring for unloading ring Tension spring Ring plate Valve spring 3132 083 Suction valve retaining plate R717 3134 008 Guide ring for discharge valve 1413 343 Socket cap screw M6 x 30 Gasket 3112 097 Cylinder liner with suction valve E HP R717 Cylinder liner E Unloading ring with pins E Washer dia 8 4 3 x 0 5 Spring for unloading ring Tension spring Ring plate Valve spring 3132 083 Suction valve retaining plate R717 3134 008 G
130. 3 12 234AB 87 5 123 23456AB 91 7 1234B 93 8 123456B 100 0 1S 12S 1238 1234 123456 72 342 0178 933 ENG Rev 2005 12 09 04 technical description fm Service manual SMC TSMC 100 Mk4 4 Technical Description Extended Unloading The additional capacity stages are obtained by changing the unloading of one SMC 104 106 and 108 or two SMC 112 and 116 cylinder pairs in such a way that the relief system only works the one cylinder while the other one is constantly con nected Note When the mentioned systems are used the compressor will not start up completely un loaded but with capacity as shown in Table 4 8 Table 4 8 104 106 108 112 116 25 16 5 12 5 16 5 12 5 The change is obtained by removing the following pos nos from the constantly connected cylinder both systems of rocker arms pos 15A 1 bearing cup pos 15B 1 spring retainer pos 15C 1 spring 0178 933 ENG Rev 2005 12 09 pos 15D 1 and tand washer for bearing cup pos 15E 1 The constantly connected cylinder is not mounted with unloading ring pos 19B washer pos 19C 1 spring pos 19D 1 and spring pos 19E It is marked 5 on the guide ring for the discharge valve pos 19J 1 See the position of the cylinder in Fig 4 47 Fig 4 46 Cylinder Liner with Suction Valve 19J SNNNSSNNSSNN 73 342 Service manual SMC TSMC 100 Mk4 4 Technical Description Fig 4 47
131. 3 342 Service manual SMC TSMC 100 Mk4 3 Safety Precautions First aid for accidents with ammonia Chemical formula NH refrigerant no AN 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 a di stinctive pungent odour that even at very low harmless concentrations is detectable by most persons Since ammonia is self alarming it serves as its own warning agent so that no person remains vol untarily in hazardous concentrations Since am monia is lighter than air adequate ventilation is the best means of preventing an accumulation Experience has shown that ammonia is extremely hard to ignite and under normal conditions a very stable compound At extremely high though limit ed concentrations ammonia can form ignitable mixtures with air and oxygen and should be treat ed with respect Basic rules for first aid Always call a doctor immediately Be prepared Keep an irrigation bottle available containing a sterile isotonic 0 9 NaCl solution salt water A shower or a water tank should be available near all bulk installations with ammonia When applying first aid the persons assisting must be duly protected to avoid further injuries 24 342 R717 First aid measures Inhalation Immediately move affected person nel into fresh air and loosen clothing restricting breathing Call a doctor ambulance with oxyg
132. 3 53 0178 933 ENG Rev 2005 12 09 295 342 Service manual SMC TSMC 100 Mk4 18 Part list Compressor SMC Designation Analogous control and safety equipment 39A 1 3146 042 Gauge panel 39B 1 1413 382 Socket cap screw M10 x 60 39C 1 2213 142 Console 39D 1 2213 143 Bar for controls 4 controls 39D 2 2213 144 Bar for controls 5 controls 39D 3 2213 145 Bar for controls 6 controls 39D 4 2213 154 Bar for controls 7 controls 39D 5 2213 368 Bar for controls US SMC 39D 6 2213 369 Bar for controls US TSMC 39J 1 1413 330 Socket cap screw M5x10 39K 1 1437 021 Spring washer dia 9 5 Cooling water 40A 1 3185 230 Set of hoses for cooling water SMC104 40A 2 3185 231 Set of hoses for cooling water SMC106 40A 3 3185 232 Set of hoses for cooling water SMC TSMC108 Set of hoses for cooling water SMC TSMC108 Aves 3185 235 cide cover only 40A 9 3185 233 Set of hoses for cooling water SMC112 40A 11 3185 246 Set of hoses for cooling water SMC112 side cover only 40A 10 3185 234 Set of hoses for cooling water SMC TSMC116 Set of hoses for cooling water SMC TSMC116 side cover 40A 8 3185 236 only Purge valve 42A 1 2412 585 Purge valve 42B 1 1349 078 Threaded nipple 42C 1 1349 062 Male stud coulping 42E 1 2313 045 Nut 42F 1 2334 027 Connecting pipe with collar
133. 5 50 25 TSMC 116 100 83 67 50 33 On the SMC 112 116 two thermo pumps have been mounted as shown in the principle drawings Fig 4 74 Fig 4 75 and Fig 4 76 97 342 Service manual SMC TSMC 100 Mk4 4 Technical Description Fig 4 74 SMC 112 Fig 4 75 SMC 116 98M 98M 98M vv gt Y 98 342 i M A 1 1 1 98M 0 po y 1 1 1 7 1 BY A 1 Rat 0178 933 ENG Rev 2005 12 09 04 technical description fm Service manual SMC TSMC 100 Mk4 4 Technical Description The total capacity of the thermo pumps is adapted to the compressor capacity by stopping and start ing the thermo pump marked with an X on the principle drawing The stopping and starting is achieved through the wire connection of the thermo pump via terminals 5 and 6 7 or 8 to the capacity regulating system of the compressor The supply voltage to the thermo pump must be switched off once the compressor capacity has been reduced to the values indicated in the Table 4 11 Table 4 11 Compr Thermo Pump at Compressor Capacity Shaft End Working Not Working SMC 112 SMC 116 100 83 67 100 87 75 63 50 33 50 37 25 When the compressor is stopped th
134. 6 108 TSMC 108 SMC 112 116 TSMC 116 105 116 0178 933 ENG Rev 2005 12 09 06 technical data fm Service manual SMC TSMC 100 Mk4 6 Technical Data The procedure for alignment of compressor and motor is described in chapter 7 Installation In structions Balancing must be made before the key groove is After boring the coupling flanges are balanced This is characterized by one or more holes on the side of the flange Max permissible imbalance can be seen from the table Table 6 8 engraved Table 6 8 Compressor HPC SMC 104 106 108 SMC 112 116 Balancing TSMC 108 TSMC 116 Gmm Coupling hub motor AMR 3125 AMR 350 S 550 Coupling hub compressor AMR 312 AMR 350 400 0178 933 ENG Rev 2005 12 09 141 342 Service manual SMC TSMC 100 Mk4 6 Technical Data V belt drive for SMC TSMC 100 Fig 6 35 By letting the electro motor drive the compressor through a V belt drive the speed of the compres sor can be selected so that the max capacity cor responds to the capacity requirements of the plant The V belts are referred to as SPB Red Power Their cross section dimensions are shown in Fig 6 36 Fig 6 36 S C plus SPB 2650 The V belts are of an excellent quality Under nor mal operating conditions they do not require any service and are shape permanent which means that they can be characterised as S C plus 142 342 whic
135. 7 References to Instructions 327 ele tle big e AA Ar s 327 Torque Moments for Screws and Bolts 328 Coupling dala AA AA a Ad 330 Sundry Clearances and Check Dimensions 331 dene oe estu AA 333 8 342 0178 933 ENG Rev 2005 12 09 02 signs and warnings fm Service manual SMC TSMC 100 Mk4 2 Signs and Warnings 2 Signs and Warnings The purpose of this chapter is to describe How Sabroe Refrigeration equipment be identified All warning signs used on equipment deliv ered by Sabroe Refrigeration How information important to the safety of personnel and equipment is presented in in structions belonging to equipment delivered by Sabroe Refrigeration This chapter is intended for all user categories This chapter describes the importance of the indi vidual signs which are attached to the Sabroe Refrigeration products 0178 933 ENG Rev 2005 12 09 x SABROE Before a compressor unit is put into operation it must be provided with the warning signs corre sponding to the actual type of compressor unit in accordance with the rules and regulations in force A Danger Risk of injury to personnel and damage to equip ment Always read the safety precautions be longing to this equipment before starting the in stalla
136. 8 933 ENG Rev 2005 12 09 x SABROE Check end play crankshaft by pressing shaft up against pressure bearing Pos 6C and measure clearance in the other bearing using a feeler gauge The permissible end play is indicated in the section Various clearances and adjustment measurements End play adjustment is achieved by means of the gasket Pos 5D The gasket be supplied in the following thicknesses see the spare parts list 0 3mm 0 5mm 0 75mm 1 0mm 1 3mm 1 5mm 1 75mm 2 0mm Main bearings The main bearings pos 5C and 6C are mounted on the main bearing covers and their purpose is to guide the crankshaft both radially and axially They consist of a steel bushing with collar The collar and the inside of the bushing are provided with a thin white metal coating The bushing can be pressed out and replaced by new ones and needs no further machining after mounting On mounting the bushings it is recommended to secure them with Loctite 601 When a new bearing bushing pos 6C at the shaft seal end is put into place in cover pos 6A the in and outlets of the lubricating channels must be positioned in a four o clock position as illus trated in fig 1 below The bearing bushing pos 5C is positioned with in and outlets in a 12 o clock position 249 342 Service manual SMC TSMC 100 Mk4 13 Service Instructions Fig 13 16 Mounting of bearing bushing pos 6C Cover pos
137. 9 342 Service manual SMC TSMC 100 Mk4 6 Technical Data TC R22 158 70 140 60 Operating Limits Single Stage 122 50 9 9 Compressor type 1 104 40 CMO 8 SMC 8 86 30 2 ea 20 3 o 5 50 10 32 0 14 10 4 20 22 30 60 50 40 30 20 10 0 10 20 30 40 C 76 58 40 22 4 14 32 50 68 86 104 F 111 127_2 Evaporating temperature TYPE AREA OIL COOLING REQUIRED1 REMARKS MAX MIN 1 No 1500 2 No 20 30 900 3 At less than 50 capacity 1800 4 Yes 1 1000 No 2 1200 No SMC100S 700 3 At less than 50 capacity 1800 4 Yes 1 2 2 1000 No SMC100L 3 700 At less than 50 capacity yes 1200 4 Yes 1 2 2 SMC180 3 At less than 50 capacity yes 4 750 450 Nag Top covers Air cooled only 1 When required choose freely between A or B B Built in refrigerant cooled oil cooler with except SMC180 where only A may be selected 2 Not applicable A Water cooled side covers 120 342 thermostatic expansion valve 0178 933 ENG Rev 2005 12 09 06 technical data fm Service manual SMC TSMC 100 Mk4 6 Technical Data R22 Operating L
138. 933 ENG Rev 2005 12 09 04 technical description fm Service manual SMC TSMC 100 Mk4 4 Technical Description Table 4 6 Extended unloading Base Capacity step by one cylinder For SMC 112 and SMC 116 min load two cylinders TSMC not included Load Type SMC 100 104 12 5 106 108 112 116 16 7 18 8 25 0 31 3 33 3 37 5 41 7 43 8 50 0 56 3 58 3 62 5 66 7 68 8 75 0 81 3 83 3 87 5 91 7 93 8 100 0 The system is optional and can be ordered when an order for a new compressor is placed Already delivered SMC 100 compressors can be converted for extended or totally unloaded sys 0178 933 ENG Rev 2005 12 09 tems by means of reconstructing kits supplied by Sabroe Refrigeration s After Market Service De partment 71 342 Service manual SMC TSMC 100 Mk4 4 Technical Description Extended unloading solenoid valve no according to Fig 4 45 Table 4 7 Type SMC 100 Load 104 106 108 112 116 12 5 0 0 16 7 0 0 18 8 A 25 0 0 5 31 396 33 3 5 37 5 3 6AB 41 7 4A 43 8 56B 50 0 5 2 3S 4AB 56AB 56 3 456A 58 3 34B 62 5 23 456AB 66 7 25 34AB 68 8 3456B 75 0 1 235 234 3456AB 81 3 23456A 83
139. 98V 1 1372 422 Solenoid valve 2 2 EVRA 1 5 98X 1 1373 253 PT 100 sensor 98Y 1 2412 277 Stop valve 982 1 1364 022 Non return valve Pulley 999 1526 073 Clamping unit 999 2152 151 Pulley DP 400 4 Grooves SPB 999 2152 152 Pulley DP 400 6 Grooves SPB 999 2152 153 Pulley DP 400 8 Grooves SPB UNISAB 3184 379 Kit assembly support for UNISAB Support for UNISAB Distance washers Hexagon head M10 x 20 Hexagon head M6 x 20 Washer 3084 394 Normal spare parts set Set of accessories UNISAB II 302 342 EPROM tongs 0178 933 ENG Rev 2005 12 09 tool list fm 18 spare parts list Service manual SMC TSMC 100 Mk4 18 Part list Designation EEPROM tongs SABROE Compressor SMC EEPROM 2kB serial To be used in version Eprom 1 10 and earlier versions EEPROM 4kB serial To be used in version Eprom 1 12 and later versions 3084 383 Certificate set 3084 394 Normal spare parts set 1573 007 Front cover with sheet and display Sabroe logo 1572 026 CPU print rev C 1574 016 Relay print rev G 1373 249 Pressure transducer dia 10 AKS32R 1 9 bar 1 1373 271 Pressure transducer dia 10 AKS2050 1 25 bar 1373 251 Pressure transducer dia 10 AKS32R 1 59 bar 2 3449 542 Pt100
140. B Refrigerant liquid for oil cooling Power Connection Fig 4 78 T K1 The control box is geared for the 3 voltages listed below Terminal 1 Voltages n 110V 50 60Hz 220V 50 60Hz Terminal 2 240V 50Hz PT100 sensor V Terminal 1 GND N The control box contains a terminal strip as shown in Fig 4 78 Terminal 4 M2 K2 GND Terminal 2 X E ermina Upper level sensor GND Terminal 1 Lower level sensor Main voltage selector VS1 100 342 0178 933 ENG Rev 2005 12 09 04 technical description fm Service manual SMC TSMC 100 Mk4 4 Technical Description 2a Air Cooled Top and Side Covers R22 R134a R404A R507 Use the same cover mounting as described in par agraph 1a As indicated in the Operating Limits Di agrams in Section 6 Technical Data there is no need for oil cooling 2b Air Cooled Top Covers and Water Cooled Side Covers R22 R134a R404A R507 If water is available and a need for cooling exists according to the Operating Limits Diagrams Sec tion 6 Technical Data this system is an excellent solution The water cooled side covers are mounted as de scribed in paragraph 1b Fig 4 67 Fig 4 79 Cooling of Side Covers only 0178 933 ENG Rev 2005 12 09 Table 4 12 Pos No Hose type Length mm 1 715 2 175 3 230 4 765 2 Air Cooled Top and Side Covers and Refrigerant Cooled Oil Cooler R22
141. Before tightening screws 19N make sure that suction valve plate can be moved freely in its guide Tighten screws Pos 19N to torque of 1 4 Kom 14 Nm Inserting cylinder lining Rotate crankshaft to position the piston top dead centre Check that the long plug from the tool kit is screwed into relief cylinder see Top covers section Check that gasket Pos 19K is in position frame Lubricate piston piston rings and cylinder face with clean refrigeration machine oil Likewise grease O ring Pos 19M on HP cylinder of TSMC compressor with clean re frigeration oil Rotate piston rings on piston in order to stagger ring gaps at 120 to each other Press cylinder lining down over piston care fully The chamfering on the cylinder interior will catch the piston rings and squeeze them 0178 933 ENG Rev 2005 12 09 13 service instructions fm Service manual SMC TSMC 100 Mk4 13 Service Instructions to the diameter of the cylinder If possible fit cylinder in same place from which it was taken Press cylinder lining down manually with no rotary movements until it makes contact with gasket Pos 19K Check clearance volume which is de scribed in section Control measurements for insertion of new cylinder lining Discharge valve Pos 20 and safety head spring Pos 21 can then be fitted Fit gasket and top cover Once top cover is in position see cov er
142. C TSMC 100 Mk4 4 Technical Description Fig 4 20 Instrumentation Analogous control and safety system UNISAB II Analogous control and safety system 46 342 0178 933 ENG Rev 2005 12 09 04 technical description fm Service manual SMC TSMC 100 Mk4 4 Technical Description Two stage Compressors Type TSMC 100 The TSMC compressors are so called compound machines in which the refrigerant gas is com pressed in two stages The compressor is divided into a low pressure section LP and a high pres sure section HP The cylinders in the low pres sure section compress the gas from evaporating pressure PE to intermediate pressure During the compression the gas is heated and must consequently be cooled down in the interme diate cooling system before it reaches the high pressure stage At the high pressure stage the gas is compressed from PI to the condensing pressure PC The system is described in detail in Cooling of the intermediate discharge gas on TSMC compres sors later in this section The TSMC 100 compressors are available with 8 or 16 cylinders divided as indicated TSMC 108 6 low pressure LP cylinder 2 high pressure HP cylinder TSMC 116 12 low pressure LP cylinder 4 high pressure HP cylinder 0178 933 ENG Rev 2005 12 09 x SABROE TSMC 100 compressors are connected to instal lations where the compression ratio PC PE is higher than the permissible compression
143. Discharge Pipe Thermostat KP98 oe NANA pa ied eee 78 Discharge Valve xb pet e ddl tim tss 37 Discharge VAIS ccm 237 aLa A PAO BA 239 ME 238 Dismantling plant win aaa Naa dead oa 267 DVEA MN RN 82 Electric Motor haaa eae 130 Direction or Rotation idee PH cadet Deae Ad 136 Emergeri y Stop rer pt tes foto 16 Ensuring Liquid to the Thermo PUMP sists cues ceed NADAANAN 99 Evacuating Valve a arate MA 44 EXDIGSION szia AA a 102 Explosion proof heating ecce Rana AKA AA AG 102 Explosion proot solenoid valves maa Aa Ama 102 Extended set of tools cau aa aaa eem deos 102 Fault finding How to carry out fault finding na ANA Se es 214 Filter bag SM aas ideo bent a deste oo ae 38 Final Disposal ted aene elegit t de dun ee beds tee 325 First aid Accidents with ammonia Uu 24 Accidents wit FRG IAG PG unen Dagger abduci gute 25 Handling of Compressor and Unit 137 Heating Rod SMC 44 lalis em 6176 22 Hub Boring Of Hub ode aaa 138 Installation and Rel
144. It is recommended to seek advice from a consult ing firm experienced in noise damping in order to obtain the solution best suited to your plant For this purpose computer calculated frequency analyses can be requested from Sabroe Refrigeration for the compressor unit in question Another and very efficient solution would be to noise insulate the compressor unit itself Sabroe Refrigeration is able to deliver pre fabri cated and tested noise baffle boards Fig 6 47 0178 933 ENG Rev 2005 12 09 In General The following paragraphs include a description of the factors that influence the acoustic quality of a machine room Reverberation Time By a correct application of noise absorbing mate rials it is possible to change the reverberation time of a machine room which is defined as the time it takes for the sound pressure level L to drop 60 dB once the noise source stops The duration of the reverberation time depends on the volume of the room as well as the average ab sorption coefficient for the noise absorbing mate rials that are fitted in the room as they should be Absorption Coefficient Usually the absorption coefficient a for noise ab sorbing materials is 0 5 to 0 8 See the following il lustration Fig 6 48 Fig 6 48 Noise damping gt lt material Incident sound power Absorbed 5 Transmitted J sound power X Reflected sound power Incident sound power
145. MC TSMC 112 and 116 as shown in Fig 6 39 Fig 6 38 SMC 104 106 108 TSMC 108 Nominal center distance 900 mm TTTTTTTTTTTTTTRE Fig 6 39 SMC 112 116 TSMC 112 116 ae Nominal center JI distance 11A 500 Ay HUT lt A 1 EL Can an NO FC F lt Papa e gt kE The driving part of the V belts must always be closest to the base frame as shown with A in Fig 6 40 146 342 The compressor pulley is bored with a cylindrical hole and is fitted to the crankshaft with a clamping unit The end of the crankshaft and the outer face ofthe clamping unit must be aligned Thus the belt pulley can be mounted on the crankshaft without previous adjustment It must be tightened with the nine screws on the clamping unit see fig 6 41 The screws are tightened with a torque wrench Fig 6 41 Align these faces NITA a SS UYY When dismounting the belt pulley loosen the screws on the clamping unit 0178 933 ENG Rev 2005 12 09 06 technical data fm Service manual SMC TSMC 100 Mk4 6 Technical Data The motor pulley is tightened to the motor shaft by means of a conical bushing pos 1 in Fig 6 43 which fits the
146. Maintenance Instructions 212 342 0178 933 ENG Rev 2005 12 09 12 fault finding instructions fm Service manual SMC TSMC 100 Mk4 12 Fault finding Instructions 12 Fault finding Instructions The purpose of this chapter is to Describe the dangers resulting from failure to comply with instructions and safety pre cautions during the fault finding process Provide a list of common problems For each problem suggest cause s and recommend actions to solve the problem This chapter is primarily intended for service engi neers UN Danger Risk of injury to personnel and damage to equip ment Always read the safety precautions belong ing to this equipment before start Failure to com ply with safety precautions may cause death or in jury to personnel It may also cause damage to or destruction of the equipment 0178 933 ENG Rev 2005 12 09 Safety Precautions UN Danger Risk of injury to personnel and damage to equip ment In addition to the safety precautions in this chapter always read the general safety precau tions belonging to this equipment before starting the fault finding process Failure to comply with safety precautions may cause death or injury to personnel It may also cause damage to or de struction of the equipment Qualification Requirements Fault finding requires highly skilled qualified per sonnel with extensive knowledge of the system in question The formal req
147. Motor speed 1460 rpm 50 Hz V belts 730 817 912 976 1022 1150 1295 1460 rpm 2 22 22 30 30 30 37 45 45 3 30 37 45 45 45 55 55 75 4 37 45 55 55 55 75 90 90 AY 5 45 55 75 75 90 110 110 6 55 75 75 90 90 110 132 132 8 75 90 106 110 118 132 150 169 Number of Motor speed 1760 rpm 60 Hz V belts 792 836 880 985 1100 1166 1232 1386 1474 rpm 2 26 36 36 36 44 44 3 26 26 36 44 44 54 54 66 66 4 36 44 44 54 66 66 66 90 90 5 54 54 54 66 90 90 108 108 6 66 66 90 108 108 132 132 8 66 90 90 108 127 132 143 158 171 144 342 0178 933 ENG Rev 2005 12 09 06 technical data fm Service manual SMC TSMC 100 Mk4 6 Technical Data SABROE Table 6 11 Power Transmission kW SMC 112 116 and TSMC116 Number of Motor speed 1460 rpm 50 Hz V belts 730 817 912 976 1022 1150 1295 1460 rpm 3 55 55 55 4 55 55 55 75 75 90 5 55 75 75 90 90 110 kW 6 75 90 110 110 132 8 90 106 110 110 132 150 169 Number of Motor speed 1760 rpm 50 Hz V belts 792 836 880 985 1100 1166 1232 1386 1474 rpm 3 54 66 66 4 54 66 66 66 90 5 54 54 66 90 108 108 kW 6 54 66 90 90 108 132 8 66 66 90 108 108 132 132 158 158 0178 933 145 342 Rev 2005 12 09 Service manual SMC TSMC 100 Mk4 6 Technical Data Construction of V Belt Drive On standard units the nominal shaft distance be tween motor and compressor is 900 mm for SMC TSMC 104 to 108 as shown in Fig 6 38 and 500 mm on S
148. NG 3 1500 At less than 50 capacity 1 2 2 No MC100L 1 SMC100 000 700 1200 At less than 50 capacity Top and side covers Air cooled 1 When required choose freely between A or B A Water cooled side covers B Built in refrigerant cooled oil cooler with thermostatic expansion valve 122 342 2 Not applicable 0178 933 ENG Rev 2005 12 09 06 technical data fm Service manual SMC TSMC 100 Mk4 6 Technical Data Condensing temperature Evaporating temperature R134a Operating limits Two Stage Compressors TCMO TSMC 100 S L TO111163 2 Area rpm Oil cooling required 1 Note max min 1 1500 20 30 2 1800 900 1 3 1500 1 1000 TSMC 100 5 2 1200 700 No 1 3 1500 1 2 TSMC 1001 2 1000 3 1200 700 1 and side covers Only air cooled 1 Part load operation By pass equipment required to maintain intermediate temperature at minimum load 2 Not applicable 0178 933 ENG Rev 2005 12 09 SABROE 123 342 Service manual SMC TSMC 100 Mk4 6 Technical Data R404A TC F A C 1407 60 Operating Limits Single Stage 122 50 Compressors type o 104 40 CMO amp SMC o 5 86 30 a 5
149. P The intermediate discharge temperature of the compressor is dependent on the evaporating tem perature ET the condensing temperature CT and of the ratio between the capacity at the LP and HP stages corres ponding to the number of cylinders that is working at each stage TSMC compressor is working at 100 capac ity the ratio between the number of cylinders is 3 1 as indicated in the Table 4 9 When unloading the cylinders this ratio is changed to 2 1 or 1 1 and the intermediate pres sure will drop accordingly The intermediate discharge pressure is deter mined by entering the suction tempera ture ET and the condensing temperature CT into the cal culation programme COMP 1 The lower limits for the intermediate discharge pressure are the same as stated above 15 C 5 F for R717 plants and 25 C 13 F for HFC and HCFC plants To ensure correct operating conditions all partial load possibilities must be calculated If the result of the calculation shows values below the stated limits a by pass must be fitted as described above However it is also possible to connect the capac ity regulating system in such a way that the com pressor cannot operate at the capacity stages which produce suction temperatures lower than the limiting value of the refrigerant in question As described in the section Capacity regulation the TSMC compressors can be capacity regulated at the following stages 0178 933 ENG Rev
150. PM not allowed Included refrigerant cooled oil cooler Thermopump Top and side covers are cooled by injected refrigerant Oil cooling is included in the system 0178 933 ENG Rev 2005 12 09 Water cooled Top and side covers are water cooled Oil cooling is included in the system Discharge temperature must not exceed 150 C 302 F at full load and at part load 1 Discharge temperature at part load has to be checked Booster operation Only water cooling available 117 342 Service manual SMC TSMC 100 Mk4 6 Technical Data TC op 140 122 Operating Limits Single Stage 104 Compressor 86 SMC100E gt 5 68 5 50 o 32 o c 9 14 c 4 22 60 50 40 30 20 10 10 20 30 40 76 58 40 22 4 14 32 50 68 86 104 Evaporating temperature 0111140 2 AREA rpm COOLING NOTE max min Booster HP conditions SMC100E 1500 700 Water cooling only a Discharge temperature must not exceed 150 C Top and side covers are cooled by injection refrigerant Oil cooling is included in the system Water cooled Top and side covers are water cooled Oil cooling is included in the system 118 342 302 F at full load and at part load 1 Discharge temperature at part load has to be checked
151. Position of cylinders in compressor frame SMC 104 SMC112 The valve body as for Total unloading is used to regulate the capacity stages instead of the stand ard valve body and the corresponding connecting pipes are mounted The increased starting torque must therefore be taken into consideration when choosing motor and start system For this purpose the start up torque curves for R717 compressors and for compres sors might be useful These figures can be seen in chapter 6 Technical Data Starting torque of the 74 342 SMC116 compressor Please note that the max rpm is shown in the Operating Limits Diagrams in chap ter 6 Please note that if the motor is started up by means of a Y A starter the starting torque of the compressor may exceed the starting torque of the motor at a high differential pressure In these cas es the compressor must be equipped with a by pass system which makes the pressure on the discharge side of the compressor equivalent to the suction pressure as illustrated in Fig 4 48 0178 933 ENG Rev 2005 12 09 04 technical description fm Service manual SMC TSMC 100 Mk4 4 Technical Description Fig 4 48 valve or Solenoid a automatically controlled valve stop valve Y gt 1 After long operating hours at minimum capacity the temperature of the compressor block and the oil will exceed the normal operating temperatures It is
152. R717 31A 6 1541 077 R407C and R507 31A 7 1541 076 R22 R134a and R404A 31C 1 1412 350 Screws for gauges M4 x 20 0178 933 ENG Rev 2005 12 09 293 342 Service manual SMC TSMC 100 Mk4 18 Part list 3188 021 Designation Gasket kit pressure gauges Compressor SMC 30B 1 Nozzle and gasket dia 14 0 8 x 1 5 30C 1 Gasket dia 11 4 x 1 5 31B 1 Nozzle and gasket dia 14 0 8 x 1 5 Oil suction filter 3184 374 Kit assembly oil suction filter 33A 1 Oil suction filter 33B 1 Male stud coupling 33C 1 Oil pipe suction 33D 1 Flange connector el bow 22 mm pipe CR mat Suction filter 3188 035 Service kit suction filter Suction filter open complete 3188 011 Gasket kit suction filter 3188 036 Service kit suction filter Suction filter closed complete 3188 012 Gasket kit suction filter 3188 037 Service kit suction filter Suction filter open complete 3188 013 Gasket kit suction filter 3188 038 Service kit suction filter Suction filter closed complete 3188 014 Gasket kit suction filter 3188 011 Gasket kit suction filter O ring 75 57 X 5 33 O ring 91 67 X 3 53 3188 012 Gasket kit suction filter O ring 75 57 X 5 33 O ring 91 67 X 3 53 3188 013 Gasket kit suct
153. ROE above oil level Any foaming that may occur will soon be dissolved in the crankcase The system has one further advantage as the oil does not pass the level switch vessels 2a and 2b Should foaming occur this is not going to interfere with the working of the level switch In case the oil return system is regulated by means of a float valve as described under System A the same system as the one shown in Fig 4 38 should be used 61 342 Service manual SMC TSMC 100 Mk4 4 Technical Description System C System C is a float regulated oil return system which is used when only two compressors are op erating in parallel with the same condenser It is not a requirement that the suction pressure is the same on the two compressors The float valve is of the same type as the one used in system A The oil level equalizing system is illustrated in Fig 4 38 It works by pressing the oil from one compressor to the next by means of the oil pump pressure 4 5 bar pos 3 in each of the compressors Fig 4 38 SNV8 CD The oil level in the crankcase is regulated by a float valve pos 2a or 2b which opens at a falling oil level in the compressor If e g the oil level in compressor A is too low the float valve pos 2a will open The oil pump in compressor B will now supply oil through the sole noid valve nozzle incl pos 1a until a normal oil level has been established whereupon the float valve will close
154. SAB II has a systematic and easily ac cessible user interface which does not re quire any special knowledge or education Operational data and status appear from the distinct display which features four lines with twenty characters each The user interface also has arrow keys for menu selection set key for parameter changing as well as keys for selection of manual automatic operation start stop manual capacity regulation and resetting 0178 933 ENG Rev 2005 12 09 04 technical description fm Service manual SMC TSMC 100 Mk4 4 Technical Description Safety Monitoring and Control UNISAB II provides safe monitoring by means of warning and alarm values settings for all measuring points If a set value is ex ceeded a red diode will flash slowly in warn ing situations without stopping the compres sor and quickly in alarm situations with compressor shut down A display text will show the cause of the alarm In both warn ing and alarm situations separate relays are activated for connection of a remote lamp bell or alarm panel It is easy to find all the set values and their warning and alarm values through the straightforward menu system Besides monitoring the compressor pres sures and temperatures the UNISAB II also calculates the suction pressure vapour overheating monitors the capacity slide po sition and oil flow and calculates the oil filter differential pressure on screw compressors For correct fa
155. Safety precautions chapter in the Operating manual It is the responsibility of the operator or his employer that the Operating manual is always available This sign must not be removed nor be damaged in any way Antes de manejer instalar poner en mar cha o dar servicio al compresor y la uni dad leer la secci n Precauciones de seguridad en el Libro de Instruc ciones Es respondabilidad del operar o o de su patr n que el libro de instrucciones permanezca siempre al alcance de la mano Esta sefial no debe de ninguna manera suprimirse o danarse 2516 297 14 342 The sign HIGH VOLTAGE UN Danger HIGH VOLTAGE Before working on any electrical circuits turn the main switch OFF and lock it Dismantle the main fuses to the compressor unit Unless expressly stated in applicable Sabroe Refrigeration documentation or by a Sabroe Refrigeration field service representative do NOT work with the electrical power ON Any work with the electrical power ON should be per formed by a Sabroe Refrigeration field service representative The customer and subsequent transferees must make sure that any other person performing work with the electrical power ON is trained and technically qualified 0178 933 ENG Rev 2005 12 09 02 signs and warnings fm Service manual SMC TSMC 100 Mk4 2 Signs and Warnings The sign The temperature of tangible surfaces When a compressor is working
156. T SMC 104 108 Mk4 Bushing 3188 132 Gasket kit end bearing cover T SMC 104 108 Mk4 3188 135 Service kit main bearings T SMC 112 116 Mk4 Bushing Half section bearing 276 342 0178 933 ENG Rev 2005 12 09 tool list fm 18 spare parts list Service manual SMC TSMC 100 Mk4 18 Part list 3188 133 Designation Gasket kit end bearing cover T SMC 112 116 Mk4 Compressor SMC 3188 136 Service kit main bearings T SMC 104 108 Mk4 under size Bushing for repair 3188 132 Gasket kit end bearing cover T SMC 104 108 Mk4 3188 137 Service kit main bearings T SMC 112 116 Mk4 under size Bushing for repair Half section bearing for repair 3188 133 Gasket kit end bearing cover T SMC 112 116 Mk4 3184 385 Kit assembly driving hub for oil pump 7A 1 Driving hub for oil pump 7B 1 Spring washer 7C 1 Hexagon head screw Shaft seal 3184 355 Kit assembly shaft seal cover Shaft seal cover Gasket for cover Hexagon head screw M10 x 40 3184 356 Kit assembly hose connection Hose connection Hose 3184 357 Kit assembly shaft seal Spirolox ring dia 76 Lock spring Groover pin dia 4 x 20 Retaining flange Spring Locking ring 0178 933 ENG Rev 2005 12 09 277 342 Service manual
157. TN 2 92 1371 340 Nozzle no 02 for T2 TE2 valve 92 1371 027 Expansion valve TS 2 92 1371 340 Nozzle no 02 for T2 TE2 valve 92 1371 085 Expansion valve TU A 92 1371 366 Nozzle no 04 for TUA valve 92 1371 027 Expansion valve TS 2 92 1371 366 Nozzle no 04 for TUA valve 92 1371 230 Expansion valve TEA20 2 w nozzle Thermo pump 98A 1 3113 145 Side cover for thermo pump 98B 1 1553 215 Control box for thermo pump 98D 1 1372 179 Valve block EVRB 98 1371 037 3 3 mm orifice for mounting in valve block 0178 933 ENG 3185 038 Rev 2005 12 09 Level feeler complete for SMC 301 342 Service manual SMC TSMC 100 Mk4 18 Part list 98G 1 1372 422 Designation Solenoid valve 2 2 EVRA 1 5 Compressor SMC 98H 1 1372 423 Solenoid valve 2 2 EVRA 3 5 98J 1 1372 537 Coil 10W 220 230V 50 60Hz 98J 2 1372 538 Coil 10W 110V 50 60Hz 98J 3 1372 539 Coil 10W 240V 50Hz 98K 1 1364 008 Check valve 98M 1 2314 103 VA joint 98Q 1 3113 143 Cooling cover 98R 1 Gasket for top and side cover 98S 1 1424 081 Hexagon head screw M14 x 80 98T 1 4242 029 Oil cooler type OOSI for R717 98U 1 1372 422 Solenoid valve 2 2 EVRA 1 5
158. Technical Data List of Part Numbers for Available Sabroe Oils Oil brand Oil code no Part no 20 litre pail 208 litre barrel Mobil Gargoyle Arctic 300 M1 M68 1231 264 1231 296 Sabroe Oil A100 A3 A100 1231 263 1231 262 Sabroe Oil AP68 AP 1 AP68 1231 257 1231 260 Sabroe Oil PAO68 P68 1231 256 1231 259 Mobil Gargoyle Arctic SHC 228 5 P100 1231 282 1231 283 Mobil Gargoyle Arctic SHC 230 9 P220 1231 284 1231 285 Mobil EAL Arctic 68 E3 E68 1231 272 1231 273 Mobil EAL Arctic 100 E5 E100 1231 274 1231 275 Mobil EAL Arctic 220 E9 E220 1231 279 Sabroe H oil E11 E370 3914 1512 954 1 9415 0008 000 FUCHS DEA Reniso C85E E85 85 1231 304 2 1 18 9 litre pail 6 US gallons 2 10 litre The oils recommended by the former Stal Refrigeration correspond to the following oils Stal Refrigeration oil type Sabroe oil A Mobil Gargoyle Arctic 300 M1 M68 B Sabroe Oil PAO 68 PAO 3 PAO 68 Mobil Gargoyle Arctic SHC 230 PAO 9 220 H Sabroe H oil E 11 E 370 0178 933 ENG Rev 2005 12 09 181 342 Service manual SMC TSMC 100 Mk4 6 Technical Data R22 single stage reciprocating compressors Code no A3 Area no 1 A Condensing temperature Contact Sabroe Refrigeration 76 58 40 22 4 14 32 50 68 F Evaporating tem
159. The solenoid valve pos 1 is open when the compressor in question is running 1b Solenoid valve 2a 2b Float valve 3a 3b Connection to oil pump discharge 4a 4b Standard oil return system 62 342 0178 933 ENG Rev 2005 12 09 04 technical description fm Service manual SMC TSMC 100 Mk4 4 Technical Description Capacity Regulation of Compressor All compressors have a built in capacity regulat ing system which continually adjusts the compres sor capacity to the cooling requirements of the plant Even at reduced capacity the compressor works very efficiently This makes it very well suit ed for plants with reduced cooling requirements for lengthy operating periods Fig 4 39 Capacity Regulating Mechanism 13 4 2 The capacity regulating system including the frame pos 13 is activated by the compressor oil pressure and controlled by means of solenoid valves fitted on the compressor At a capacity re duction two suction valves are forced open at a time In this case no compression takes place in the relevant cylinders as the sucked in gas in the cylinders is pressed back to the suction chamber through the suction valves A The above forced opening of the suc
160. Threaded joints and flanged joints Valve spindles Shaft seals Relief equipment Expansion valves Pressure transducers and pressure gauges Safety valves 0178 933 ENG Rev 2005 12 09 Method of Searching for Leaks HFC HCFC Move the leak detection probe slowly along the places where leaks are possible and move all the way around couplings and the like Continue searching for leaks even after finding one the system may be leaking at other places Before proceeding wipe away any oil that is present after fixing a leak Write all observations into a log book searching fixing topping up the refrigerant etc After concluding maintenance or repairing tasks check that the reciprocating compressor unit is tight The air that remains must be removed with a vacuum pump before putting the unit back in op eration Ammonia Leak detection with ammonia is carried out in the same way as with HFC HCFC using sulphur sticks instead of the leak detection probe Motor Lubrication For electric motors it is absolutely essential to lu bricate the bearings in the right way and use the correct type of grease For correct service please follow the instructions of the motor manufacturer Replacing Motor Bearings Contact Sabroe Refrigeration s service organization Major Overhaul of the Compressor Contact Sabroe Refrigeration s service organization 211 342 Service manual SMC TSMC 100 Mk4 11
161. WW WW WW AW WA 10X3 1 a 9 v 1H913M 62XL9ZW 39uvHosia 9 EXE S8 vX6 88IN DEMS 90k OWS NOLLONS T EX6 88W SPXL 9LN 01 OWS SNOLLO3NNOO SNIGT3M KINO H31VM HdWOO 8 89 131100 ANY LNI H31VM WALSAS dWNdOWHSHL 2149 318008 431009710 2149 0 10 HOJ O3NNOO WALSAS JA3VHSMNVHO ONIMVHOHLIM HO 1739 A SNIMVHOHLIM SAATWA dOLS ONLIVH3dO HOI SITOH 052 Sle 015 ud EN KY E DOO 111 342 0178 933 ENG Rev 2005 12 09 HOLOW 0 120 8 owz sic wr osee 9066 Lraboz 06011 sze set san sog 9 _Wose_ 80 oz 092 522 ONS 02 000 081 sau zn core org ooez 826 9 8 SEOL 9 8 091 566 Sor ng osig 052542 ons rm 002 0861 081 091 ET ovv oszz 0612 1052 27808 068 oeg 0001 006
162. aining Areas of Application of the Reciprocating Compressor Unit Application In view of preventing an unintended application of the compressor which could cause injuries to the operating staff or lead to technical damage the compressors may only be applied for the following purposes As a refrigeration compressor with the number of revolutions pr minute specified by Sabroe Refrigeration and the operating limits as stated in this manual or in a written agreement with Sabroe Refrigeration Compressor types SMC 100 and TSMC 100 in S or L execution can as standard compressors be used with the following re frigerants R717 R22 R134a R407C R404A R507 R600 R600A R290 LPG This manual only deals with the ones written in bold letters Compressor types SMC 100 and TSMC 100 in an E execution are as standard compres sors used with R717 only The compressors be used with other frigerants but only following a written agree ment with Sabroe Refrigeration SMC 100 and TSMC 100 compressors in 5 L or E executions may be used at a max dis 0178 933 ENG Rev 2005 12 09 charge design pressure of 25 bar See Test Pressure Levels for Standard Compressors and Components in chapter 6 The compressors are approved for applica tion in an explosion prone environment pro vided they have been fitted with explo sion proof equipment This can be seen from the Ex namepla
163. alfunctions states how to remedy the observed error See the following example for the correct procedure 0178 933 ENG Rev 2005 12 09 12 fault finding instructions fm Service manual SMC TSMC 100 Mk4 12 Fault finding Instructions SABROE Cause Codes 26 liquid in suction line 32 too much coolant air to condenser 39 Expansion valve provides too little superheating Example Observed error Too low discharge pipe tempera ture error code 15 Table 12 1 Observed error Cause code 1 Compressor fails to start 1 2 3 4 5 6 7 9 10 12 14 2 Compressor starts and stops too often A P pa P E F ES 55 86 3 Compressor starts but stops 3 5 6 9 10 11 12 13 14 15 17 18 4 again immediately 42 49 50 55 61 4 Compressor operates continuosly 8 21 22 24 41 46 52 53 56 60 5 Abnormal noise from compressor 5 Id O al DA ded 9d 6 Insufficient capacuty on compressor pa Hi 4t b n 1 re E F 22 7 Slugging in compressor during start up 16 18 26 37 38 39 44 56 61 8 Slugging in compressor during operation 21 23 26 37 39 9 Excessive condenser pressure 9 25 28 29 30 31 33 10 Too low condenser pressure 22 32 51 52 54 60 11 Excessive suction pressure 13 17 26 34 39 52 53 54 5 60 12 Too low suction pressure 11 13 20 21 22 23 32 35 36
164. ame type and make 6 44 Iced up evaporator Defrost evaporator adjust defrosting time if re quired 6 49 Defective oil pump and hence failing Repair or replace oil pump oil pressure 6 56 Defective capacity regulating sys Cause is most often failure in oil pressure or re tem frigerant in oil see 4 5 0178 933 ENG Rev 2005 12 09 219 342 Service manual SMC TSMC 100 Mk4 12 Fault finding Instructions 7 Liquid stroke in compressor during start up Liquid stroke in the compressor should not occur as in the worst instance this can cause rupture to the valve ring plates and damage to the inbuilt relief devices Furthermore it can result in damage to the connecting rod bearings and cylinders if the coolant degreases the faces and impairs the lubricating capacity of the oil 7 18 Adsorption of H CFC refrigerant in oil Sudden reduction in pressure across the oil sump suction pres sure produces foaming Reduce compressor capacity or start with throt tled suction stop valve Follow instructions in 18 7 26 Refrigerant has condensed in suc tion line or crankcase Suction line has free fall towards compressor Heating element in crankcase should be connect ed for 6 8 hours before starting so that refriger ant dissolved in oil can be boiled out before start ing compressor up Start with throttled suction stop valve stop when hammering is heard Liquid separator sho
165. andard belt pulley diameters is able to provide the com pressor with the correct number of revolutions and consequently the desired compressor capacity For more information read chapter 6 Technical Data Please note that the compressor must be modified in order to change the direction of rotation the oil pump must be changed on Mk4 Extent of Delivery The compressors can be delivered as blocks only in standard execution or mounted on a base 76 342 be mounted for the SMC compressors and two oil separators for the TSMC compressors Oil return from oil separator to compressor is controlled by a system as described in the section return to the compressor SMC 100 Unit V belt Driven frame as standard units as illustrated on dimen sion sketches in chapter 6 Technical Data see also Dimension and Piping diagrams Further more it is possible to have compressors built into non standard units following a specific agreement with Sabroe Refrigeration standard compressor is delivered without oil in the crankcase but charged with Nitrogen N to 0 2 bar 3 psi overpressure A yellow label Fig 4 50 on the compressor indi cates this Nitrogen charge Fig 4 50 Pafyldt beskyttelsesgas No Charged with inert gas Enthalt Schutzgas 0 2 bar Charg du gaz protecteur 3 PSI Contiene gas protector 1534 169 0178 933 ENG Rev 2005 12 09 04 technical description fm Servi
166. ankshaft SMC 106S Mk 4 complete 16A 3 3121 266 Crankshaft SMC 108S Mk 4 complete 16A 4 3121 277 Crankshaft SMC 104L Mk 4 complete 16A 5 3121 280 Crankshaft SMC 106L Mk 4 complete 16A 6 3121 283 Crankshaft SMC 108L Mk 4 complete 16A 7 3121 270 Crankshaft SMC 112S Mk 4 complete 16A 8 3121 274 Crankshaft SMC 116S Mk 4 complete 16A 9 3121 286 Crankshaft SMC 112L Mk 4 complete 16A 10 3121 289 Crankshaft SMC 116L Mk 4 complete 16A 11 3121 243 Crankshaft SMC 104E Mk 4 complete 16A 12 3121 246 Crankshaft SMC 106E Mk 4 complete 16A 13 3121 249 Crankshaft SMC 108E Mk 4 complete 16A 14 3121 252 Crankshaft SMC 112E Mk 4 complete 16A 15 3121 255 Crankshaft SMC 116E Mk 4 complete 16F 1 1413 260 Plug M12 S type 16F 2 1943 141 Plug 1 4 L type Connecting rod 17 3123 004 Connecting rod complete Half section of bearing Bushing for piston pin Bolt for connecting rod Lock nut 282 342 0178 933 ENG Rev 2005 12 09 tool list fm 18 spare parts list Service manual SMC TSMC 100 Mk4 18 Part list 17 3123 006 Designation Connecting rod complete Compressor SMC 17A 1 Half section of bearing 17B 2 Needle rollar bearing 17C 1 Bolt for connecting rod 17D 1 Lock nut Piston 18 1 3124 002
167. another speed than 1460 rpm correct the service interval according to table Table 11 1 Rpm 970 1 170 1 460 1 760 Correction 15 125 1 00 0 83 factor Correction may also be calculated according to the formula below 1460 Rpm Correction Example The service interval of a compressor is 10 000 hours according to the diagram If the compressor runs at 970 rpm the service in terval will be 1 5 x 10 000 15 000h Note Always replace oil filter when changing oil or when indicated by control lamp or UNISAB II The scope of the overhaul must follow the scheme below 204 342 1 x service interval Use service set A 2 x service interval Use service set 3 x service interval Use service set A 4 x service interval Use service set The service sets include parts which should al ways be replaced regardless of appearance when compressor is opened The above cycle is repeat ed as long as the compressor is in operation After first 200 hours of operation use service set Inspection parts In addition to the predetermined replacement ac cording to above service sets certain parts must be inspected Inspection and replacement criteria for inspected parts are shown in separate instruc tion Nice to have part sets A list of recommended parts supporting the parts inspection is available The list contains all parts necessary
168. arine 1 Esso Exxon FuchsDEA Hydro Texaco Kuwait Petroleum Q8 Mobil Petro Canada Shell Statoil Sun Oil 0178 933 ENG 173 342 Rev 2005 12 09 Service manual SMC TSMC 100 Mk4 6 Technical Data Selecting Lubricating Oil for SABROE Reciprocating Compressors Refrigerant HFC HCFC R744 In a period from 1990 to 1995 Sabroe Refrigeration experienced a rising number of problems with the use of mineral oils especially in R717 plants The problems can be divided into two groups The oil changes viscosity within a few operat ing hours f The oil dissolves becomes very black The problems have been observed in connection with several different types of mineral oil and often occur within only a few operating hours The con sequences have been severe for both compres sors and plants On the basis of the thorough investigation subse quently carried out by Sabroe Refrigeration it was decided to introduce a series of synthetic oils complying with the requirements of modern refrig eration plants Mineral oils can however still be used in refriger ation plants provided the lubricating quality is carefully monitored For modern high capacity re frigeration plants where a long service life for both lubricant and moving parts is expected Sabroe Refrigeration recommends the use of synthetic oils Areas of application and spe
169. arts please state the for warding address and the address where the in voice should be sent If appropriate please state the name of your local bank how you wish the goods to be transported and a delivery date 4 Classification certificate If requiring a certificate from a classification au thority please mark the order appropriately as the inspection and issuing procedures take extra time and incur extra expenses 5 Quotation no If you have received a quotation no in earlier cor respondence please refer to this when placing your order it will help us identify and execute your order quickly 269 342 Service manual SMC TSMC 100 Mk4 13 Service Instructions 270 342 0178 933 ENG Rev 2005 12 09 tool list fm 18 spare parts list Service manual SMC TSMC 100 Mk4 18 Part list 18 Part list How to use the part list The key to identify a spare part is the pos no of the spare part By means of the pos no the position of the spare part can be found on the spare parts drawings Usually the spare part no is stated next to the pos no If no spare part no is stated it may be be cause the part is not considered a spare part or because the part is not sold as a spare part Example Component Kit assembly Service kit Gasket kit The part list is divided into sections with the main components of the compressor as headlines For each main part e g cylinder liner complete the part
170. ature TE Fig 11 2 HCFC HFC R290 SMC 100 S L TC eF 158 70 140 60 122 50 6 000 104 40 8 000 86 30 10 000 68 20 50 10 32 0 Condensing temperature 14 10 12 000 4 20 22 30 13 000 60 50 40 30 20 10 0 10 20 30 40 ca 76 58 40 22 4 14 32 50 68 86 104 F T0113099 1 Evaporating temperature 0178 933 ENG Rev 2005 12 09 SABROE 2 Read the operating hours service interval from the curves in the diagram Fig 11 3 R717 TSMC 100 S L E type Multiply by 0 75 TC oF lec 140 60 N 50 e 40 30 20 Corgensigy temperat 60 50 40 30 20 10 76 58 40 22 4 14 32 of 0113098 1 Evaporating temperature Fig 11 4 HCFC HFC R290 TSMC 100 S L TC 140 60 122 50 E000 o 40 6 000 5 8 000 B6 30 10 000 8 20 11 000 50 10 8 12 000 32 0 60 50 40 30 20 10 0 J 76 58 40 22 4 14 32 Evaporating temperature TO113100 1 203 342 Service manual SMC TSMC 100 Mk4 11 Maintenance Instructions If the compressor operates at
171. ble in case of a new plant Condensing temperature 86 o ie ak A SABROE 76 58 40 22 4 14 32 50 68 F Evaporating temperature Max oil concentration in liquid phase contact Sabroe Refrigeration Min suction temperature 50 C At TE lt 50 C superheating must be introduced 0178 933 ENG Rev 2005 12 09 187 342 Service manual SMC TSMC 100 Mk4 6 Technical Data 76 58 40 22 4 14 32 50 68 F Evaporating temperature R404A single stage reciprocating compressors 2 gt a 2 o c O o Code no 1 E3 A E5 A Very suitable in case of a new plant Min suction temperature 50 C At TE lt 50 C superheating must be introduced Zone in which both oils are applicable 188 342 0178 933 ENG Rev 2005 12 09 06 technical data fm Service manual SMC TSMC 100 Mk4 P 6 Technical Data UN R404A two stage reciprocating compressors Code no Area no 1 A SABROE Condensing temperature 76 58 40 22 4 14 32 50 68 F Evaporating temperature A Very suitable in case of a new plant Min suction temperature 50 C At TE lt 50 C superheatin
172. capacity too high 29 Temperature of coolant air too high 60 Compressor capacity too low 30 Non condensable gases in condenser 61 Heating element in crankcase defective 31 Condenser needs cleaning 216 342 0178 933 ENG Rev 2005 12 09 12 fault finding instructions fm Service manual SMC TSMC 100 Mk4 12 Fault finding Instructions Remedying Malfunctions 1 Compressor fails to start 1 6 Control current circuit open owing to Pinpoint open switch and activated remedy cause of pressure cut outs interruption thermostats motor protection device defrosting timer 1 9 High pressure cut out has cut Reset pressure cut out and investigate cause of high condenser pressure 1 10 Low pressure cut out has cut Compressor cannot start before suction pressure has risen above set point for pressure cut out re starting 1 12 Oil pressure cut out has cut Compressor starts at reset Check oil level If oil foams in crankcase see 18 2 Compressor starts and stops too often 2 9 High pressure cut out cuts at High condenser pressure see 9 high pressure Check condenser cooling and adjust pressure cut out to correct breaking pressure see table Pressure and temperature settings Replace defective pressure cut out 2 10 Low pressure cut out cuts at too low Low suction pressure see 12 DIESSUIB If low pressure cut out is set too high adjust pressure cut out 2 11 Low p
173. ce manual SMC TSMC 100 Mk4 4 Technical Description Instrumentation In the standard version the compressors are avail able with one of the following two systems A analogue reading and safety system B UNISAB II reading safety and capacity regulating system The compressors are designed so that either the analogue system or the UNISAB II system can be fitted without changing the compressor They each have their own characteristics however as described in the following A Analogue Reading and Safety System The analogue system only has reading and safety functions and cannot control the com pressor capacity Capacity control is handled by an external system built into the electrical switchboard and connected to the compressor on the mounting site Some mounting costs must be expected The control system can be one of many types and makes It must however be able to send out opening and closing signals to the solenoid valves of the compressor in the prescribed unloading and loading sequence as already described in this section Capac ity Regulation and Unloading of Compres sor In special cases a manually operated switch system can be used instead of the automat ic one This makes it possible to regulate the compressor capacity by hand 0178 933 ENG Rev 2005 12 09 SABROE In its standard execution the analogue sys tem consists of controls built onto the com pressor on delivery but without
174. cifications for the syn thetic oils mentioned are described in the follow ing pages Supervisors and or users of plants are at liberty to choose between Sabroe Refrigera tion s own oil brands and alternative oil brands provided they comply with the specifications re quired General This recommendation will only deal with the lubri cation of the compressor The performance of the 174 342 lubricant in the plant receiver evaporator etc must however also be considered Lubricating oils with relatively high viscosity must be used to ensure a satisfactory lubrication of re frigeration compressors To achieve the best lubrication the oil must possess the correct viscosity under all oper ating conditions possess acceptable viscosity at start up possess sufficient oxidation stability the oil must be free of moisture when charged to the system possess sufficient chemical stability when used together with HFC HCFC Moreover the extent to which different refriger ants dissolve in the oil must be determined so that the oil return system etc can be designed to per form at its optimum Stratification Note that the oil in some plants is layered in refrig erant receivers and evaporators under certain op erating conditions and at certain oil concentra tions This applies in particular to HFC HCFC plants The oil recommendation diagrams for SABROE compressors with HFC and HCFC refrigerants in
175. conical boring of the belt pulley The bushing is bored and equipped with a key which fits the motor shaft in question When mounting the pulley first place the belt pulley and the bush ing on the motor shaft then fix the pulley to the bushing by means of two or three screws pos 2 in Fig 6 43 Mount the screws in the holes where the thread faces the belt pulley Thus the conical bushing is pressed around the motor shaft so that it both holds and centers the belt pulley Before tightening the belt pulley is placed on the motor shaft so that it is flush with the compressor belt pulley Tighten the screws pos 2 with the torque as indicated in chapter 21 Fig 6 43 When dismounting the belt pulley first dismount the two or three screws pos 2 and then mount one or two of the screws in the free hole s where there is only a thread in the side which faces the bushing By tightening the two screws evenly it is now possible to press the belt pulley off the bush ing The bushing and the belt pulley can now be dismounted manually The V belts must only be mounted and dismount ed when the motor is placed close to the compres sor to avoid damage of the belts 0178 933 ENG Rev 2005 12 09 Tightening and Adjusting the V Belt Drive When the necessary number of belts have been mounted corresponding to the number of grooves on the motor pulley max 8 the V belt drive is tightened by moving the motor away from the com
176. connection Spindle Lock washer for spindle Guide pin 3184 370 Kit assenbly stop valve 100 Screw bonnet valve M 12 x 30 Front part for cone Rear part for cone Screw for valve cone Threaded connection Spindle Lock washer for spindle Guide pin 3184 371 Kit assenbly stop valve 125 Screw bonnet valve M16 x 60 Front part for cone Rear part for cone Screw for valve cone Threaded connection Spindle 0178 933 ENG Rev 2005 12 09 Lock washer for spindle 291 342 Service manual SMC TSMC 100 Mk4 18 Part list Designation Guide screw Compressor SMC 3184 372 Kit assembly hand wheel 120 Hand wheel dia 120 Skrue M5x10 Kv 8 8 Washer for hand wheel 3184 373 Kit assembly hand wheel 180 Hand wheel dia 180 Screw for hand wheel M8 x 16 Washer for hand wheel 3188 015 Gasket kit stop valve 50 65 Gasket for screw dia 31 24 x 1 5 Sealing ring dia 62 45 x 3 Gasket for bonnet dia 72 39 x 5 33 Packing gland O ring 21 82 x 3 53 Nylon washer dia 39 5 28 x 1 5 Gasket for welding nipple Gasket for valve compr Gasket for plug 3188 016 Gasket kit stop valve 100 Gasket for screw dia 36 28 x 1 5 Sealing ring dia 110 90 x 3 Gasket for bonnet dia 116 84 x 7 Packin
177. consequently the inclination of the compressor If the inclination is too large the amount of oil charged will not be sufficient to keep Fig 4 2 the oil suction strainer fully submerged in oil The result will be lack of oil pressure and potential bearing damage The SMC 100 compressors will operate efficiently even below limits of inclination Transversal Table 4 1 Allowed inclination Axial rotation around crankshaft axis Transversal rotation around degrees axis perpendicular to crankshaft Static Dynamic Static Dynamic Short blocks 15 22 5 10 15 SMC 104 106 108 Long blocks 15 22 5 5 7 5 SMC 112 116 Usually ships primarily list athwart thus installa tion of the compressor with crankshaft in fore and aft direction is recommended 0178 933 ENG Rev 2005 12 09 33 342 Service manual SMC TSMC 100 Mk4 4 Technical Description Description of the Compressors Compressor Types Reciprocating compressor types SMC 100 and two stage compressors with the following type TSMC 100 represent a series of open compres designations sors with 4 to 16 cylinders in one and the same block The cylinders are positioned in a V or W po sition and have the same internal diameter of 100 mm The series comprises 15 single stage and 6 Fig 4 3 Compressors with 4 6 and 8
178. cooled Oil Cooler R717 Air cooled top and side covers are covers without cooling fins but with a surface large enough to re 86 342 lease any surplus heat in the compressor into the environment see Fig 4 59 and Fig 4 60 Fig 4 59 Air cooled Top Cover Fig 4 60 Air cooled Side Cover There is therefore no need for forced cooling air flow past the covers It is however necessary to cool the oil in the com pressor by means of a built in oil cooler which is cooled by the refrigerant in the plant The cooling system is built onto the compressor It operates as illustrated in piping diagram Fig 4 61 for a nor mal single stage compressor and in Fig 4 62 for a booster compressor The cooling system consists of an oil cooler mounted on the oil pipe which connects the oil pump with the shaft seal The oil cooler is dimen sioned to maintain the oil temperature at 50 70 C 122 158 F The expanding gas is led through pipe pos 1 Fig 4 61 to the compressor suction side On the outside of the pipe the sensor for the thermostatic expansion valve type TEA is fitted 0178 933 ENG Rev 2005 12 09 04 technical description fm Service manual SMC TSMC 100 Mk4 4 Technical Description The expansion valve type TEA is particularly suited for R717 In the liquid line there is also a so lenoid valve which closes when the compressor is stopped Fig 4 61 Normal single stage Compressor R717 T
179. cture Identification no Individual no for identification of supplied pipe system Design code For PED orders EN 378 2 0178 933 ENG Rev 2005 12 09 SABROE If the unit has been approved by an author ity the design code will be shown here Approval no If the unit has been approved by an author ity the approval no will be shown here Pressure system Low pressure side of compressor piping is referred to as LP High pressure side of compressor piping is referred to as HP Fluid Group Refrigerant designation according to 150817 or fluid group according to directive 67 548 EEC Max allowable pressure PS Shows max allowable pressure relative to atmospheric pressure for which the pipe system has been designed Leak test pressure PT Shows the pressure with which the pipe sys tem has been leak tested Design temperature TS Shows min and max temperatures for which the pipe system including components has been designed CE xxxx The four digits compose the registration no of the notified body in charge of the assess ment modules for the vessel 11 342 Service manual SMC TSMC 100 Mk4 2 Signs and Warnings Compressor name plate Fig 2 3 Compressor name plate VA Christian X s 201 2516 327 8270 Hojbjerg Denmark SABROE Compressor No Year Type __ Nominal speed E Swept volume m3 h Max allowable pressure Ps OS Max allowable pressur
180. d This chapter is primarily intended for operators and service engineers AN Danger Risk of injury to personnel and damage to equip ment Always read the safety precautions belong ing to this equipment before start Failure to com ply with safety precautions may cause death or in jury to personnel It may also cause damage to or destruction of the equipment 0178 933 ENG Rev 2005 12 09 Safety Precautions AN Danger Risk of injury to personnel and damage to equip ment In addition to the safety precautions in this chapter always read the safety precautions be longing to this equipment before start Failure to comply with safety precautions may cause death or injury to personnel It may also cause damage to or destruction of the equipment Safety Measures AN Danger The paragraphs that follow present some impor tant safety considerations for this type of com pressor unit Before starting maintenance work study carefully the general safety instructions reg ulations that apply to this series of compressor units Failure to follow these instructions regula tions can lead to personal injury and even death Moreover the equipment can be damaged or de stroyed 201 342 Service manual SMC TSMC 100 Mk4 11 Maintenance Instructions Maintenance of the Compressor Unit General To make certain that the compressor unit oper ates without problems throughout a long service life follow the system of
181. d There should be a minimum gas volume of 5 6 slight overpressure should normally re main in the piping system this safeguards the system against the penetration of air and moisture 7 Before dismantling parts the operator should put a gas mask on Dismantling plant In order to prevent moisture penetrating into the refrigeration plant during repair work it is advisa ble to follow the rules below 1 Nocomponent should be opened unneces sarily 2 When dismantling the system the pressure in the system should be a little higher than atmospheric Note If the piping system is colder than the sur roundings there is a considerable risk of damp precipitation condensation on cold plant parts Plant components to be dismantled must be warmer than the ambient temperature 3 two points in the system should be opened at the same time 267 342 Service manual SMC TSMC 100 Mk4 13 Service Instructions 4 Plug close or at least cover opening with oiled paper or suchlike 5 Be aware that filters may be very moist Tightness testing and pump down of refrigeration plant Before charging refrigerant into that part of the re frigeration plant which has been opened this should be pressure tested as described in the sec tion entitled Pressure testing Afterwards pump down in order to eliminate air and moisture In this regard consult the section on Evacuation Otherwise follow the instructions
182. d closes tightly between discharges The disc which is the only moving part rises and falls in response to dy namic forces produced by the gas flowing through the trap Liquid and or gas enters the trap through the cen tral orifice lifts the disc and is discharged through the outlet orifice The gas passes along the under side of the disc at high velocity and collects in the control chamber above The resulting pressure 54 342 imbalance forces the disc downward onto the seating surfaces and stops the flow The trap remains tightly closed until the loss of heat through the trap body lowers the control chamber pressure allowing the inlet pressure to raise the disc and repeat the cycle One side of the disc 3 is plain with a single scratch towards the outer edge whereas the oth er side of the disc has a machined circular groove The trap is supplied with the single radial scratch side of the disc 3 towards the seating faces If there are iregularities in the oil return check that the scratch side of the disc is towards the seating surface Also check that the strainer 49 is free from impurities Also if plant condensing temperature is equal to or lower than machine room temperature the disc must be fitted with the bleed scratch towards the seating faces Fig 4 29 Circular groove Correct fit with circular groove upwards and radial scratch down towards seats 0178 933 ENG Rev 2005 12 09 04 tec
183. d dE 77 Teteres ten Su Rem KAG p PA Sac dug suos C pcd 79 Cooling of the Intermediate Discharge Gas on TSMC Compressors 82 Automatic Regulation of Intermediate Pressure IP 84 Determining the Intermediate 84 Cooling Systems Tor Compressors 86 Standard Cooling Systems for Compressors eee 86 LT QE emis ES Bade 86 Mounting of Cooling Water Hoses 88 Pressure Loss in the Cooling System in SMC TSMC Compressors 93 Description of the Pumping Cycle 97 Ensuring Liquid to the Thermo Pump 99 Power 100 Compressor 102 Types or Spare Palte SOb xx moe ADB LAN ma es 103 Technical Data cine so wil Oe ATEN UE NG Wa as Glade AN NG ee ae ee 105 Technical Data for the SMC 100 106 Compressor Capacity auos sus Soc bin paved Ph va 109 Dimension Sketches of Compressor Block 109 Planning the Machine
184. d un less it is charged with oil Reduce pressure in crankcase e g throttling suction stop valve until suction pressure gauge shows pressure slightly be low atmospheric Fill pipe connected to oil charging valve with refrigeration oil and place free end of pipe in a receptacle containing fresh refrigeration oil Open oil charging valve carefully Thus ex ternal air pressure will force oil into crank case Avoid getting air or other impurities sucked into compressor Note In order to achieve pressure below atmospheric it will sometimes be necessary to set the low pres sure cut out so that the compressor can operate down to this pressure Remember to set the pres sure cut out to its normal setting after oil charging 210 342 When in operation the compressor may be re charged with oil using the hand operated oil pump Note Since halocarbon refrigerants such as R22 mix with refrigeration oils there will always be a good portion of oil blended with the refrigerant in the plant Therefore it is often necessary to recharge with refrigeration oil after starting up for the first time and after charging with fresh refrigerant Therefore the oil level in the compressor must be watched closely after start up Table 11 2 Oil Charge Compressor Size Liter US gal HPC 100 104 26 6 9 SMC 100 106 28 7 4 TSMC 100 108 30 7 9 Mk4 S L E 112 47 12 4 116 50 13 2
185. denser Follow instructions for condenser 10 Too low condenser pressure 10 32 Excessive condenser cooling Regulate condenser cooling 10 51 Defective piston rings or Replace worn parts See compressor instruc worn cylinders tions 10 52 Discharge valves are defective or See compressor instructions Check valve ring leaky plates and piston rings 10 54 Bypass between high pressure side Check compressor for internal leakage by per and suction side of compressor forming pressure drop test See compressor instructions 10 60 Compressor lacks capacity Check whether compressor capacity corre sponds to load on plant Reduce condenser cooling 0178 933 ENG Rev 2005 12 09 SABROE 221 342 Service manual SMC TSMC 100 Mk4 12 Fault finding Instructions 11 Excessive suction pressure 11 26 Error in setting of liquid regulation Liquid refrigerant in suction line valve Adjust repair replace expansion valve 11 53 Leaky suction valves See compressor instructions Remove cylinder covers check valve plates Renew if needed 11 54 Open by pass between suction side Check system for any by pass detectable as a and high pressure side of compres warm connection sor Safety valve leaky or opens Adjust or repair leaky valves prematurely 11 60 Compressor lacks capacity Regulate compressor capacity Check whether all cylinders are operati
186. dition however that the compressors keep working at the same suction pressure Fig 4 33 Principle Diagram Standard Oil separator with solenoid valve controlled oil return Alternative Oil separator with float valve controlled oil return 5 gt 8 12 14 11 Lg H 4 Table 4 3 1 Compressor 9 Oil vessel 2 Float valve 10 Non return valve 1 bar 3 Filter 11 Solenoid valve 4 Stop valve 12 Nozzle dia 3 3 mm 5 Oil separator 13 Filter 6 Solenoid valve incl nozzle Fig 4 33 14 Heating cartridge 7 Non return valve 15 Oil charging valve 8 Float valve 16 Oil level glass 0178 933 ENG 57 342 Rev 2005 12 09 Service manual SMC TSMC 100 Mk4 4 Technical Description As illustrated in Fig 4 34 a float valve pos 2 is fitted on each of the compressors in front of the oil level glass This makes the oil level in the float house equal to that in the crankcase This can be checked visually in the oil level glass Fig 4 34 Float Valve Housing with Float Valve Pipe E connection E3 Vent valve Oil level glass UN on compressor EET jo The float controls a needle valve which opens at a fa
187. e Discharge valve C 237 Refrigeration Plant 231 aNG 234 Service Instructions 227 Servicing th PIAN XA NAKA 231 AA 195 Set Up and Operation Safety rtr DINER RUNE 21 Shaft Seal ce 43 Shaft seal 247 252 244 Dismantling AP ERAP 245 34 Sign CAUTION pup 14 abii Av 15 Dangerous noise level 15 0178 933 ENG 339 342 Rev 2005 12 09 Service manual SMC TSMC 100 Mk4 340 342 Hazardous SUDSLANCE maa PO n ANA aa 15 HIGA VOLTAGES paa 14 Internal overpressure Aa 15 Internal protection erm 15 Temperature of tangible surfaces 15 SIGHS and Warnings aaahh a Ga 9 Signs in instructions actus 14 SInglesstaje soc ebbe t o Denn eet 35 SMC Cylinder liners masa aNG end AL 36 D signatio cac odit eise dent tta rt
188. e o ef 38 By pass valve EGO Wem TR LETT 254 C Capacity Regulation Xa AA AA a 63 Capacity Regulation of Thermo Pump neret oh rne neces 97 Capacity Stages eeu pa AA 68 Caution Texts Marked with Caution 17 Charging the Compressor with 159 Choice of Electric Motor deeper ccc 130 Compressor ANAND GAAN 102 Compressor Block AA AS 47 Compressor name plate aaa ABA 12 Compressor Shaft 138 Compressor DAANAN AA 76 Connecting Rod SMO aa 37 Connecting rod panaman RA 241 PM ER 242 marec cH S T S oo o mE 242 Conversion of TSMC Mk2 to essere nnne 50 Ly sie e TR 29 Cooling of Compressor and Oil 0178 933 ENG 333 342 Rev 2005 12 09 Service manual SMC TSMC 100 Mk4 334 342 OMO AA ANA 45 Cooling system Booster DO 87 di 0a emt Ed 93 Lou s 86 corse a uc a maala Ma dabas due das 86 Tho DENN a eb utet ed dee osten 94 95 Water TOW E 92 Water 5 92 Wate
189. e LENG IS Aa ata 157 83 The compressor must NOT be used 31 Thermo Pump 0178 933 ENG Rev 2005 12 09 0178 933 ENGIX fm Service manual SMC TSMC 100 Mk4 P SABROE roce aasa 97 Thermo pump HX AA 94 Description of the Pumping Cycle 97 Liquid Mc cce 99 Power pong Oa cs bata Ei NA a GG 100 SUUCIUIB LI tU ee 95 Thermodynamic Liquid Trap mak Aa 54 she EET 268 TLT Thermodynamic Liquid Trap Uu 54 TOOL Safety NAA ERO 20 Top Covers Mounting top and walter COVERS saan ANAN GANG 236 Top covers AA 234 Total Unl ading 68 TWA Time weighted average 26 SAS 35 Two stage Compressors TSMO 47 Type AA 34 34 34 Types or Spare Parts Set t tne uis p MU US ERE 103 pec AA AA ee 80 Unit pipe system name plate 11 dro uet mmc 142 elis
190. e Nr Naa 34 Safety Spring deese eb et e ie de eee 37 Type E oce AB t 34 34 TYDES La 34 104 Special Unloading 70 Sound Data GHOCK Rees E 152 Pare css ese TEES 102 Special unloading Od so o t e aaa 70 Specification of Materials ae 156 Start ama xd tociens BANA GAN chase uix puts ot dense p un aS 65 Start up SMC HPC 100 HFC HCFC 25 load 134 Start up torque SMC HPC 100 R717 25 load 133 Starting NORQUC Ss cose adv ort sateen case ad rait eri dne ba Pu enn 132 Stop Valves cj O EM 45 Structure of the Thermo 95 Suction Filter estes ker EE f 37 Suction filter MEM PE 257 SMO 257 LEILA AA MA sa denen AA 257 SUGHION 49 Round Noles aaa ha eal 49 Square holes naam kA NAAN AA 49 Suction Valve AA 37 PEA m 83 TOCHIGI ALY m 106 Technical Description 31 Test Pressur
191. e Pss 221 bar The compressor name plate is positioned on the compressor The plate contains the following in formation Compressor Compressor manufacturing number 12 342 Year Year of manufacture Type Manufacturer s type designation Nominal speed Shows rotational speed of drive shaft at typ ical running condition Swept volume Shows swept volume of compressor m3 h at nominal speed Max allowable pressure Ps Shows max working pressure of compres sor Max allowable pressure Pss Shows max allowable pressure at compres sor standstill 0178 933 ENG Rev 2005 12 09 02 signs and warnings fm Service manual SMC TSMC 100 Mk4 2 Signs and Warnings Vessel name plate Fig 2 4 Vessel name plate Christian X s Vej 201 2516 326 4 8270 Hojbjerg Denmark SABROE Beholder Vessel Behalter Type Type Typ Nr Ar No Year Nr Beregningsnorm Design code Godkendelsesnr Abnahmenummer Svob Shell Mantel Ror Tube Rohr Side Side Seite Medie Fluid Medium Tilladeligt tryk Allowable pressure Zulassiger Druck Tilladelig temperatur Allowable temperature Zulassige Temperatur Volumen Volume Volumen 0062 The vessel name plate is positioned on the shell of the vessel The name plate contains the follow ing information Vessel no Vessel number stated by Sabroe Refrigeration Year Year of manufacture Type Manu
192. e compensation range slacken the balancing screw for approx 1 0178 933 ENG Rev 2005 12 09 x SABROE minute then retighten This must be done at the average operating temperature under which the instrument will be functioning Example If the mid compensation range is to be moved from 20 C to 10 C equalization must be per formed at 10 C When the screw is then retight ened the middle of the compensation range will have been moved down to 10 C The total stretch of the compensation range remains unchanged Fig 13 29 The middle of the compensation range Tighten the balancing 10 2 45 10 50 20 2 0 C 60 30 C gt 10 70 261 342 Service manual SMC TSMC 100 Mk4 13 Service Instructions Cleaning and refilling glycerine filled gauges Remove blowout disk and temperature compensator from back of housing Wash gauge interior with warm water and allow to dry carefully Fill gauge housing with fresh glycerine until it flows out of bleeder hole Note The glycerine must be absolutely waterfree Refit compensator and blowout disk in gauge housing and cover centre hole in blowout disk with a piece of tape 262 342 Note Glycerine should be refilled at a room tem perature of 20 C when mounted and the com pensator must be its normal shape as shown in top of the following drawing Clean gauge exterior with wa
193. e current to the thermo pump is cut off closing the solenoid valves pos 98H and pos 98G At the same time solenoid valve pos 98V opens and drains the liq uid in the thermo pump back to the evaporating side of the plant See the previously mentioned point b 0178 933 ENG Rev 2005 12 09 Ensuring Liquid to the Thermo Pump The thermo pump must always be ensured liquid from the plant irrespective of whether the plant lacks liquid or if some other factor prevails Thus the thermo pump must also be ensured uid during a possible pump down by means of the compressor In other words During operation the compressor must never be short of cooling This safety is achieved either by taking the liquid directly from the receiver pipe connection B or by building a priority tank into the liquid line of the plant Fig 4 77 The liquid volume A of the priority vessel must be minimum 10 litres per thermo pump The liquid tube from the priority vessel to the ther mo pump must be dimensioned to prevent the for mation of flash gas along the way 99 342 Service manual SMC TSMC 100 Mk4 4 Technical Description Fig 4 77 v 2 P Receiver 3 B B 2 4 5 1 Refrigerant liquid from condenser receiver 2 Refrigerant liquid to evaporator 3 Refrigerant liquid reserve for oil cooling
194. e frame 0178 933 ENG Rev 2005 12 09 06 technical data fm Service manual SMC TSMC 100 Mk4 6 Technical Data Handling of Compressor and Unit When lifting the compressor only use the lifting eyes M20 Fig 6 27 which are fitted in the thread ed holes at the top of the block The weight of the compressor block is indicated in Table 6 1 in the beginning of this section Note It is only the compressor block which may be lifted in the lifting eye The same applies to the motor Fig 6 27 The unit is lifted in the lifting eyes which are weld ed onto the base frame and clearly marked with red paint When the unit is lifted make sure that 0178 933 ENG Rev 2005 12 09 uf SABROE the wires do not get stuck and thus damage the pipes or any other components on the unit Fig 6 28 Alternatively the unit can be lifted with a forklift truck It is recommended to make the distance x as wide as possible yet still keeping it within the sup ports as illustrated in the Fig 6 29 Be careful that the unit does not tip sideways as the point of grav ity is rather high Fig 6 29 The weight of the unit can be seen in the shipping documents or in Table 6 2 137 342 Service manual SMC TSMC 100 Mk4 6 Technical Data Compressor Shaft All compressors have the same shaft size On the shaft it is possible to mount either coupling flange
195. e is to cool the oil in the crankcase the other to cool the discharge gas and consequently the discharge side of the compressor Fig 4 62 Booster Compressor R717 T od Oil separator LP le gt lt 1 H 117 Y 4 5 Liquid from Oil cooler TEAT P Filter SE rave Solenoid valve Fig 4 63 Two stage TSMC Compressor R717 Oil TY IP HP Separator o N RR Separator 7 ur y V LP IP X 63 M dq C3 og 7 x Liquid from receiver s H 4 HX Stop valve Fiter Solenoid valve 87 342 Service manual SMC TSMC 100 Mk4 4 Technical Description The TEAT valve is set to inject liquid into the com pression chamber of the compressor via the oil cooler in order for the discharge gas to maintain a temperature between 55 C and 95 C 131 F and 203 F The diagrams Fig 4 61 to Fig 4 63 do only show the principle of the different systems and must not be used directly 1b Water cooled Top and Side Covers R717 The water cooling system must cool the entire compressor block In principle it consists of plane covers which are fixed on the top and side covers with a gasket in between as shown in Fig 4 64 and Fig 4 65 A system of canals is thus created between the two covers in which the water is distributed evenly and cools effectively As the water covers can
196. e same time under the same cylinder lining Gasket 19K HPC SMC 180 thickness SMC 100 part no part no 0 5mm 2356 111 2356 116 0 8mm 2356 233 2356 249 Adjustment is carried out as follows The rocker arm system is lowered by fitting the long plug no 4 from the tools kit in the unloading cylinder pos 12 instead of screw pos 12D Insert an 0 5mm gasket pos 19K and mount cylinder lining 258 342 Press cylinder lining against gasket pos 19K by means of two locking devices no 1 from the tools kit Fit the locking devices di agonally as shown in Fig 13 25 Fig 13 25 6 1 for SMC 100 type S and L E for SMC 100 type E pos 19K Turn crankshaft until piston is in top posi tion Using depth or slide gauge measure X as shown in Fig 13 26 Fig 13 26 Cylinder lining 0178 933 ENG Rev 2005 12 09 13 service instructions fm Service manual SMC TSMC 100 Mk4 13 Service Instructions X must be within the mentioned limits in the table and may and as mentioned earli er be adjusted by the use of gasket pos 19K Clearance volume min max x mm mm HPC SMC 100 0 6 1 0 Mk1 Mk2 Mk3 Mk4 SMC 180 Mk1 Mk2 52 15 Adjustment of the lifting reserve can now performed if necessa
197. e to the different movable parts The human ear can normally perceive frequen cies in areas ranging from 20 Hz to 20 k Hz but it does not perceive all frequencies equally well Consequently a sound meter must measure the sound pressure at various frequencies and then filter the measuring corresponding to the percep tual capacity of the ear the A weighting To this must be added the purely subjective per ception of sound as most human beings feel con siderable unease on hearing the so called pure notes If a frequency is followed by a sound pres sure of 3 6 dB above the other frequencies this feels annoying In case of screw compressors itis a fact that 300 and 600 Hz is normally felt to be an noying whereas reciprocating machines issue a more low frequency pleasant sound 149 342 Service manual SMC TSMC 100 Mk4 6 Technical Data 2 Assessing the Measured Values 2 1 As a consequence of the difference between the actually measured sound and the sound that the ear perceives the measured values are weighted in the sound meter Usually the sound meter is set for A weighted values called dB A based on a logarithmic scale That is why it is so important to apply the same unit of measure on comparing values from several different machines Further we would like to point out that the sound pressure level Lp measured in the machine room as described under pt 1 2 will always be above the one indicated in table
198. e valve with the discharge gas also called liquid stroke Such stroke should not nor mally occur as liquid cannot pass through the valve as quickly as the compressed gas This pro 0178 933 ENG Rev 2005 12 09 20H 20G 3136 090 duces a violent increase in pressure in the com pression chamber In order to avoid pressure of such intensity that it may damage the bearings in the compressor the discharge valve is retained in position by the safe ty spring Pos 21 which allows it to raise a little un der the strain of increased pressure If liquid strokes can be heard as a distinct ham mering in the compressor the cause must be found immediately and the malfunction rectified 237 342 Service manual SMC TSMC 100 Mk4 13 Service Instructions Discharge valve types Depending on the refrigerant and operating condi tions under which the compressor operates vari ous discharge valves need to be used to achieve an optimal function The discharge valves are selected as shown in the diagram below on the basis of the condensing or intermediate pressure temperature Refrigerant Conditions Valve type lt 15 C LP R717 lt 15 C HP R22 lt 15 C LP R134a 45 R404A R507 maga 15 lt TC lt 50 C R22 HP R507 70 R134a 45 C R404A R507 gt 50 C R22 VHP 70 C R134a R410A TC all HP R744 Note Marking Thus sa
199. eans that the thermo pump works slowly when the oil is cold e g right after start up of the com pressor but as the oil temperature gradually rises the pump capacity will increase accordingly The thermo pump does not start however until the discharge gas temperature exceeds 80 C 176 F The pumping cycle of the thermo pump i e a fill ing and an evacuation period lasts between 4 and 8 minutes depending on the number of cylinders of the compressor its capacity the oil tempera ture in the crankcase and the operating pressure and temperatures of the plant The filling period takes about 45 sec The thermo pump has an important advantage namely that the refrigerant pumped by the thermo pump is led directly into the discharge gas of the compressor Consequently this will have no in fluence on the compressor capacity 0178 933 ENG Rev 2005 12 09 04 technical description fm Service manual SMC TSMC 100 Mk4 4 Technical Description The Structure of the Thermo Pump The side cover see Fig 4 71 pos 98A together with the cooling cover pos 98Q constitute a pump vessel pos 98 which is supplied with heat Fig 4 71 Side Cover with Thermo Pump 98G 98D B alge N As indicated the principle drawings of the SMC 108 Fig 4 72 anda TSMC Fig 4 73 the thermo pump has the following connections Connection pos A which is linked to the compressor suction side and
200. ecessary it is possible to convert a two stage compressor into a single stage compressor The following variations are possible a Altering the compressor and using the same refrigerant Altering the compressor and changing the re frigerant from R717 to HFC HCFC at the same time Altering the compressor and changing the re frigerant from HFC HCFC to R717 at the same time Generally the conversion includes the following points 1 Replacing the suction filter with a normal single stage suction filter on the HP side 2 Dismantling the pipe connection on the HP suction side and installing a standard cover pos 34 50 342 3 Changing the pipe connections on the discharge side As the built in channel which connects the top covers on a single stage compressor does not exist between the HP and LP top covers this connection must be established externally 4 Changing the HP stage connecting rods to the single stage type journal bearing in small end The piston pins must be changed 5 Ensuring that the correct suction and dis charge valves are fitted 6 Installing the correct by pass valves 7 Adjusting the safety pressure controls Moreover it is necessary to replace the compres sor name plate and the name plates on the safety valves Please contact Sabroe Refrigeration s After Mar ket Sales Department for further information 0178 933 ENG Rev 2005 12 09 04 technical descript
201. ecting rod 242 PISTOM ESS a D 243 Fitting piston rings In piston 243 Assembling and stripping down piston and connecting rod 243 curpE AA 244 Assembling and mounting shaft seal 247 Grankshaft 248 Dismantling crankshaft 248 INSPECCION doo RR 249 Hering crankshaft ea oa tes ANA eee ES E 249 bearings xe SEG eed oe Shes os SSA Ce SKN REOR Sede RES ESS SEGRE ES 249 Compressor lubricating system 251 sc 25451042 252 Dismantling pump makuwa ng eee ced ome hd ceo oma n E ee eb Mea oe see edt 252 Oil pressure valve REREA ER ES 253 Dini PEDES 253 s LITT 253 By pass valve pos 24 254 Saner ihe CC HM 255 COU MICS aaa CE R NG gees BUGA rg ta iy eet e cael een AN 255 leal cde PPP EPIIT 257 Monitoring cylinder lining insertion
202. ed to the pressure in the crankcase The pressure cut out has a built in time de lay of 60 sec which keeps it idle during the start up of the compressor until the correct oil pressure has been established 78 342 The pressostat has a manual reset function as well as a yellow indicator lamp which when illuminated indicates that the electric circuits are working Normal oil pressure in the compressor is 4 5 bar 65 psi which is indicated on the manometer 9 on Fig 4 52 Discharge Pipe Thermostat KP98 Adjusted to stop the compressor if the discharge gas temperature exceeds 150 C 302 F for R717 120 C 248 F for HFC HCFC This adjustment can however be set to 20 C 68 F above the normal discharge gas temperature once this is known from experience This makes it possible to safe guard the compressor against excessive temperatures The thermostat has a manual reset function Oil Thermostat KP98 Adjusted to stop the compressor whenever the oil temperature in the crankcase ex ceeds 80 C 176 F The thermostat has a manual reset function Oil Filter Differential Pressostat Indicates when oil filter pos 9A needs to be replaced Connections on the pressostat has a transparent housing and will indicate power supply with green LED and filter re placement with red LED 0178 933 ENG Rev 2005 12 09 Service manual SMC TSMC 100 Mk4 P 4 Technical Description UN SABROE Manometers For reci
203. electrical connections The controls are not factory adjusted and should therefore be adjusted before the ini tial start up of the compressor As may be seen from the drawing Fig 4 51 some of the controls have a dual function i e the type designation KP15 indicates that 1 is the low pressure and 5 the high pres sure cut out function KP98 e g has two temperature systems incorporated The specific controls are mentioned in the following with reference to the numbers in Fig 4 51 Fig 4 51 771342 Service manual SMC TSMC 100 Mk4 4 Technical Description High Pressure Cut out KP15 Adjusted to stop the compressor if the dis charge pressure rises to a pressure 2 bar 29 psi lower than the setting pressure of the by pass valve The pressostat has a manual reset function Low Pressure Cut out KP15 Adjusted to stop the compressor if the suc tion pressure drops to a pressure corre sponding to 5K lower than the lowest evap orating pressure The pressostat has an automatic reset function and will therefore restart the compressor once the pressure rises again Intermediate Pressure Cut out KP5 Used only on TSMC compressors Stops the compressor if the intermediate pressure has risen to 8 bar 116 psi The pressostat has a manual reset function Oil Differential Cut out MP55 Adjusted to stop the compressor if the pres sure in the lubricating system drops below 3 5 bar 51 psi compar
204. en equipment Keep the patient still and warmly wrapped in blan kets If mouth and throat are burnt freeze or acid burn and the patient is conscious let him drink water in small mouthfuls If the patient is conscious and mouth and throat are not burnt feed him sweetened tea or coffee never feed an unconscious person Oxygen may be given to the patient but only when authorised by a doctor If the patient stops breathing apply artificial respiration Eyes In case of injuries from liquid splashes concentrated vapour immediately rinse with wa ter preferably using an eye rinser and consult a doctor Continue rinsing until otherwise stated by a doctor If the affected person wears contact lenses these must be removed before the rinsing Skin In case of burns from liquid splashes or con centrated vapour immediately wash with large quantities of water until the pain stops Consult a doctor about actual burns After washing apply wet compresses wetted with a sterile isotonic 0 9 NaCl solution salt water to affected areas until medical advice is available 0178 933 ENG Rev 2005 12 09 03 safety precautions fm Service manual SMC TSMC 100 Mk4 3 Safety Precautions First aid for accidents with HFC HCFC UN Warning No plant can ever be said to be too safe safety is a way Of life General HFC HCFC form colourless and invisible gasses which are heavier than air and sme
205. ench NV 3 4 1 1 13 12 Socket wrench NV 11 16 1 1 14 Ratchet handle 1 15 Speed handle 1 16 Universal joint for socket wrench 1 17 1 Extension rod for socket wrench 1 17 2 Extension rod for socket wrench 1 19 1 Torque wrench 15 90 Nm 1 19 2 Torque wrench 40 200 Nm 1 1 1 20 Coupler for torque wrench 1 2 2 1 1 21 1 Open spanner for torque wrench NV 11 16 1 1 21 2 Open spanner for torque wrench NV 3 4 1 1 22 Feeler gauge 1 306 342 0178 933 ENG Rev 2005 12 09 tool list fm 18 spare parts list Service manual SMC TSMC 100 Mk4 18 Part list Supplementary tool set for SMC 100 Mk4 Line A605 Supplementary tool set for Mk4 no 3183 148 Pos 7 Line No N i Designation Dimension Part No 0 605 1 Allen key for needle valves pump housing 1 4 1612 417 1 2 Box spanner insert for water cooled covers 22 mm 1612 323 1 1 2 square Bit adapter for Mk4 coupling 6 mm Allen 3 key 1612 342 1 1 2 square 4 end spanner for torque wrench NV 13 1612 262 1 temporarily for Mk4 coupling 5 Oil filter wrench for Spin on oil filter dia 100 1612 166 1 0178 933 ENG Rev 2005 12 09 307 342 Service manual SMC TSMC 100 Mk4 18 Part list 308 342 0178 933 ENG Rev 2005 12 09 Service manual SMC TSMC 100 Mk4 19 Drawings SABROE 19 Drawings SMC 104 106 108 Drawing no 0662 020 sued ejeds 64 1 81 1
206. ents of the classification societies 103 342 Service manual SMC TSMC 100 Mk4 4 Technical Description 104 342 0178 933 ENG Rev 2005 12 09 06 technical data fm Service manual SMC TSMC 100 Mk4 6 Technical Data 6 Technical Data The purpose of this chapter is to provide the tech nical data of the equipment In this chapter technical data is defined as Data for compressor Data for unit Working range Handling the compressor Area of application 0178 933 ENG Rev 2005 12 09 Noise level data Vibration data Test pressure for compressors Assessing the oil Selecting lubricating oil This chapter is primarily intended for designers service engineers sales personnel and prospective customers 105 342 Service manual SMC TSMC 100 Mk4 6 Technical Data Technical Data for the SMC 100 Series Table 6 1 Compressor type Number of Bore Stroke Max min Swept Weight of Weight of cylinders speed volume compressor compressor mm nominal at max block block rpm speed 1 2 m3 h kg Ib SMC 104S 4 271 580 1279 SMC 106S 6 407 675 1488 SMC108S 8 80 1800 700 542 740 1631 SMC112S 12 815 1250 2756 SMC 1165 16 1086 1350 2976 SMC104L 4 283 580 1279 SMC106L 6 424 675 1488 ja SMC108L 8 100 565 740 1631 SMC112L 12 848 1250 2756 SMC116L 16 1131 1350 2976 SMC104E 4 100 1500 700 339 600 1323 SMC106E 6 509 700
207. eported for non ammonia applications 2 SAN Strong Acid Number is only reported for non ammonia applications A report is drawn up for every sample received This report indicates Whether oil can still be used without taking any further action Whether the oil can be used after it has been filtered through a very fine filter If this is necessary the oil must be pumped directly from the compressor unit through a 3 micron filter and back to the unit The sys 0178 933 ENG Rev 2005 12 09 tem must be completely closed to prevent the oil from being affected by moisture in the air Whether the oil is no longer fit for use The report will always be sent to the address stat ed on the sample label included in the form set Acopy will also be sent to Sabroe Refrigeration so that we are in a position to advise our customers if required 209 342 Service manual SMC TSMC 100 Mk4 11 Maintenance Instructions Charging Compressor with Lubricating Oil Since all SABROE reciprocating compressors are supplied with a special oil charging valve on the crankcase refrigeration oil may be charged while the compressor is in operation For this purpose use a hand operated oil pump as mentioned earlier or follow the procedure out lined below Oil charge and oil level are shown in Table 11 2 and Table 11 3 Note When charging for the first time use the oil pump The compressor must never be starte
208. er Warning Daily maintenance is normally conducted by oper ating personnel Other maintenance and service tasks which require the refrigeration system to be opened must only be conducted by authorized personnel 2 Periodic maintenance Motor lubrication and other routine mainte nance tasks are usually based on running time Note however that these can be con ducted more frequently if necessary 3 Major overhaul For major maintenance tasks such as com pressor overhauls the usual procedure is to call in the supplier s service personnel The different parts of the compressor unit that re quire regular periodical maintenance are indicat ed below 0178 933 ENG Rev 2005 12 09 11 maintenance instructions fm Service manual SMC TSMC 100 Mk4 11 Maintenance Instructions Service intervals The service interval for a reciprocating compres sor should be determined as follows 1 Choose the appropriate diagram corre sponding to refrigerant and compressor type Service interval diagrams Fig 11 1 R717 SMC 100 S L E type Multiply by 0 75 TC oF lec 140 60 04 40 6 000 t 86 30 8 000 10 000 68 20 11 000 14 10 12 000 13 000 60 50 40 30 20 10 0 10 20 30 40 C 76 58 40 22 4 14 32 50 68 86 104 701599721 Evaporating temper
209. era ture pressure 4 21 Restricted supply of refrigerant to Remove dirt in filters and check function of ex evaporator Compressor working at pansion device as per special instructions too low suction pressure 4 22 Refrigerant charge unsufficient Top up with refrigerant of correct type 218 342 0178 933 ENG Rev 2005 12 09 12 fault finding instructions fm Service manual SMC TSMC 100 Mk4 12 Fault finding Instructions 5 Abnormal noise from compressor 5 16 Compressor capacity too high dur Reduce capacity ing start up 5 17 Oil pressure too low See 13 5 26 Liquid refrigerant in suction line Liquid stroke See 7 and 8 Adjust expansion or float valves 5 48 Incorrect alignment of motor and Check alignment as per special instructions compressor Loose bolts in coupling Tighten with torque wrench 5 50 Worn or defective bearings Overhaul or replace 5 51 Too much oil circulating Check oil level pad through ine plant sulting nies Solenoid valve filter or jets in oil return system 5 57 low oil level in may be clogged Leaky suction valve ring plates 5 58 compressor piston rings worn out cylinder may also pro duce such oil consumption 5 56 Capacity regulation oscillating owing Low oil pressure see 13 to failing oil pressure 6 Too little capacity on compressor 6 15 Insufficient oil charge Top up with fresh oil of s
210. eral When the compressor requires maintenance it is important to follow the instructions given below In order to make sure that the compressor is working correctly the gauge measurements and screw torques must be strictly adhered to Before open ing the compressor it is expedient to ensure that you have spares of those seals and gaskets to be stripped down or dismantled An O ring which has been exposed to oil and heat for any length of time may have expanded so much that it has lost its flexibility and cannot be refitted All seals and gaskets used are resistant to oil HFC HCFC and ammonia All O rings are made of neoprene rubber Preparation for maintenance Pump down Before opening up the compressor for inspection the pressure inside must be lowered to slightly above atmospheric pressure This can be done in one of the following ways depending on whether the compressor is operational or defective 1 If the compressor is operational Run the compressor at minimum capacity at nor mal operating temperature Adjust the low pressure cut out so that the com pressor stops at a suction pressure of approx 0 1 barg Throttle the suction stop valve very slowly Keep an eye on the suction pressure gauge The suction pressure must be lowered slowly enough to give the refrigerant dissolved in the oil time to escape without the oil foaming This is of 0178 933 ENG Rev 2005 12 09 x SABROE great importance in c
211. ermissible inlet temperature 10 C 50 F Max permissible outlet temperature 55 151 F Max permissible temperature rise from inlet to outlet on compressor 15 C 59 F Max permissible cooling water pressure 8 bar 0178 933 ENG Rev 2005 12 09 04 technical description fm Service manual SMC TSMC 100 Mk4 4 Technical Description Pressure Loss in the Cooling System in SMC TSMC Compressors Totally for Side and Top Covers Fig 4 69 Pressure loss diagram Pressure loss TSMC 108 aNG 1 SMC 106 HPC 106 smc 104 HPC 104 SMC TONG SMC 86 T SMC 88 100 500 1000 1500 Volume flow V Water Quality Water that can be used as cooling water Water from the water works or sea water Fresh ground water Water from cooling towers or condensers 0178 933 ENG Rev 2005 12 09 Closed water systems in which the water is cooled and recirculated Salt water Brine Note Do not use sea water as cooling water on top covers Obviously it is very important that the water does not cause algae to grow or calcareous deposits to develop in the cooling system This means that when water is recirculated in a closed system a water treatment plant will usually be required Sabroe Refrigeration can help you to choose the best treatment Please contact Sabroe Refrigeration for
212. es as well as capacity regulation of the compressor To illustrate the structure of the dimension sketch es three examples have been included Fig 6 1 Fig 6 2 and Fig 6 3 Moreover reference is made to Dimension and Piping Diagram which in cludes dimension sketches of all compressors and units However during the final planning the latest di mension sketches from Sabroe Refrigeration are required 109 342 0178 933 Rev 2005 12 09 Service manual SMC TSMC 100 Mk4 6 Technical Data SMC 100 V belt Driven Anolog System Fig 6 1 mm ais OXOEOL sevizi S69 S99 sor SOP 006 0601 seri OzOz WSIE 00Z OX026 ozo syo see see azz seor 0601 0108 WSi 00 SOIOWS 100 ali pi sevizt ose orr azz 0001 9601 9111 0802 516 002 FOLDNS NI H Sio p yoron ON ww ww WW WW ww ww wn WW WW HLON3T LOVX3 ss 002 saa 3dAL JO 1 udwoo IVN OL HLAIM ONY HLON31 TIVH3AO YOLOW aav BVSINN SLINN 6 2XL9 N gexeriin
213. ev 2005 12 09 39 342 Service manual SMC TSMC 100 Mk4 4 Technical Description The by pass valve is delivered pre set sealed and adjusted to the following opening pressures Standard for SMC and TSMC HP stage compressors 24 bar 348 psi Special for SMC and TSMC HP stage compressors 22 bar 319 psi this is only delivered following a specific order and applied in accordance with local rules and regulations concerning pres sure vessels as e g oil separators The current set pressure is stamped into the name plate pos A Standard for TSMC LP stage compres sors 12 bar 174 psi The by pass valve is of the high lifting type which makes it robust and durable Moreover the by pass valve is independent of the pressure on the suction side of the compressor Consequently it opens only when the pressure on the discharge side exceeds the set pressure com pared to that of the atmosphere Note The by pass valve should not be consid ered a safety valve Fig 4 9 SMC 104 108 Short Block ff S gt Le amp 40 342 Fig 4 10 TSMC 112 116 Long Block
214. evacuation system emptying the pump vessel through solenoid valve pos 98V whenever the thermo pump stops Please note that the pipe connection pos D to the plant evaporating side must be ata place where there is suction pressure and no risk of the liquid flowing back to the compres sor through the suction line Connection should e g be made to the liquid separator or the evaporator A safety circuit with a non return valve pos 987 which opens for the flow in the pump vessel at a pressure 3 bar 44 psi higher than the one in the compressor discharge gas line 0178 933 ENG Rev 2005 12 09 04 technical description fm Service manual SMC TSMC 100 Mk4 4 Technical Description Description of the Pumping Cycle Filling the Pump Vessel As soon as the liquid leaves the bottom level sen sor the control box will activate the solenoid valves pos 98H in valve block pos 80 and pos 98G Thus solenoid valve pos 98G opens in the pipe connection to the compressor suction side and the pressure in the pump vessel decreases slight ly At the same time solenoid valve pos 98H opens and refrigerant liquid starts flowing to the pump vessel through pipe connection B Emptying the Pump Vessel When the top sensor pos 98C has registered that the liquid has reached the top level both so lenoid valves will be closed by the control box The pressure in the pump vessel will now rise as a consequence of the heat impact fro
215. evel glass pos 1B indicates the pre scribed oil level in the crankcase See chapter 6 Technical Data Charging the Compressor with Oil Evacuating valve pos 42 Fig 4 19 for evacu ating the compressor of refrigerant or air after service 0178 933 ENG Rev 2005 12 09 04 technical description fm Service manual SMC TSMC 100 Mk4 4 Technical Description Fig 4 19 SMC 104 108 Short Block 42 lt N 25 4 25 3 The stop valves pos 25 3 and 25 4 are fitted on the compressor discharge and suction flanges for efficient blocking off of the compressor from the refrigeration plant The stop valves have welding 0178 933 ENG Rev 2005 12 09 SABROE flanges for connection to ISO and ASME standard pipes Pipe dimensions are indicated on the di mension sketches in chapter 5 Physical and Con necting data Instrumentation As standard equipment the compressors are fitted with either an analogous reading and safety system consisting of pressure gauges pressure switches and thermostat or with a SABROE microelectronic reading and con trol system UNISAB II as shown in Fig 4 20 Both systems are described in detail later in this section Cooling of compressor and oil On request the compressor can be delivered with a built in cool ing system with either water or refrigerant as de scribed in the section Cooling Systems for Com pressors 45 342 Service manual SM
216. f the motor is such that the shaft seal can be removed from the compressor without removing neither compressor nor motor This facilitates mainte nance considerably PT N37 wo 4 1 PDI N LA W E a 1iL1 4D 1 pa tat 2 4 1 2 _ 1 E 33A 1 TT 87 0178 933 ENG Rev 2005 12 09 43 342 Service manual SMC TSMC 100 Mk4 4 Technical Description Fig 4 17 Shaft seal Pos 10 IN GAZE The heating rod pos 57 Fig 4 18 keeps the oil warm when the compressor is not in operation This reduces the refrigerant content in the oil and eliminates starting up problems caused by oil foaming and subsequent insufficient oil pressure While the compressor is operating the heating cartridge can be switched off but if it is problem atic to maintain the oil temperature sufficiently high it may be an advantage to keep the heating cartridge on during operation 44 342 Fig 4 18 SMC 100 block Pump end Oil draining valve pos 23 for draining charging of oil An inner socket at the draining valve ensures that the oil sump is properly drained so that the compressor does not have to be opened when changing oil and filters The oil l
217. facturer s type designation 0178 933 ENG Rev 2005 12 09 SABROE Design code Shows the design code according to which the vessel was manufactured Approval no CAT Shows the approval no of the vessel issued by the relevant authority as well as the cat egory according to PED 97 23 EEC Article 9 Side Refers to the columns Shell and Tube Fluid Shows the refrigerant designation accord ing to 150817 Allowable pressure PS Shows min and max pressure relative to at mospheric pressure for which the vessel or vessel part has been designed Allowable temperature TS Shows min and max temperatures for which the vessel has been designed Volume Shows volume of the vessel in litres CE xxxx The four digits compose the registration no of the notified body in charge of the assess ment modules for the vessel 13 342 Service manual SMC TSMC 100 Mk4 2 Signs and Warnings In the following section all signs which may be found on the equipment are described The number of signs however may vary from product to product Signs in instructions The sign CAUTION A CAUTION tag like the one illustrated below is fixed to the compressor The sign imposes the us ers to read the Safety precautions chapter in the manual before handling operating or servicing the compressor and unit 4 N Before handling installing operating servicing the compressor and unit read the
218. fety instruc tions regulations Moreover the manual explains the different settings that can be of assistance to those who are responsible for the daily operation and maintenance of the equipment To prevent any accidents assembly and disas sembly of components should only be carried out by authorized personnel It is essential that the operating personnel famil iarize themselves with the contents of this manual in order to ensure a proper and efficient operation Sabroe Refrigeration YORK Denmark ApS hereafter referred to as Sabroe Refrigeration is not liable for damage occurring during the warran ty period where this is attributable to incorrect op eration Sabroe Refrigeration s manual concept covers six standard manuals Engineering Operating Serv ice Installation and Commissioning Transport and Spare Parts Therefore references may be made to chapters which are not part of this manu al This manual was produced by Sabroe Refrigeration YORK Denmark ApS Chr X s 201 P O Box 1810 8270 H jbjerg Denmark Phone 45 87 36 70 00 Fax 45 87 36 70 05 www sabroe com Reg No 19 05 61 71 Copyright 2004 Sabroe Refrigeration This manual must not be copied without the writ ten permission of Sabroe Refrigeration and the contents must not be imparted to a third party nor be used for any unauthorised purpose Contravention will be prosecuted In the space below you may enter the name and address
219. filter bag pos 34B has been fitted in the suction filters The filter bag filters off the tiny rust particles that may pass the suction filters and is thus pro viding the compressor with considerable protec tion from dirt mixing with oil The filter bags are used no longer than 50 hours after initial start up of the compressor This also applies when chang Fig 4 7 By pass valve The compressor is equipped with a built in mechanical by pass valve Fig 4 7 and Fig 4 8 pos 24 which safeguards the compres sor against unintended over pressure in case the 38 342 SMC 100 Filter Section and by pass valve es which may cause impurities in the suction gas are made on the plant After the 50 hours the filter bags and the inserts for the filter bags pos 34C must be taken out and discarded Used filter bags must be disposed of according to existing environ mental legislation see also chapter 11 Mainte nance Instructions and chapter 20 Final Disposal electric safety equipment should fail The bypass valve acts as a kind of over pressure safeguard between the discharge and suction side of the compressor 0178 933 ENG Rev 2005 12 09 04 technical description fm Service manual SMC TSMC 100 Mk4 4 Technical Description Fig 4 8 SMC TSMC 100 By pass Valve x SABROE 0178 933 ENG R
220. filter into the lubricating system The oil pressure regulating valve pos 22 Fig 4 12 regulates the oil pressure in the com pressor lubricating system It can be adjusted from the outside by means of a screw driver when the pointed screw which locks the regulating screw has been loosened For variable speed driven compressors the oil pressure has to be ad justed to the minimum oil pressure at minimum speed Due to rising pressure drop at high oil flow the pressure will rise when running at maximum rpm 0178 933 ENG Rev 2005 12 09 SABROE Fig 4 12 pressure regulating valve The oil suction strainer pos 33A prevents dirt particles in the oil of the crankcase from entering the oil pump with a subsequent wear on the pump bearings The filter is of the full flow filter type The filter can be cleaned Fig 4 13 suction strainer Pos 33A External oil filter pos 9A After the oil pump the oil is furthermore filtered in an external oil filter of the full flow filter type pos 9A before it is led into the lubricating system The filter element is a dis posable filter and must be replaced by a new one as soon as its filtering ability has been used up The replacement can be carried out without re ducing the refrigerant pressure on the compres sor 41 342 Service manual SMC TSMC 100 Mk4 4 Tech
221. for R744 CO triple point Fig 6 11 TC 5 The Lowest Permissible Condensing Pressure At condensing pressures lower than the ones specified the dampening effect from the gas on the valve plates against the valve retaining plate is reduced This increases the risk of valve breakdown 0178 933 ENG Rev 2005 12 09 Minimum Difference between Condens ing and Evaporating Temperature If there is less difference than specified the compressor will not get sufficiently warm Lubrication problems may occur when the refrigerant content in the oil is too high with a subsequent risk of oil foaming in the com pressor It should also be noted that some of the equipment in a refrigeration plant requires a certain pressure difference in order to func tion properly TC TE The Highest Permissible Evaporating Pressure In the crankcase there will always be an evaporating pressure An increase in the evaporating pressure will increase the load on the thrust bearing at the crankshaft as well 115 342 Service manual SMC TSMC 100 Mk4 6 Technical Data Furthermore the refrigerant content in the 7a The Highest Permissible Evaporating oil is going to increase primarily refrigerants Pressure used with soluble oil and this may cause lu The limitation curves represent the highest brication problems The HFC and HCFC re permissible suction pressure without reduc frigerants which are relatively heavy will ing the nu
222. frigerant oil Operating data for the compressor Discharge gas temperature Oil temperature Normal oil temperature in crankcase is 50 60 C 163 342 Service manual SMC TSMC 100 Mk4 6 Technical Data Max permitted oil temperature set point for alarm Min permitted oil temperature set point for alarm if there is any The viscosity of the oil in the compressor during operation Type of refrigerant and solubility of re frigerant in the oil Operating temperatures Vapour pressure in the oil reservoir Suction pressure and oil temperature in the crankcase Compatibility with neoprene O rings The aniline point indicates how the O ring material reacts to the oil Atan aniline point less than approx 100 C the material has a tendency to swell and at an aniline point higher than approx 120 C it has a tendency to shrink Thus it cannot be recommended to change the oil type from M to PAO with out changing the O rings at the same time as a leak may otherwise easily oc cur in the compressor or the plant Sabroe Refrigeration recommends therefore the use of the Sabroe AP68 oil since this type of oil in this case reduces considerably the risk of leaks Sabroe Refrigeration can supply a list of operat ing data on request Please note the viscosity limits during ation e Optimum viscosity limits 20 to 50 cSt Max permitted viscosity 100 cSt
223. from the oil separator is led to the compressor crank case via valve block pos 80A and the TLT valve pos 80C In the oil separator at position C the pipe is insert ed 10 mm into the end plate whereby any sedi ment can settle at the bottom of the oil separator Compressor J Valve block A Pos 80A 1 Solenoid valve Orifice Pos 80B 1 stop valve Qpes ANG 2 NG Filter TLT valve 52 342 Pos 80C 1 0178 933 ENG Rev 2005 12 09 04 technical description fm Service manual SMC TSMC 100 Mk4 4 Technical Description In valve block pos 80A Fig 4 27 the oil first passes a stop valve which is normally completely open This is not a regulating valve and it is closed only during maintenance work on the com pressor and during cleaning of the filter in the valve block Fig 4 27 Valve Block pos 80 Oil Return Outlet Wire mesh From the stop valve the oil passes a wire mesh which can be removed and cleaned The filtered oil now passes the solenoid valve which must be closed at dead coil whenever the compressor is stopped When the compressor is operating the 0178 933 ENG Rev 2005 12 09 x SABROE solenoid valve is open allowing the oil to flow to the compressor As stated above it is recomme
224. further in formation about water treatment A Warning The recirculation water system may contain chemicals or biological contaminants including legionella which can be harmful if inhaled or in gested Water systems should only be operated with an effective biological treatment programme 93 342 Service manual SMC TSMC 100 Mk4 4 Technical Description 1c Cooling with Thermo Pump R717 The thermo pump is a compressor cooling system which makes the compressor completely inde pendent of the cooling water The system is there fore very applicable in areas where there is a shortage of water resources or where the water quality is poor The thermo pump system can only be used with R717 The purpose of the thermo pump is both to cool the oil in the crankcase and to cool the compres sor discharge gas in order to lower the tempera ture in the whole compressor Fig 4 70 Short Block with Thermopump The thermo pump is mounted as a side cover on the compressor and works by pressing the refrig erant into the canal system on the top covers and into the oil cooler which depending on the oper ating conditions is built into the crankcase 94 342 On TSMC compressors cooling only takes place in the high pressure stage top covers and no oil cooler is used in the crankcase The thermo pump works under the influence of heat coming from the oil in the crankcase In this way it also regulates its own pump capacity This m
225. g gland O ring 28 17 X 3 53 Nylon washer dia 48 34 x 1 5 Gasket for welding nipple Gasket for valve compr Gasket for plug 292 342 0178 933 ENG Rev 2005 12 09 tool list fm 18 spare parts list Service manual SMC TSMC 100 Mk4 18 Part list 3188 018 Designation Gasket kit stop valve 125 Compressor SMC 25F 2 Gasket for screw dia 36 28 x 1 5 25H 3 Sealing ring dia 133 110x3 0 25J 3 Gasket for bonnet dia 167 5 x 148 5 x 2 0 25M 2 Packing gland 25P 2 O ring 28 17 X 3 53 25Q 2 Nylon washer dia 48 34 x 1 5 25Y 3 Gasket for welding nipple 25AG 3 Gasket for valve compr 25AH 1 Gasket for plug 25V 1 1437 023 Spring washer 25Z 1 1424 241 Screw valve compr M14 x 40 254 2 1424 242 Screw valve compr 14 x 45 252 3 1424 102 Screw valve compr M16 x 45 252 4 1424 268 Screw valve compr M16 x 100 Pressure gauges 1 1541 108 R717 30A 2 1541 068 R407C and R507 30A 3 1541 074 R22 R134a and R404A 30A 4 1541 136 R410A and R744 Dicsharge pressure gauge 31A 1 1541 029 R717 31A 2 1541 069 R407C and R507 31A 3 1541 075 R22 R134a and R404A 31A 4 1541 137 R410A and R744 31A 5 1541 101
226. g must be introduced 0178 933 ENG Rev 2005 12 09 189 342 Service manual SMC TSMC 100 Mk4 6 Technical Data R410A reciprocating 122 compressors 104 o 86 5 68 2 50 HH 6 32 A a O 14 4 22 60 50 40 30 20 10 0 10 20 30 40 50 76 58 40 22 4 14 32 50 68 F Code no Area no Evaporating temperature 1 A very suitable in case of a new plant 4 concentration in liquid phase at 2 W 190 342 0178 933 ENG Rev 2005 12 09 06 technical data fm Service manual SMC TSMC 100 Mk4 6 Technical Data SABROE R507 E i F single stage reciprocating compressors 104 40 9 86 30 3 pun 5 68 20 a 50 10 D 2 32 0 o 14 10 4 20 22 30 Area no Code no 1 2 E3 A E5 A A Very suitable in case of a new plant Min suction temperature 50 C At TE lt 50 C superheating must be introduced KI Zone in which both oils are applicable 0178 933 ENG Rev 2005 12 09 22 4 14 32 50 Evaporating temperature 191 342 Service manual SMC TSMC 100 Mk4 6 Technical Data R507 two stage reciproca
227. gized the valve will reverse so that the passage of the oil flow from oil discharge 0178 933 ENG Rev 2005 12 09 pipe 1 to 2 is open and the connection to pipe 3 is closed The solenoid valves are mounted in joint blocks Fig 4 43 with one two three or four solenoid valves in each block 65 342 Service manual SMC TSMC 100 Mk4 4 Technical Description Fig 4 43 Solenoid Valve Block ANA REE PN 707777107770 o gt J E IN 0 In the block there is supply of pressure oil from the oil pump pipe a to the solenoid valves as well as a common connection to the crankcase pipe c Each solenoid valve has its own oil connection to the relevant regulating cylin der pipe Regulating Sequence As described earlier the compressors are always completely unloaded during start up exept for the compressor with extra capacity stages ex tended unload which will always have one or two cylinders loaded during start up SMC104 108 and SMC 112 116 66 342 Standard compressors however with 2 cylinders on the SMC 104 106 108 compressors 4 cyl inders on SMC 112 and 116 will be set to work when the compressor oil pump has worked up an oil pressure in the lubricating system
228. h is stamped on the outside of the belts see Fig 6 37 Moreover the V belts are made with such narrow tolerances that they can be fitted im mediately which means that it is no longer neces sary to check whether the belts match A V belt drive which has been set up and adjusted correctly will usually have a long life time Fig 6 37 Transmission Ratio The required transmission of speed between mo tor and compressor is achieved by choosing the right combination of pulley diameters as stated in the Table 6 9 It appears from the table that there is only one pulley diameter for the compressors and that the transmission ratios are achieved by choosing among the standard motor pulleys Thus the Compressor Speed for Motor Speed 1460 rpm 50Hz and 1760 rpm 60 Hz stated in the table is achieved The nominal V belt length is stated in the column Length of V belt and the same length is stamped on the outside of the V belts as in the example shown in Fig 6 37 0178 933 ENG Rev 2005 12 09 06 technical data fm Service manual SMC TSMC 100 Mk4 6 Technical Data Table 6 9 Standard Programme for V Belts and Pulleys SMC TSMC 100 Standard V belt pulley Compressor speed compared Length of V belts Diameter mm to Motor speed mm Compressor Motor 50 Hz 1460 rpm 60 Hz 1760 rom SMC 104 106 108 112 116 TSMC 108 TSMC 116 180 792 1900 190 836 2650 1900
229. hatched area represents the torque available to the motor when speeding up the compressor 0178 933 ENG Rev 2005 12 09 06 technical data fm Service manual SMC TSMC 100 Mk4 6 Technical Data Fig 6 22 Start up torque SMC 100 R717 25 load SMC 104 E R717 start up torque at 25 loa 500 750 1000 1250 1500 RPM SMC 104 L R717 start up torque at 25 load 1750 750 1000 1250 1500 RPM SMC HPC 104 S R717 start up torque at 25 load 1750 750 1000 1250 1500 RPM 0178 933 ENG Rev 2005 12 09 1750 SABROE 2000 2000 Only HPC 104 S 2000 133 342 Service manual SMC TSMC 100 Mk4 6 Technical Data Fig 6 23 Start up SMC 100 HFC HCFC 25 load SMC 104 E HFC HCFC start up torque at 25 load 500 750 1000 1250 1500 1750 2000 RPM SMC 104 L HFC HCFC start up torque at 25 load 750 1000 1250 1500 1750 2000 RPM SMC 104 S HFC HCFC start up torque at 25 load 750 1000 1250 1500 1750 2000 RPM 134 342 0178 933 ENG Rev 2005 12 09 06 technical data fm Service manual SMC TSMC 100 Mk4 6 Technical Data SABROE Moment of Inertia As to the moment of inertia Table 6 4 and Table 6 5 the SMC HPC TSMC
230. he service instructions should therefore be read and followed carefully Check Interval Activity Excessively high pressure may be due to reduced cooling effect Condensing pressure TP Pressure and low condensing pressure implies a temp Daily risk of restricting the refrigerant supply to the evaporator Discharge pipe temperature Normal discharge pipe temperature according to instructions Filter in Accumulated dirt causes reduced refriger liquid line Cjeanwhen ant supply to the evaporator Filters thermostatic valve If a filter has a hot inflow and cold dis suction line q charge this may be due to clogging of the oil return component Some installations are provided with a sight glass featuring moisture indicator If Dehumidifier Moisture in the sight glass en the indicator colour switches from green to on installations required yellow there is moisture in the refrigerant Change the drying filter regularly Inadequate charging results in reduced Refrigerant charge plant capacity and it often leads to an ex cessively high discharge pipe tempera ture Refrigerant Periodically The plant must be searched regularly for leaks Flanges and joints settle during the Leak detection initial operation period of the plant They must therefore be tightened and checked Safety pressure controls Automatic operat
231. he reason for this is ex plained in the following Generally speaking the calculated power de mand should be increased by one of the fol lowing factors in order to ensure that the mo tor has sufficient driving power both during start up at minor deviations from the worked out operating conditions and with regard to mechanical transmission loss for instance in the V belt drive 1 Air conditioning plant Factor 1 10 2 Other refrigeration plants Factor 1 15 3 For V belt drive Factor 1 05 130 342 B Doconsider however which type of plant the compressor is going to work on and then di mension the motor in accordance with the fol lowing rules a For plants in which a higher ET may be expected and consequently also a higher CT in the start up phase the motor must be dimensioned to meet the higher operating temperatures Usually this does not incor porate factor 1 and 2 Likewise special consideration should be given concerning the booster compressors b Alternatively the motor can be connected to a system for Ampere limitation which re duces the compressor capacity until the planned operating temperatures have been reached This element is found in UNISAB II which must be linked to the Amp signal however In this case factor 1 and 2 should also be omitted Note Sabroe Refrigeration would like to point out that when using a motor with a class F insula tion 105K for operating conditions like for
232. his problem As a consequence we have designed the compressors and units with a view to meeting market demands concerning maximum noise levels Of course modern compressor units are loud and must be expected to make noise and this makes it the more important that the sound data stated for a compressor or unit should be evaluated cor rectly The above issue will be discussed in the following In this connection Sabroe Refrigeration would like to point out that at a fairly low cost it is possible to make the machine room a pleasant work place The use of noise absorbing materials could be one solution to the problem 1 Sound Power and Sound Pressure As seen in Table 6 13 sound data is indicated as sound power level Ly or sound pressure level Lp It is essential to distinguish between these two values as they are stated in dB decibel and should be read as follows 1 1 Sound Power Level Ly According to ISO 9614 2 Ly is measured directly at the unit Fig 6 44 by installing a measuring grid as close to the unit as possible 148 342 Fig 6 44 Unit covered with a measuring grid The measuring grid is divided into fields of max 1 sq m each The measuring is carried out by moving the sound level meter in a kind of back and forth movement as illustrated in Fig 6 44 The sound level meter now calculates the total sound power level Ly for the entire unit The sound power level Ly is however dependent on the surround
233. hnical Description The Oil Return Systems from the Oil Separa tors are the same as the ones described in Oil re turn to the compressorin this section The only dif ference is that the oil return system is not connect ed to the compressor but taken to the common oil vessel pos 9 Solenoid valve pos 6 closes whenever the actu al compressor stops In case the oil return system from the oil separa tors is controlled by a float valve which is also de scribed in this section it will be necessary to mount a pipe connection to the discharge pipe as illustrated in Fig 4 36 This ensures a slight gas flow to the oil vessel pos 9 and consequently overpressure that presses the oil out to the compressors through 0178 933 ENG Rev 2005 12 09 x SABROE float valves pos 2 Solenoid valve pos 11 clos es when the plant stops and all the compressors are stopped Fig 4 36 Oil separator with float valve control led oil return B 41 X ES 8 sk 12 M Bae pay XI qu 13 59 342 Service manual SMC TSMC 100 Mk4 4 Technical Description System B System B is used where more than two compres sors are working in parallel but where they do not have any joint suction line The refrigerant may be HFC HCFC or R717 Principle diagram Fig 4 37 is an example of a plant with two compressors working in parallel but which do not have the same suction pre
234. hnical description fm Service manual SMC TSMC 100 Mk4 4 Technical Description Fig 4 30 Side with single radial scratch must be towards seating faces Replace the cap no gasket is required but a suit able high temperature anti sieze grease without copper should be applied to the threads 0178 933 ENG Rev 2005 12 09 SABROE Mounting In principle the liquid trap can function in all posi tions but to minimise uneven wear and thereby achieving maximum life time mounting it in a ho rizontal line with the cap up or down is recom mended See also Fig 4 26 The surface of the connection is machined to make a tight sealing using Al gasket Fig 4 31 Principle piping diagram Oil separator TLT 15 pig Reciprocating compressor 245893 Nozzle 3 3 mm 55 342 Service manual SMC TSMC 100 Mk4 4 Technical Description B Float Valve Controlled Oil Return The float valve is located in a separate float ves sel mounted on the side of the base frame and connected to the oil separator and compressor as illustrated on Fig 4 32 Fig 4 32 Float Valve Control Oil Return m To the compressor A D The separated oil is drained through stop valves A and filter D to the float vessel C and here the float valve opens at an increasing oil level
235. ical Data Selecting Lubricating Oil The correct oil is selected by means of the follow ing diagrams When the general conditions con cerning the lubrication of the compressor have been considered the specific conditions of the plant must be taken into account Use the oil recommendation diagrams to select the correct oil code number The oil code number consists of letters indicating the oil type and viscosity number Table 6 21 Code Oil types design M Mineral oil A Synthetic oil based on Alkylbenzene PAO Synthetic oil based on Polyalphaolefin AP Mixture of A and PAO oils E Synthetic ester based lubricants In the oil recommendation diagrams it is possible to find the code number best suited for the operat ing conditions in question With the code number itis possible to select the correct Sabroe oil for the application in question Oil Types and Oil Companies Due to the large number of oil companies offering oil for refrigeration plants it has not been possible for Sabroe Refrigeration to test all the different oil brands on the global market It is our experience that certain oil brands can change character during use and thus no longer correspond to the specifications stated by the oil companies on delivery We have thus experi enced changes in specifications as well as formu la and performance without having received infor mation on this beforehand from the oil company This ma
236. ical lifting and carrying equipment for heavy bulky or unwieldy objects Use hook up methods recommended by your safety department and familiarise yourself with the signals for safely directing a crane opera tor Never place any part of your body under a sus pended load or move a suspended load over any other persons Before lifting be certain that you have a safe spot for depositing the load Never work on a component while it is hanging from a crane or any other lifting mechanism If in doubt as to the size or type of lifting equip ment the method and procedures to be used in connection with lifting contact 0178 933 ENG Rev 2005 12 09 03 safety precautions fm Service manual SMC TSMC 100 Mk4 3 Safety Precautions Sabroe Refrigeration before proceeding to lift the compressor motor unit or its components Always inspect slings chains hoists and other lift ing devices prior to use Do not use lifting devices which are defective or in a questionable condition Never exceed the lifting capacity of cranes slings eyebolts and other lifting equipment Follow standards and instructions applicable to any lifting equipment used Before inserting an eyebolt be certain that both the eyebolt and the hole have the same size and type of threads To attain safe working loads at least 90 of the threaded portion of a standard forged eyebolt must be engaged UN Warning Failure to follow safety instructions on thi
237. ies It is extremely important that the new unused oil is taken directly from its original container and that both the brand and the type correspond to the specifications of the plant 166 342 Make sure that the original oil container is sealed properly during storage so that moisture from the air is not absorbed by the oil Many oils particular ly polyolester oils are extremely hygroscopic It is therefore recommended only to buy the oil in con tainers whose size correspond to the amount to be used In case all of the oil is not used make sure that the rest of the oil is sealed in the original container and stored in a warm dry place It is recommend ed to charge nitrogen to keep the water content below 50 ppm Ideally oil containers should be equipped with a barrel tap to ensure an effective airtight seal 0178 933 ENG Rev 2005 12 09 06 technical data fm Service manual SMC TSMC 100 Mk4 6 Technical Data Oil Changing Intervals A list of the recommended oil changing intervals is included in the instruction manuals of the com pressors This list is for guidance only The actual oil changing intervals are often determined by a number of operating parameters in the plant Oil recommendation diagram symbols In case of a new plant Very suitable 090 In case you wish to change from mineral oil x SABROE It is strongly recommended to monitor the quality of the oil by performing oil analyse
238. ig 6 15 Direction of rotation for compressor is uni directional seen from A The direction of rotation for the pump is indicated by a guide pin Counterclockwise compressor rotation Marking in cover to the right of the logo Fig 6 17 LO o gt Guide pin An arrow cast into the bearing cover indicates the 4 Tan gt Fig 6 16 NOE p Clockwise compressor rotation Marking in cover to the left of the logo direction of rotation as shown in the picture C Fig 6 18 JEN gt O os At times it may be necessary that the crankshaft Guide pin of rotates in the opposite direction e g if the com LC 0178 933 ENG 129 342 Rev 2005 12 09 Service manual SMC TSMC 100 Mk4 6 Technical Data Choice of Electric Motor The IEC electric motors type IP23 or IP54 55 IP Index of Protection are normally used to drive the compressors and the base frames are standard design for these motors Fig 6 19 IP23 Drip proof Motor When selecting an electric motor the following factors must be taken into consideration Motor Dimension The size of the motor is determined on the basis of the power demands of the compressor under the current operating conditions calculated by means of the Sabroe COMP1 PC program However for various reasons always choose a motor a little bigger T
239. il the crankshaft and the shaft seal components thor oughly with the same type of oil as used in the compressor 1 2 Unit with slide ring Pos 10E 1 Before fitting slide ring Pos 10E tighten screws Pos 10 until there is approx 2 mm spacing and parallelism between the two flanges Check also that locking ring Pos 10H is mounted as shown in the drawing and that O ring Pos 10D is in its correct position Position slide ring Pos 10E on shaft and make sure that tightening flange makes contact with shaft shoulder Crosswise tighten screws 10J al ternately with Allen wrench from tool kit The torque is specified in the instruction manual Check axial position of shaft seal by measuring distance from frame sealing face to slide face on Pos 10E This must measure approx 5 5 mm as shown in the drawing Unit with shaft seal cover Pos 8A 1 Mount O ring Pos 10G and the ten spi ral springs 10B in shaft seal cover Pos 8A then position carbon slide ring Pos 10F carefully Rotate carbon slide ring 0178 933 ENG Rev 2005 12 09 x SABROE so that slot fits in over the retention pin Pos 8H With tool no 2 fitted as shown see Fig 13 14 press carbon slide ring pos 10F against spring pos 10B Locking ring Pos 8G can now be fitted Observe closely that the carbon slide ring is not overloaded by misbalanced pressure and that its slide face is not damaged Give complete shaft seal c
240. imits 2 Two Stage o 5 Compressor type TCMO amp TSMC D o 76 58 40 22 4 14 32 oF rotita Evaporating temperature TYPE AREA REM OIL COOLING 1 NOTE MAX MIN 1 2 1500 TCMO2 N 20 30 3 1800 900 1 1000 5 1005 2 1200 700 Yes 2 3 1800 1 3 TSMC100L 2 1000 7 Y 2 3 1200 1 2 3 750 450 Yes 2 Top covers Air cooled only 2 By pass equipment required to maintain in 1 When required choose freely between termediate temperature A or B except TSMC180 where only A 3 Not applicable may be selected A Water cooled side covers B Built in refrigerant cooled oil cooler with ther mostatic expansion valve 0178 933 ENG 121 342 Rev 2005 12 09 Service manual SMC TSMC 100 Mk4 6 Technical Data TC JE R134a 158 70 140 Operating Limits Single Stage 1224 50 Compressor type 10440 CMO amp SMC 5 86 S 8 e8 20 2 o 50 10 o 32 8 14 10 4 20 22 30 94 58 40 22 4 14 32 86 104 oF T011162_2 Evaporating temperature TYPE AREA ail OIL COOLING 1 NOTE MAX MIN 4 2 1200 No At less th it 20 30 1500 900 ape 3 1800 At less than 50 capacity 1 1000 No 2 N SMC100S 1200 700
241. ing compressors comply with the ISO 10816 standard Part 6 Annex A group 4 AB which fixes max permissible operating vibrations at 17 8 mm s Vibration data for Sabroe Refrigeration s Sabroe screw compressors comply with ISO 10816 Fig 6 49 DV CV DH CH x Pay attention to the following however Motors comply with EN 60034 14 CEI IEC 34 14 Class N When placing the unit the vibration dampers supplied by Sabroe Refrigeration additional the vibrations against the foun dation are reduced by 85 95 for screw compressor units 80 for reciprocating compressor units However higher vibration level may occur if motor and compressor have not been aligned as described in the Instruction Manual 0178 933 ENG Rev 2005 12 09 standard part 1 Annex B Class C which fixes max permissible operating vibrations at 11 2 mm s The measurements are made as illustrated in the figure below points A D the compressor runs at an incorrect V ratio This applies to screw compres sors the piping connections have been exe cuted in a way that makes them force pull or push powers on the compressor unit or transfer vibrations to the unit caused by natural vibrations or connect ed machinery the vibration dampers have not been fit ted or loaded correctly as indicated in the foundation drawing accompanying the order 155 342 Service manual SMC TSMC 100 Mk4
242. ing controls Periodically Adjust operating point and check the func controls Alarms tion Replace switch system if sticking 0178 933 ENG Rev 2005 12 09 231 342 Service manual SMC TSMC 100 Mk4 13 Service Instructions Check Interval Activity Electric motor Lubrication of electric motors Alignment of coupling V belt drive Periodically Clean and lubricate according to supplier s instructions At temperatures lower than 25 C use special lubricant Check in accordance with the instructions of the instruction manual Tighten loose V belts if any or replace with new ones Condenser Corrosion Periodically normally min 4 times a year Marine condensers are normally protected against galvanic corrosion by the mounting of corrosion plugs in the condenser covers Metallic contact between corrosion plug and cover is essential to proper function ing Evaporator Frosting up When required Unproblematic operation is conditioned by the evaporator being kept free of ice Defrost as and when required Oil draining ammonia plant Periodically Check evaporator intermediate cooler receiver etc for oil accumulation Exercise caution use a gas mask 232 342 0178 933 ENG Rev 2005 12 09 13 service instructions fm Service manual SMC TSMC 100 Mk4 13 Service Instructions Maintenance of reciprocating compressor Gen
243. ings of the noise source Conse quently it is a somewhat theoretical value Here the sound pressure level L becomes of inter est 0178 933 ENG Rev 2005 12 09 06 technical data fm Service manual SMC TSMC 100 Mk4 6 Technical Data 1 2 Sound Pressure Level Lp It is actually the sound pressure level Lp that is measured by the sound meter In the sound meter this is then automatically converted to the sound power level Ly by means of its built in calculation programs The sound pressure measuring is however de pendent on the room in which the measuring is carried out As a consequence this may yield dif ferent results from one room to another The arrangement of the room as well as building materials have a considerable influence on the re sults of the measuring This is why the measured values of the manufac turers for sound pressures are based on standard measures according to ISO 3989 which refers sound pressure level Lp to a free field above a reflecting plane at a distance of 1 meter from the measuring grid as described in pt 1 1 Above facts should be taken into consideration during a check measuring on the plant in question as mentioned in points 2 1 and 2 3 0178 933 ENG Rev 2005 12 09 x SABROE 1 3 Frequency Sound is fundamentally a pressure wave in the air at a given wave length frequency From a compressor unit sound waves are emitted at many different frequencies du
244. ion filter 294 342 O ring 104 1 x5 33 0178 933 ENG Rev 2005 12 09 tool list fm 18 spare parts list Service manual SMC TSMC 100 Mk4 18 Part list Designation O ring 120 24 X 3 53 SABROE Compressor SMC 3188 014 Gasket kit suction filter 34D 1 O ring 104 1 x5 33 34 1 O ring 120 24 3 53 34B 1 3425 083 Filter bag 34B 2 3425 096 Filter bag 34C 1 3424 058 Insert for filter bag 34C 2 3424 061 Insert for filter bag 34E 1 3422 103 Cover for suction filter 34E 2 3422 114 Cover for suction filter 34G 1 1424 217 Hexagon head screw M12x40 34G 2 1424 102 Hexagon head screw M16x45 34H 1 1437 027 Spring washer 34H 2 1437 026 Spring washer Discharge pipe oil system 38A 1 3141 176 Discharge pipe oil system 38C 1 2333 024 Connection for discharge pipe 38C 2 2333 025 Connection for discharge pipe 38C 3 2333 026 Connection for discharge pipe 38H 1 3141 114 Discharge for oil pipe 38J 1 2213 150 Support for oil pipe 38K 1 1424 189 Hexagon head screw M10 x 16 38L 1 1437 027 Spring washer 3188 139 Gasket kit discharge pipe oil system O ring 21 82 x 3 53 O ring 21 82 x 3 53 O ring 29 51 x 5 33 O ring 21 82 x 3 53 O ring 26 58 x
245. ion fm Service manual SMC TSMC 100 Mk4 4 Technical Description Oil Separator Type OVUR The purpose of the oil separator is under all kinds of operating conditions to separate the oil which is conveyed with the disharge gas out of the compressor so that it will be led back to the com pressor crankcase The oil separator is mounted on the compressor unit and connected to the discharge gas outlet of the compressor as indicated in the drawing Fig 4 24 On some units the oil separator is not mounted Fig 4 24 Standard Compressor Unit Separator Mode of Operation The discharge gas from the compressor flows through the oil separator Fig 4 25 from A to B passing a number of filters in which the oil is sep arated from the discharge gas The filters consist of a stainless steel wire mesh which usually needs no cleaning and which is not worn down Consequently the filters cannot be removed from the oil separator The oil separators are dimensioned for compres sor full load and they ensure an oil carry over of max 35 ppm after the oil separator at full load 0178 933 ENG Rev 2005 12 09 SABROE Fig 4 25 Oil Separator ms 50557 5 505 SS vat KG 299 6 OK KO Discharge gas inlet B Discharge gas outlet L Oil return to
246. ipe Thermostat 8 2 2 1 78 DVEN m beu du t 82 High Pressure Cut out KP15 78 Intermediate Cooling iz qm 83 0178 933 ENG Rev 2005 12 09 0178 933 ENGIX fm Service manual SMC TSMC 100 Mk4 P 0178 933 ENG Rev 2005 12 09 SABROE 342 dec AA ANA 83 C 82 Intermediate Pressure Cut Out KP5 78 Low Pressure Cut out KP15 Iani intended 78 Oil Differential Cut out 5 00 0 00 4 78 Thermostat GA 78 Regulation of Intermediate Pressure 84 SMC By pass Valyg NN EE 38 Connecting 37 Cooling of Compressor and Oil 45 PC crgo 40 Cylinder liners AA oo TS 36 Discharge Valve c H 37 Draining valve ee aa re rr 44 Eva uating YANG oe 44 Filter bag mc E 38 Heating KOO 44 Hp dg Pom m 45 wig 41 Oil Level Glass eee ree 44 Oil Pressure Regulating Valve 41 Qil PUN AANGAL 41 gri ge c T et aed ec ae P aa 36 Safety
247. is not used in one go the container should be tightly sealed and stored in a warm place to prevent the absorption of moisture Note It is inadvisable to reuse oil which has been drawn from a compressor or plant This oil will have ab sorbed moisture from the air and may cause oper ating problems Always switch off the power to the heating rod be fore drawing off the oil Chapter 6 Technical Data Charging the Com pressor with Oil includes a detailed description of lubricating oils as well as directions for selecting the correct oil UN Caution Never add oil until the reason for the drop in the oil level has been found and remedied AN Warning Corrosive oil is a hazardous substance It can cause irritation and other injuries 207 342 Service manual SMC TSMC 100 Mk4 11 Maintenance Instructions Assessing the Oil Refrigeration machine oil is a vital part of the com pressor as it not only lubricates and cools the movable parts of the compressor but also pre vents abrasive particles from entering the bear ings An analysis of the oil can give important informa tion on how the compressor is running We would therefore advise that the oil analyses be carried out at the intervals prescribed An oil sample must be drawn off while the com pressor is in operation which gives a represent ative sample Before taking the sample clean the drain valve and drain off some oil This is done to prevent any impu
248. kes it extremely difficult for 0178 933 ENG Rev 2005 12 09 Sabroe Refrigeration to give a general approval of other oil brands In co operation with a large respected oil compa ny Sabroe Refrigeration has therefore developed a series of three different oils covering most de mands Furthermore a list of the oils which can be supplied through Sabroe Refrigeration has been prepared Data for these oils is included in the ta ble Data for Sabroe Oils We recommend that you use these oils which can be delivered in 20 litre pails or 208 litre drums When ordering use the part no stated in List of Part Numbers for Availa ble Sabroe Oils It is of course possible to use similar oils from oth er oil companies If this is the case use the table Data for Sabroe Oils Please note that Sabroe Refrigeration has not tested other oils than our own brand Thus we cannot guarantee the quality stability or suitability of other oils The respective oil companies are thus responsible for the quality and suitability of the oil delivered and if there are any problems with these oils in the compressor or the refrigera tion plant contact the oil supplier directly When selecting oils from other oil companies special attention should be paid to the suitability of the oil in the compressor and the refrigeration plant as a whole Please note in particular the following points Oil type Compressor type Miscibility between re
249. lates which become illegible Re placement plates can be purchased from Sabroe Refrigeration Safety guards shields barriers covers and pro tective devices must not be removed while the compressor unit is operating All safety features disengagements and inter locks must be in place and function correctly be fore this equipment is put in operation Never by pass or wire around any safety device Keep all parts of your body off the compres sor motor unit during operation Never lean on or reach over the compressor During operation pay attention to the compressor unit process Excessive vibration unusual sounds etc can indicate problems requiring your immediate attention 21 342 Service manual SMC TSMC 100 Mk4 3 Safety Precautions Maintenance Safety Do not attempt to perform maintenance on the compressor unit until you have read and under stood all the safety instructions Assign only qualified service or maintenance per sonnel trained by Sabroe Refrigeration to per form maintenance and repair work on the unit They should consult the service manual before at tempting any service or repair work and contact Sabroe Refrigeration in case of questions Use only Sabroe Refrigeration original spare parts other parts may impair the safety of the compres sor unit Before removing or opening any electrical enclo sure cover plate or door be sure that the Main Disconnect Switch is in the OFF position and
250. le Strength test Strength test working pressure stand still pressure pressure pressure Leak test PS PSs pressure High pressure side Low pressure side High pressure side Low pressure side Bar Psi Bar Psi Bar Psi Bar Psi Bar Psi Compressor block T SMC 28 411 18 265 42 617 27 397 7 103 TCMO Compressor block HPC 40 588 26 382 80 1176 40 588 7 103 Units T SMC 24 353 18 265 27 397 27 397 103 T CMO Units HPC 39 573 26 382 43 632 40 288 7 103 HPO 158 342 0178 933 ENG Rev 2005 12 09 06 technical data fm Service manual SMC TSMC 100 Mk4 6 Technical Data Charging the Compressor with Oil Usually the compressor is delivered without any oil in the crankcase As a principal rule the amount of oil indicated in the table Table 6 19 should be charged to the compressor Table 6 19 Charging Compressor Amount of oil in crankcase Type Size Liter US gal 104 26 6 9 SMC HPC 106 28 7 4 108 30 7 9 112 47 12 4 SMC 116 50 13 2 108 30 7 9 TSMC 116 50 13 2 After some hours of operation the compressor must be recharged with oil however as part of the oil has been absorbed by the refrigerant This is especially the case for and HCFC refriger ants The amount of oil to be recharged depends on the size of the refrigeration plant and the amount of refrigerant Oil is charged to the middle of the oil level glass and the amount of oil needed in
251. line See 17 26 18 61 Too much refrigerant dissolved in oil Before starting compressor heating element must have been on for at least 8 hours in order to boil refrigerant out of oil During start up phase capacity should be con nected at a slow rate to prevent sudden drop in pressure on suction side with resultant foaming Under normal operating conditions com pressor should operate under as stable pressure conditions as possible 19 Crankcase sweating or frosting up 19 26 Liquid in suction line See 17 26 19 37 Expansion valve sensor misplaced Check positioning of expansion valve sensor cf instructions for expansion valve 19 39 Liquid regulating valve or float valve Increase superheating on thermostatic expan producing too much liquid sion valve 20 Capacity regulation oscillating 20 18 Oil foaming in crankcase See 18 21 Impossible to bleed plant 21 43 Solenoid valve leaky Pinpoint and seal leak or change leaky compo nent 21 51 Defective piston rings Check and replace any defective parts 21 52 Defective discharge valves Check and replace any defective parts 21 53 Defective suction valves Check and replace any defective parts 0178 933 ENG Rev 2005 12 09 225 342 Service manual SMC TSMC 100 Mk4 12 Fault finding Instructions 226 342 0178 933 ENG Rev 2005 12 09
252. ll faintly of chloroform at high concentrations Characteristics e non toxic non inflammable non corrosive When heated to above approx 300 C they break down into toxic acid gas components which are strongly irritating and aggressive to nose eyes and skin and generally corrosive Besides the obvious risk of unnoticeable heavy gases displacing the atmospheric oxygen inhala tion of larger concentrations may have an accu mulating anaesthetic effect which may not be im mediately apparent 24 hours medical observation is therefore recommended 0178 933 ENG Rev 2005 12 09 Basic rules for first aid When affected persons are moved from low lying or poorly ventilated rooms where high gas con centrations are suspected the rescuer must wear a lifeline and be under constant observation from an assistant outside the room Do not use adrenaline or similar heart stimuli Inhalation Immediately move affected persons into fresh air Keep them still and warm and loos en clothing restricting breathing If the patient is unconscious call a doctor ambu lance with oxygen equipment immediately Apply artificial respiration until a doctor authorizes other treatment Eyes Immediately rinse with water preferably using an eye rinser and consult a doctor Contin ue rinsing until otherwise stated by a doctor If the affected person wears contact lenses these must be removed bef
253. lling oil level letting the oil flow from the oil ves sel pos 9 return to the compressor This ensures a constant oil level in the compressor Fig 4 35 Oil Vessel pos 9 To common suction line 215 X 4 240 W pl Max oil level To float valves 58 342 The oil vessel pos 9 is illustrated by the principle drawing Fig 4 35 Its size is calculated so that an extra amount of oil is available to ensure the oil level in the compressor The total volume of the vessel should be approx 50 of the oil volume in all the compressors and the vessel should not be charged to more than 50 This means that the amount of oil in the vessel corresponds to 25 of the total amount of oil in the compressor The oil vessel must be equipped with heating rod 240 W pos 14 oil charging valve pos 15 oil level glass pos 16 From the top of the oil vessel pos 9 a pipeline is taken to the suction side of the plant A non return valve pos 10 Fig 4 33 has been inserted in the pipeline and this valve opens ata differential pressure of 1 bar This way the pres sure in the oil vessel will be 1 bar higher than the suction pressure in the plant This is sufficient in order to squeeze the oil through the float valves pos 2 without causing foaming in the float valve houses 0178 933 ENG Rev 2005 12 09 04 technical description fm Service manual SMC TSMC 100 Mk4 4 Tec
254. lter as described below On SMC compressors the two suction filters are identical and should only be fitted with an O ring in the end facing up towards the suction stop valve The filters are open at both ends TSMC 116 The suction filter fitted on the righthand side oppo site the high pressure cylinders has a closed end bottom which must face upwards and close towards the suction stop valve This suction filter must be fitted with O rings at both ends 257 342 Service manual SMC TSMC 100 Mk4 13 Service Instructions Monitoring cylinder lining insertion When reassembling the slide linings it is impor tant to check the clearance volume as described in section 1 below When mounting new cylinder linings both the clearance volume and the so called lifting re serve must be checked in the order mentioned and as described in sections 1 and 2 During serv ice itis recommended that the cylinder linings are marked so that they can be reassembled in the same place as before 1 Checking clearance volume After each cylinder lining assembly it is recom mended that the clearance volume be checked as it directly influences the compressor perform ance Adjustment of the clearance volume is done by means of gasket pos 19K which in addition to its sealing function is also used as an adjusting ele ment Consequently the gaskets come in two siz es and may sometimes be used at th
255. m the com pressor oil and will when it exceeds the pressure on the compressor discharge side make the re frigerant flow through the pipe connection C to the top covers and the oil cooler At the top covers the refrigerant expands through the nozzles pos 98M directly into the hot dis charge gas resulting in immediate cooling of the discharge gas The oil cooler OOSI not always required is a heat exchanger in which the expanding refrigerant 0178 933 ENG Rev 2005 12 09 after cooling of the oil is taken to the compres sor discharge side Once the liquid in the pump vessel has returned to its lowest level it is registered by the bottom sen sor and the control box opens the two solenoid valves for a new pumping cycle Capacity Regulation of Thermo Pump When reducing the compressor capacity it will be necessary to reduce the cooling effect of the ther mo pump as well This is done as follows SMC 104 106 108 TSMC 116 The pipe connection from the pump vessel to the top covers is divided into two pipe lines In one of these pipe lines a solenoid valve pos 98U is fit ted This solenoid valve is wired to the capacity regu lating system of the compressor and it closes when the compressor capacity has been reduced as indicated in the following table Table 4 10 Table 4 10 Compressor Solenoid Valve pos 98U Capacity Open Closed SMC 104 100 50 SMC 106 100 67 33 SMC 108 100 7
256. mber of revolutions raise the pressure drop through the dis Fig 6 14 charge and suction valves and this will im TC pede the proper functioning of the valves Fig 6 13 da TC The following Operating Limits diagrams include the refrigerants R717 R134a R22 R407C R404a 410 R507 and R744 The cooling systems for compressors which are mentioned in the Operating Limits Diagrams be low are described in detail in chapter 4 Technical Description Cooling Systems for Compressors 116 342 0178 933 ENG Rev 2005 12 09 06 technical data fm Service manual SMC TSMC 100 Mk4 6 Technical Data TC oF 140 60 ET Operating Limits Single Stage 104 40 Compressor Type CMO amp SMC 20 Condensing temperature 32 0 BOOSTER OPERATION 14 10 4 20 22 30 60 50 40 30 20 10 0 10 20 30 40 C 76 58 40 22 4 14 32 50 68 86 104 F 70111123 6 Evaporating temperature rpm TYPE AREA COOLING NOTE max min 1 2 Air cooled top and side covers or water cooled 20 30 3 1800 900 4 Thermopump or water cooled i 1 2 Air cooled top and side covers or water cooled SMC100S L 3 1500 700 4 Thermopump or water cooled i 1 750 Water cool SMC180 579 2 14000 450 ater cooled SMC 188 840 920 R
257. me valve type name valves are not iden tical in above table Valve type are refering to re frigerant as well Fig 13 8 238 342 All pressure valves supplied by Sabroe Refrigeration today are marked as described below and shown on the sketch Large groove for None for R717 ts Small grooves One for LP Two for HP Three for VHP 0178 933 ENG Rev 2005 12 09 13 service instructions fm Service manual SMC TSMC 100 Mk4 13 Service Instructions Refrigerants HFC HCFC All discharge valves are marked with a large groove near the upper edge of the valve feet Refrigerant R717 There is no large groove at the upper edge of the valve feet Conditions The valve type is marked with one two or three small grooves below the large groove if any One small groove LP Two small grooves HP Three small grooves VHP Dismantling When the top cover has been removed spring Pos 21A and discharge valve Pos 20B can be lifted out by hand See disman tling of top cover Tighten discharge valve a soft jawed vice then dismantle the nut Pos 20E and re move the lock washer Pos 20H Valve seat 20 discharge valve Pos 20B and ring plate Pos 20C can now be disassembled by hand Remove valve springs 20G by hand Assembly Before assembling the discharge valve make sure that the valve springs Pos 20G are in good condition and fixed fir
258. mended tightening torques KI ou N tem 2 36 150 5 32 M28 170 190 Clamping element T SMC HPC 100 Kpm 8 5 ft Ibf 61 2 Nm 83 SABROE 329 342 Service manual SMC TSMC 100 Mk4 21 Appendices Coupling data Fig 21 2 n _ 51 B IN gl A 5115 OD GIC N VA N N py Ng O 2 HA f B A_ Table 21 1 Compressor AMR Nominal Torque moment Max variation measured with a type of Distance feeler gauge at a 180 turning of coupling the coupling B D Pos 1 Pos 2 Horizon Vertical tal max min max max mm mm Nm Nm Nm mm mm mm HPC SMC 3125 105 25 147 55 43 0 2 0 1 0 3 0 2 104 108 SMC 350 5 116 27 147 128 43 0 2 0 1 0 3 0 2 112 116 330 342 0178 933 ENG Rev 2005 12 09 21 appendices fm Service manual SMC TSMC 100 Mk4 21 Appendices SABROE Sundry Clearances and Check Dimensions Bearing clearance CMO 1 CMO 2 SMC 65 SMC 1
259. mly in their apertures 0178 933 ENG Rev 2005 12 09 Assemble the discharge valve in reverse order of the one described above Note the following how ever Tighten nut Pos 20E See Torque for screws and bolts in Chapter 21 Tightness testing of discharge valve This is done by means of the pressure drop test as described later in this manual Service life of discharge and suction valves In order to ensure that the compressor always works perfectly it is advisable at suitable inter vals to replace the suction and discharge valve ring plates It is difficult to give altogether precise times for such replacements as the durability of the valve ring plates depends on the following factors If the compressor is exposed to liquid stroke or moist refrigerant gas the service life is re duced Speed of the compressor At 900 rpm the service life of the valve ring plates is considerably longer than at 1500 rpm The compressor ratio at which the compres sor operates At high compression ratios the load on valve ring plates and springs is considerably larger than at low compression ratios When the valve ring plates are changed the valve springs should also be replaced 239 342 Service manual SMC TSMC 100 Mk4 13 Service Instructions Cylinder lining with suction valve Marking of suction valve stop Fig 13 9 Marking of suction valve AAI one groove for R717
260. mportant to monitor the plant closely The condition colour of the oil must therefore be checked on a weekly basis and for each 1 000 to 2 000 operating hours oil sam ples must be taken for further analysis Sabroe Refrigeration recommends therefore only to use M oil under moderate operating conditions see the following oil recommendation diagrams Sabroe Refrigeration is aware that several cus tomers have used mineral oils for many years without any problems The customers who wish to continue using mineral oil in existing as well as new compressors can do so provided that the compressor type and the operating conditions are similar to the existing ones 0178 933 ENG Rev 2005 12 09 06 technical data fm Service manual SMC TSMC 100 Mk4 6 Technical Data Sabroe Refrigeration has thus decided to market one brand of mineral oil which has been tested and found suitable for most of the general refriger ation purposes In case another brand of mineral oil is used follow the specifications on the data pages in this recom mendation as a guideline Mineral oil can be used in refrigeration plants pro vided the lubricating quality is carefully monitored Sabroe Refrigeration recommends however that you use synthetic oils for modern high capacity plants where a long service life for both lubricant and moving parts is expected The advantage of using synthetic lubricating oils is a much lower oil consumption and longer
261. mpressor The separated oil is returned to the compressor as de scribed in chapter 4 Technical Description Oil Separator A minor part of the oil however present in the dis charge gas as vapour cannot be separated and Oil consumption kg h x SABROE will consequently continue into the plant in which it is condensed in the condenser In R744 HFC and HCFC as well as in compact R717 refrigeration plants this oil will return to the compressor together with the suction gas In return the oil in larger and ramified R717 refrig eration plants should be drained off and never re used in the compressor This amount of oil repre sents the so called oil consumption measured in ppm parts per million and is calculated by using the following formula Circulated amount of refrigerant Q kg h x Oil consumption ppm The normal oil consumption is between 20 and 30 ppm for an SMC HPC 100 compressor 0178 933 ENG Rev 2005 12 09 Selecting Oil Separator As the velocity through the oil separator affects the ability of the oil separator to separate the oil from the discharge gas an oil separator size has been designed for each compressor The maximum oil consumption for this oil separa tor is 35 ppm Depending on the choice of lubricat ing oil the oil consumption is normally much low er 161 342 Service manual SMC TSMC 100 Mk4 6 Technical Data Selecting Lubricating Oil for SABROE Reciprocating Com
262. mpressor The performance of the 162 342 lubricant in the plant receiver evaporator etc must however also be considered Lubricating oils with relatively high viscosity must be used to ensure a satisfactory lubrication of re frigeration compressors To achieve the best lubrication the oil must possess the correct viscosity under operating conditions possess acceptable viscosity at start up possess sufficient oxidation stability the oil must be free of moisture when charged to the system possess sufficient chemical stability when used together with R717 Moreover the extent to which different refriger ants dissolve in the oil must be determined so that the oil return system etc can be designed to per form at its optimum Stratification Note that the oil in some plants is layered in refrig erant receivers and evaporators under certain op erating conditions and at certain oil concentra tions Plants with Several Different Compressor Types Makes In plants where several different compressor types makes are connected it is strongly recom mended to use the same type of oil in all the com pressors This is very important where automatic oil return systems are used If you consider changing the type of oil please read the section Oil Changing on SABROE Com pressors carefully 0178 933 ENG Rev 2005 12 09 06 technical data fm Service manual SMC TSMC 100 Mk4 6 Techn
263. n Refrigerants of the types CFC HFC and HCFC are greenhouse gases which contribute to an intensification of the greenhouse effect They must there fore never be released into the atmos phere Use a separate compressor to draw the refrigerant into the plant condenser re ceiver or into separate refrigerant cylinders Ammonia Ammonia is easily absorbed by water At 15 C 1 litre of water can absorb approx 0 5 kg liquid ammonia or approx 700 litres ammonia vapour Even small amounts of ammonia in water 2 5 mg per litre are enough to wreak havoc with marine life if allowed to pollute water ways and lakes As ammonia is alkaline it will damage plant life if released into the atmosphere in large quantities Hydro carbons HC HC gasses are a group of 1 refrigerants characterized as very flammable 0178 933 ENG Rev 2005 12 09 x SABROE Hydro carbons are odourless and non toxic gasses Specific mixtures of air and gas cre ate danger of explosion As the gasses are heavier than air they will be concentrated at the lowest possible level in case of leaks Carbon dioxide CO Carbon dioxide CO is a greenhouse gas with a GWP Global Warming Potential fac tor of 1 It is found in the atmosphere in a concentration of 0 036 vol 360 parts per million ppm As CO is extracted from at mospheric air it can safely be released into the atmosphere and does not contribute to enhancing the greenhouse
264. n the coupling 180 and by using feeler gauges measure deviations from one milli metre at both pins Move and turn the motor and repeat this measurement align the motor in accord ance with pos 1 horizontal and pos 2 in the table Remember that the motor must be firmly secured during any measurements Final installation Tighten the foundation bolts on the motor see torque table Fit four bolts into the motor coupling flange so that thin shims are placed between the flange and the lamellae with the rounded side facing lamella Tighten the bolts to torque specified in the table Readjust the flange distance C so that the lamellae are aligned by moving the motor flange on the shaft and fastening the motor flange Check the alignment of the coupling in hori zontal and vertical planes for pos 1 and pos 2 Dismantle the measuring pin and tighten the screw to the prescribed torque Fit the coupling guard Once normal operating temperature has been achieved double check the coupling alignment 0178 933 ENG Rev 2005 12 09 13 service instructions fm Service manual SMC TSMC 100 Mk4 13 Service Instructions Refrigeration plant maintenance Operational reliability The prime causes of operating malfunctions to the plant are 1 Incorrect control of liquid supply to the evap orator Moisture in the plant Air in the plant Antifreeze liquid is missing Congestion due to metal shavings and
265. nded however to keep the solenoid valve closed for 20 to 30 min utes after start up by means of a time relay which may be ordered as an accessory part Thus the oil is not returned to the compressor before the oil separator is warm and has evaporated any refrig erant which may have mixed with the oil at the bot tom of the oil separator This time function is built into the UNISAB II sys tem The solenoid valve seat is available with various boring diameters and nozzle sizes For this pur pose 03 3 mm must be used The coil for the solenoid valve can be delivered as a standard part with the following data Table 4 2 Coil Sizes 220 230 Volt 50 60 Hz 10 Watt 115 Volt 50 60 Hz 10 Watt 240 Volt 50 Hz 10 Watt UN Caution The stop valve is a membrane valve The mem brane can be damaged if the valve is closed too tight 53 342 Service manual SMC TSMC 100 Mk4 4 Technical Description Thermodynamic Liquid Trap TLT The purpose of the TLT valve is to ensure that only oil is led back to the compressor as warm dis charge gas mixed with the oil will cause the com pressor capacity to decrease Fig 4 28 Thermodynamic Liquid Trap TLT 1 Housing 4 Strainer 2 5 Strainer Cap 3 Disc 6 Gasket The TLT valve works in the following way A thermodynamic liquid trap uses a disc to control the release of liquid and to trap gas The trap cy cles open and close to discharge liquid an
266. ng Check function of capacity regulator 12 Too low suction pressure Abnormally low pressure in the refrigeration plant will increase the compression ratio of the compressor with a subsequent risk of damage to the compressor The danger of air being sucked into the refrigeration plant also increases at abnormally low pressure 12 20 Oil in evaporator Draw off oil 12 22 Refrigerant charge on plant insuffi Check refrigerant charge cient Charge plant with refrigerant Bubbles in liquid line sight glass and possibly a warm liquid line ping and Seal ay leak 12 35 Freezing up of expansion valve Thaw out expansion valve with hot wet cloths HECIMCES plant Replace dessicant in drying filter 12 36 Thermostatic expansion valve has Valve fails to open change valve lost charge 12 40 Excessive superheating of suction Regulate expansion valves to higher capaci gas ty 222 342 0178 933 ENG Rev 2005 12 09 12 fault finding instructions fm Service manual SMC TSMC 100 Mk4 12 Fault finding Instructions 12 41 Filter in liquid line clogged Check and clean filter in liquid line 12 42 Solenoid valve in liquid line fails to Coil may have blown Control signal lacking open 12 59 Compressor has excessive capacity Reduce compressor capacity Check capacity regulating system 13 Oil temperature too low
267. ng station The receiving station must com ply with the prevailing rules and regulations of the individual country 0178 933 ENG Rev 2005 12 09 21 appendices fm Service manual SMC TSMC 100 Mk4 21 Appendices 21 Appendices The purpose of this chapter is References to Instructions to collect all relevant data and tables regard The instructions from the sub suppliers must as ing torques coupling data etc far as possible be copied from the original instruc tions firstly to avoid any errors and secondly to to collect all relevant instructions of products avoid losing the right to claim damages supplied by sub suppliers and used in the Sabroe product in question Appendix This chapter includes data sheets and instructions concerning the components and the tables of torques 1 List of torques 2 Coupling data 3 Sundry Clearences and Check Dimensions 4 Instructions from sub suppliers valves sensors automatic etc 0178 933 ENG 327 342 Rev 2005 12 09 Service manual SMC TSMC 100 Mk4 21 Appendices Torque Moments for Screws and Bolts Bolts for top side and end covers T CMO HPO T SMC 100 HPC T SMC 180 Compressor Bc bai End covers NE Laang End covers Top side and end covers M M12 M14 M12 M14 M14 M14 M20 Kpm 8 6 13 7 13 2 20 3 13 7 20 3 42 7 ft Ibf 63 100 95 147 100 147 310 Nm 85 135 130 200 135 200 420 Connecting rods
268. nical Description Fig 4 14 Oil pump cover assembly Shut off valves pos 4K and pos 4D are used for dismantling the oil filter The shut off valves must be completely open during operation to avoid pressure drops in the oil system For additional information about function see oil diagram Fig 4 16 UN Caution Operating the compressor while pos 4K and or 4D are closed may damage the compressor no lubricating oil supply to the compressor The air purge valve pos 4E is used to reduce the pressure in the oil filter before dismantling The valve pos 4E further acts as a prelubrica tion valve Prelubrication of the compressor must always be carried out before the initial start up and after a long period of standstill See Maintenance Instruc tions This way the bearings and the oil system are lubri cated and the oil pump is filled with oil The hose 42 342 from the prelubrication pump must be connected to the branch pos 4F on the pump housing A Danger The oil filter pos 9A is filled with oil which may be hot and is under pressure It must not be loos ened without the pressure being removed by means of the valves pos 4K 4D and 4E See Maintenance Instructions A Danger Operating valve pos 4E without closing pos 4K and 4D will cause oil and refrigerant leaks See Maintenance Instructions The non return valve pos 4L acts as a bypass valve when the differential pressure above the oil pump i
269. nnen tc eee eg elaine NANANA NAG 42 0178 933 ENG Rev 2005 12 09 0178 933 ENGIX fm Service manual SMC TSMC 100 Mk4 P SABROE Prel brication pc 42 Preparations before Service 228 Pressure and Temperature Setting 196 Press re drop eSt ete eee ee ee 229 Pressure gauges mete 261 Ba ag AA ee 157 Pressure LVS cR 157 PM SS LOSS a NAAN 93 PUMP QOWN 233 PUMPING GOWN 267 Purging a refrigeration plant 2 40 222 28 FR 28 29 Discharge valve rr 239 Regulation of Intermediate Pressure 84 Removing refrigerant from 230 S Safety at DENG 16 Safety Instructions High voltage AA AA AA 22 Installation and 21 Lifting and Carrying 20 Maintenance Safety 22 Personal mao Sepe Ines esr AUR E 19 Set Up and Operation Tm 21 I II 20 Work Area Safety 2a 19 ad Ce NAA AA 19 Servic
270. no of the main part is stated first and then the pos nos of all single parts contained in the main part Then all kits related to the main part including the pos nos of all sub parts contained in these kits are indicated 0178 933 ENG Rev 2005 12 09 x SABROE Parts which are not sold individually are contained in spare parts kits The spare parts list contains single parts and com ponents complete main parts e g cylinder liner with suction valve kit assemblies which is a col lection of spare parts service kits and gasket kits Spare parts which are not available as single parts will be contained in complete main parts as sub parts kit assemblies service kits and gasket kits Pos 19 1 part number 3112 085 designation Cylinder liner with suction valve S amp L Part number 3184 350 designation Kit assembly oil pump housing Part number 3188 027 designation Service kit ring plates Part number 3188 009 designation Gasket kit unloading cylinder In some cases a kit will be related to several main parts which is why the kit is not indicated until after the relevant main parts Example A ring plate kit contains a discharge valve ring plate pos 20C a suction valve ring plate pos 19F and valve springs Therefore the ring plate kit will be indicated after the discharge valve ring plate pos 20 271 342 Service manual SMC TSMC 100 Mk4 18 Part list Parts list 0662 022 Relevant drawing
271. no damage is done to the carbon slide ring Pos 10F which comes out with it 4 The carbon slide ring Pos 10F can be extracted by dismounting circlip pos 8G as follows 245 342 Service manual SMC TSMC 100 Mk4 13 Service Instructions Mount tool no 2 as illustrated in Fig 13 14 and tighten screw A so that the carbon slide ring does not touch the locking ring Take care not to tighten screw A too much as this could damage the carbon ring Circlip pos 8G is now easily extracted by means of a screw driver without dam aging the slide surface of the carbon slide ring After removing tool no 2 the carbon slide ring pos 10F O ring pos 10G and springs pos 10B Fig 13 14 can now be dismantled Fig 13 14 246 342 8G 10F 10G 8A 8C Tool no 2 9 Dismantle slide ring 10E by turning the four Allen screws 10J max 2 3 turns the entire unit can then be taken out with the fingers or by using two screwdrivers in serted into the external groove on the slide ring Pos 10E and moved in the di rection of the arrow as illustrated in Fig 13 15 Fig 13 15 10 O ring Pos 10D can now be removed 0178 933 ENG Rev 2005 12 09 13 service instructions fm Service manual SMC TSMC 100 Mk4 13 Service Instructions Assembling and mounting shaft seal After thoroughly cleaning the crankshaft check that its sealing faces are smooth and free of scratches blows and wear marks Then o
272. nts the manometers are graded for that particular refrigerant The standard units on the scale is bar C but others can be delivered on request 79 342 Service manual SMC TSMC 100 Mk4 4 Technical Description B UNISAB II Reading Safety and Capacity Regulating System UNISAB II is a computerized control and monitoring system which is specially devel oped to fit all Sabroe Refrigeration s SABROE reciprocating and screw compres sors i e the same UNISAB unit is used for both compressor types It is only necessary to select type of compressor refrigerant and a few other functions and the UNISAB will be ready for operation UNISAB II is based on Sabroe Refrigeration s extensive experi ence with design and operation of compu terized compressor control systems Fig 4 53 Computerized Control and Monitoring UNISAD UNISAB 1 is designed for safe control mon itoring and optimization of compressor oper ation and a minimum of unintended opera 80 342 tion stops In addition to efficient control and monitoring of single compressors UNISAB II also designed for advanced control and monitoring of any combination of up to 14 compressors It is thus possible to centrally control and monitor up to 14 compressors by using a COMSAB or PC COMSAB module Multi lingual System UNISAB II is available in 15 different lan guages and it is possible to switch to the English version at any time Easy to Operate UNI
273. ocation Safety 21 en 77 45 336 342 0178 933 ENG Rev 2005 12 09 0178 933 ENGIX fm Service manual SMC TSMC 100 Mk4 P 0178 933 ENG Rev 2005 12 09 SABROE Intermediate Cooler Type Ja ana 82 Intermediate Cooling Liguid MNjection eec c 83 83 TEA TEX AA AA 83 Intermediate Gas i AA 49 82 Intermediate pressure AA AA LEE 48 Intermediate Pressure Cut out 78 ire 78 KPS 78 78 Lifting and Carrying Safety AER T 20 Lifting the compressor Block saaan maa shan 137 Lifting the compressor WIL AG 137 GW AA SS 83 Long eels 34 Lubricating System AASA 251 Machine Room mnes 113 249 Milintz iare 233 Maintenance Instructions 201 Maintenance Safety ee ee C 22 Manometers Description ManoOITIelel S cds nr ener a AA 79 Max Power Transmission aaa ANAN 144 Moment of Inertia 1 00 0000 00000000100000
274. of rotation is marked on the cover If the compressor direction of rotation is changed from counterclockwise standard to clockwise the oil pump must be replaced by a pump with op possite direction of rotation In that case the arrow on the compressor end cover by shaft seal pos 6A should be erased and replaced by a painted arrow indicating the new compressor direction of rotation Dismantling of oil pump When the compressor has been drained from re frigerant and secured against unintentional start up the following should be carried out 252 342 Dismantle eight M8 bolts pos 11C 1 be able to pull the oil pump out of the housing the remaining two M8 bolts pos 11X 1 must be dismantled Two bolts from pos 11C 1 are screwed in and used to pull out the oil pump After dismounting the oil pump the original two bolts pos 11X 1 should be mounted in the oil pump Note Normally the oil pump has a very long service life and therefore instead of repairing it in case of breakdown it is recommended to replace it by a new one 0178 933 ENG Rev 2005 12 09 13 service instructions fm Service manual SMC TSMC 100 Mk4 13 Service Instructions Oil pressure valve The oil pressure valve pos 22 regulates the oil pressure in the compressor Mounted in the cover Pos 6A it connects directly with the oil pressure chamber in the shaft seal housing The oil pressure is regulated by a spring
275. of your local Sabroe Representative 2 342 0178 933 ENG Rev 2005 12 09 0178 933 ENGTOC fm Service manual SMC TSMC 100 Mk4 P SABROE Table of Contents Manual for SMC and TSMC Mk4 S L E 1 AA AA 2 Signs and Wills eesis estantan Oed sad edd ad idus dad 9 Identification of Sabroe Refrigeration Equipment 10 Unit pipe system name plate 11 Compressor name plate 12 Vessel name plate 13 Signs IMINSIUCIIONS TT 14 The sign CAUTION 2 5555 5555 ERRERR EEXEEEEETFESRESEWETRERRERKERREWERES 14 The sign HIGH VOLTAGE eager we ERR KAN 14 The sign The temperature of tangible surfaces 15 The sign Internal protection 15 Other warning signs 15 Emergency St p ies tase Aui EE RA ems ck Seca a a eee 16 Safety during Service 16 Warnings in Instructions 17 Texts Marked with 17 Texts Marked with Warning
276. ompressors running on HFC HCFC An ammonia compressor can stand having the pressure reduced somewhat more quickly without the oil foaming Once the pressure is down to approx 0 1 bar stop the compressor and perform the following steps in the order specified Close suction stop valve Cut off power to compressor motor Close discharge stop valve Draw off last remains of refrigerant gas through purge valve Pos 42 Having ensured that power to compressor motor cannot be inadvertently connected the compressor may be pressure equalized with atmospheric air and opened Remove all fuses if 2 If the compressor is inoperative Leave heating rod in crankcase connected for a couple of hours before the compressor is due to be opened in order to heat up oil Warm oil does not contain as much refriger ant Suction stop valve must be open while heat ing rod is connected Keep discharge stop valve closed Close suction stop valve and disconnect heating rod Equalize pressure in compressor through purge valve Pos 42 Having ensured that power to compressor motor cannot be inadvertently connected the compressor may be pressure equalized with atmospheric air and opened Remove all fuses if 233 342 Service manual SMC TSMC 100 Mk4 13 Service Instructions Dismantling and assembly The following sections describe the individual components When dismantling and
277. onnel or of major importance to the safety of equipment is presented UN Warning Risk of damage to compressor Always consult your supplier before using a compressor under operating conditions outside the specified working range Texts Marked with Caution The example below shows how information of im portance to the safety of equipment is presented UN Caution Risk of incorrect viscosity Always make sure that all oils used are mixable without causing chemical reactions Chemical reactions might have serious effects on the viscosity Failure to observe information marked with Cau tion may cause damage to equipment 17 342 Service manual SMC TSMC 100 Mk4 2 Signs and Warnings 18 342 0178 933 ENG Rev 2005 12 09 03 safety precautions fm Service manual SMC TSMC 100 Mk4 3 Safety Precautions 3 Safety Precautions The purpose of this chapter is to provide general safety precautions for this equipment Additional safety precautions relating to a specific task are given in the corresponding documents The safety precautions are intended for all user categories UN Danger Risk of injury to personnel and damage to equip ment Always read the safety precautions belong ing to this equipment before start Failure to com ply with safety precautions may cause death or in jury to personnel It may also cause damage to or destruction of the equipment AN Warning Read related safety precautions
278. ore the rinsing Skin In case of frost bite immediately rinse with luke warm water max 37 C and remove all clothes impeding blood circulation Consult a doctor Avoid direct contact with contaminated oil refriger ant mixtures from electrically burnt out hermetic compressors 25 342 Service manual SMC TSMC 100 Mk4 3 Safety Precautions Protecting the operator as well as the environment AN Warning No plant can ever be said to be too safe safety is a way of life Increasing industrialisation threatens our environ ment It is therefore absolutely imperative to pro tect nature against pollution To this end many countries have passed legisla tion in an effort to reduce pollution and preserve the environment This legislation applies to all fields of industry including refrigeration and must be complied with Pay extra attention to the following substances e refrigerants e cooling media brine etc e lubricating oils Refrigerants usually have a natural boiling point considerably below 0 C This means that liquid re frigerants can be extremely harmful if they come into contact with skin or eyes High concentrations of refrigerant vapours can be suffocating when they displace air If high concentrations of refrigerant vapours are inhaled they will attack the human nervous sys tem When halogenated gasses come into contact with open flame or hot surfaces over approx 300 C the
279. osed in the form set in which the addresses of the laboratory in Holland are also mentioned Analysing the Oil The following table states some average values that can be applied in practice However be on the alert whenever the results of the analy ses approach these values In some cases the water content of 100 ppm in HCFC plants may be too much and thus lead to Cu plating in the shaft seal 0178 933 ENG Rev 2005 12 09 11 maintenance instructions fm Service manual SMC TSMC 100 Mk4 11 Maintenance Instructions Limiting Values SABROE Sabroe Oil PAO 68 Sabroe Oil AP 68 Sabroe Oil A 100 Parameter Unit Method A Max Min Ha Max Min Viscosity 40 cSt ASTM D 445 66 76 53 64 74 51 100 115 80 TAN 1 mg KOH g ASTM D 664 0 03 0 2 0 01 0 02 0 05 0 02 SAN 2 mg KOH g ASTM D 665 0 0 0 Water ppm Karl Fisher 100 100 100 Apperance report report report Colour ASTM D 1500 report report report Pentane Insolubles Wi 0 05 0 05 0 05 Oxidation abs cm 1700 1720 5 5 5 Nitration abs cm R 1627 1637 cm 5 5 5 Nitro Compounds abs cm R 1547 1557 cm 0 5 0 5 0 5 Maximum values for metal content in the oil Lead ppm CP 10 10 10 Copper ppm CP 10 10 10 Silicium ppm 25 25 25 Iron ppm CP 100 100 100 Chromium ppm CP 5 5 5 Aluminium ppm ICP 10 10 10 Tin ppm CP 10 10 10 1 TAN Total Acid Number is only r
280. over To keep the o ring in place a small amrount of grease may be applied in the groove for the o ring Gently place the water cover in position using the four staybolts as guides The covers should be po sitioned with the water inlet and outlet at the shaft end This means that the SABROE logo is cor rectly oriented Before tightening the nuts check that the o ring is still in its place in the groove The gab between the water and top cover should not exceed 0 5 mm before tightening Then tighten the four nuts Refit the water hoses open the wa ter supply and check that there are no leaks Top covers Dismantling top cover Before dismantling the top cover the relief mech anism must be deactivated this is done by dis mantling the short plug Pos 12D and mounting the long plug from the tool kit instead This moves the piston Pos 12B to the opposite end of the relief cylinder Also the water covers should be removed according to the above instruction if equipped so Remember to depressurise the compressor if not already done Loosen and re move screws B except for the four nuts on the staybolts C see figure Fig 13 4 0178 933 ENG Rev 2005 12 09 13 service instructions fm Service manual SMC TSMC 100 Mk4 13 Service Instructions These nuts should be loosened approx 1 and then it must be checked that the cover lifts off the gasket If on the contrary it remains fastened to the gasket
281. over an extra oiling on slide face of carbon slide ring and guide it in over shaft together with gasket Pos 8B By gently pressing shaft seal cover and carbon ring in against slide ring Pos 10E without compressing springs Pos 10B measure distance from gasket Pos 8B to sealing face of shaft seal cover This distance must be about 3 mm Make sure the hose branch Pos 8D fac es down Mount screws Pos 8C and tighten even ly crosswise This will avoid damaging the carbon slide ring Tighten screws Pos 8C to prescribed torque according to table in instruction manual Mount oil throw ring as shown in drawing After mounting coupling half or V belt disk it must be possible to turn the crankshaft easily by hand 247 342 Service manual SMC TSMC 100 Mk4 13 Service Instructions Crankshaft The crankshaft is made of heat treated SG cast iron with fine strength and glide properties The bearing journals are superfinished and oil chan nels are bored for all lubricating points At the centre and end of the crankshaft the oil channels are blanked off with 3 blind plugs on the SMC 104 106 108 and 6 plugs on the SMC 112 and 116 When fitting the crankshaft it should be checked that the plugs are mounted and tightened By way of bores in the counterweights the crankshaft is dynamically balanced with regard to 1st and 2nd order forces The crankshaft is available in three versions 5 type for compressors wi
282. ped slide surfaces Even the slightest scratch or other damage to the slide surfaces will result in leaks The O ring Pos 10D creates a seal between the slide ring Pos 10E and the crankshaft O ring Pos 10G seals between the carbon slide ring Pos 10F and the shaft seal cover Pos 8A When the shaft seal is operating a tiny amount of oil drifts out between the slide faces to lubricate them An oil throw ring Pos 8F has therefore been 0178 933 ENG Rev 2005 12 09 x SABROE fitted to prevent this oil migrating along the axle to the transmission linkage The thrower ejects the oil into the groove in the shaft seal cover Pos 8A and the oil is piped via the plastic hose to a plastic bottle positioned un der the compressor 1 Dismantling and stripping down shaft seal 1 Once the gas pressure in the compres sor has been eliminated and the motor safeguarded against inadvertent start up dismantle coupling or V belt disk Note On units featuring coupling there is no need to move the motor as the coupling and the shaft seal can be taken out between the two shaft ends 2 Dismantle shaft seal cover Pos 8A by loosening bolts Pos 8C alternately so as to displace shaft seal cover outwards without jiggling This will avoid damage to internal parts of the shaft seal 3 Once the spring force is equalized and the bolts removed the shaft seal cover can be taken off the shaft end by hand Take care that
283. perature A Very suitable in case of a new plant 4 concentration liquid phase at TE 2 W Min suction temperature 50 C At TE lt 50 C superheating must be introduced 182 342 0178 933 ENG Rev 2005 12 09 06 technical data fm Service manual SMC TSMC 100 Mk4 6 Technical Data R22 two stage reciprocating compressors Code no A3 Area no 1 A Condensing temperature 68 50 32 A Very suitable in case of a new plant 4 oil concentration liquid phase at TE 2 W Min suction temperature 50 C At TE lt 50 C superheating must be introduced 0178 933 Rev 2005 12 09 ENG 50 40 30 20 10 0 58 40 22 4 14 32 9 Evaporating temperature 10 50 SABROE 20 68 F 183 342 Service manual SMC TSMC 100 Mk4 6 Technical Data 14 R134a F single stage ang reciprocating compressors 140 122 o 3 104 S 86 9 68 2 z 50 5 9 32 4 22 Code 1 5 9 A Very suitable in case of a new plant N Zone in which both oils are applicable 184 342 60 50 40 30 20 10 0 10 20 30
284. plant to the compressor with the suction gas and thus prevent them from pene trating into the compressor The suction filters therefore have a very fine mesh and as an additional precaution they have a filter bag insert which should normally be used for 50 operating hours from the initial start up of the compressor The filter bag is then removed and disposed of If the filter bag is badly soiled after the 50 operat ing hours mentioned it is recommended that a new bag be fitted for an additional 50 operating hours Similarly a filter bag ought to be fitted fora Fig 13 24 TSMC 108 On TSMC compressors the suction filter located on the lefthand side opposite the low pressure inders see drawing is the same type as on SMC compressors i e open at both ends and with an O ring in the end facing up towards the suction stop valve 0178 933 ENG Rev 2005 12 09 x SABROE period of 50 operating hours after any major repair work to the refrigeration plant Note Do not forget to remove the filter cartridge after 50 operating hours as a blocked filter bag may cause the suction filter to burst and thus con taminate the compressor to an extreme degree There are always two suction filters in the com pressor and these are removed through the flang ed opening in the bottom end of the filter housing Attention is drawn to the fact that there are two types of suction fi
285. pment Drawing no 0662 060 ite Analogous controle and safety equipment 0178 933 ENG Rev 2005 12 09 Analogous controle and safety equipment Name plate SABROE 323 342 Service manual SMC TSMC 100 Mk4 19 Drawings 324 342 0178 933 ENG Rev 2005 12 09 20 final disposal fm Service manual SMC TSMC 100 Mk4 20 Final Disposal 20 Final Disposal The purpose of this chapter is to describe how to safely dispose of this equipment or part of it This chapter is primarily intended for the de com missioning engineers and authorities General Safety Precautions AN Danger Before dismantling the plant read chapter 3 Safety Precautions carefully Failure to do so may result in personal injury or even death Dismantling of a cooling unit which is to be scrapped must be carried out in a safe way Authorized refrigeration personnel must partici pate in the first part of the dismantling process as fundamental knowledge of refrigerating systems and the risks involved is required Before dismantling the plant refrigerant and oil must be drained into containers intended for the purpose Disconnect all electrical connections to the unit Remove fuses in the main switchboard During the dismantling process the individual ma chine parts and components must be sorted so that disposal can take place in an efficient way 0178 933 ENG Rev 2005 12 09 AN Danger Take great care if
286. possi ble for them to be so upright that there is a risk of their jamming which will make them unable to be lowered again when the cylin der is put into service Perform the adjust ment as follows Position cylinder lining incl the correct gas ket pos 19K in the compressor block and press down against rocker arms by hand The rocker arms are in their upright position as the normal plug pos 12D as well as gas 259 342 Service manual SMC TSMC 100 Mk4 13 Service Instructions ket pos 12E have been mounted in the un loading cylinder Fig 13 28 N IN as shown in Fig 13 25 and repeat meas urement 7 following table The difference in the two measurements of 7 must be within the limits stipulated in the Lifting reserve Z Min mm Max mm HPC SMC 100 0 6 1 0 Mk1 Mk2 Mk3 Mk4 SMC 180 Mk 1 Mk 2 0 8 1 5 Measure distance 7 shown in Fig 13 28 Write down the Z measure Replace normal plug pos 12D with the long plug no 4 from the tools kit lowering rocker arms in the process Press cylinder lining down against gasket pos 19K using the two locking devices no 1 260 342 Note If the difference between the two measure ments is not within the parameters stated it must be regulated by inserting or removing shims pos 15E under the rocker arm bear ings It is important that the long
287. pressor For this purpose use two washers which are part of the base frame and mounted at the feet of the motor For measuring the correct belt tension use Ten sion Gauge Il part no 1622 003 Spare Parts When delivering belt pulleys as spare parts the compressor pulley is always ready bored and balanced It can thus be fitted directly on the com pressor The motor pulley is delivered balanced and with a conical bushing which is ready bored for direct fitting on the motor shaft in question Service A correctly aligned V belt drive will have a long service life After the first adjustment the belt drive must be checked regularly Checking and adjusting the V belt drive is best carried out by means of the special tool Tension Gauge men tioned above which is available from Sabroe Refrigeration After Market Service De partment When replacing the V belts the grooves in the V belt pulleys should be checked for wear and tear by means of a Belt and pulley groove gauge part no 1622 001 which can also be ob tained from our After Market Service Department 147 342 Service manual SMC TSMC 100 Mk4 6 Technical Data Noise from Compressors and Units Noise is inevitable when a compressor or unit is working However by taking this into considera tion during the project phase it is possible to re duce noise pollution of the environment consider ably Through the years Sabroe Refrigeration has been aware of t
288. pressors Refrigerant R717 In a period from 1990 to 1995 Sabroe Refrigeration experienced a rising number of problems with the use of mineral oils especially in R717 plants The problems can be divided into two groups The oil changes viscosity within a few operat ing hours d The oil dissolves becomes very black The problems have been observed in connection with several different types of mineral oil and often occur within only a few operating hours The con sequences have been severe for both compres sors and plants On the basis of the thorough investigation subse quently carried out by Sabroe Refrigeration it was decided to introduce a series of synthetic oils complying with the requirements of modern refrig eration plants Mineral oils can however still be used in refriger ation plants provided the lubricating quality is carefully monitored For modern high capacity re frigeration plants where a long service life for both lubricant and moving parts is expected Sabroe Refrigeration recommends the use of syn thetic oils Areas of application and specifications for the syn thetic oils mentioned are described in the follow ing pages Supervisors and or users of plants are at liberty to choose between Sabroe Refrigeration s own oil brands and alter native oil brands provided they comply with the specifications required General This recommendation will only deal with the lubri cation of the co
289. procating compressors the following three 10 Low Pressure and Oil Pressure types of manometers are available Manometer Fig 4 52 Low pressure and oil pressure manometer indicating the compressor suction pressure and oil pressure in the lubricating system of the compressor Used in the SMC and TSMC compressors This manometer has two manometer works which are interconnected so that one of the works indicate the suction pressure with an arrow whereas the oil pressure is indicated by means of a dial in the middle of the ma nometer and turned round by the other works The figure on the dial right below the arrow indicates the oil pressure This makes it possible to read the oil pres sure directly from the manometer 8 High Pressure Manometer High pressure manometer indicating the The manometers can be used with several 04 technical description fm discharge pressure of the compressor and used in SMC compressors Fig 4 52 High and Intermediate Pressure Manom eter High and intermediate pressure manometer indicating the discharge pressure for the HP and LP stages on TSMC compressors Fig 4 52 This manometer has two manometer works and two arrows a red one for high pressure and a black one for intermediate pressure 0178 933 ENG Rev 2005 12 09 refrigerants HFC HCFC manometers for R22 R134a R404A R717 manometers R410A R744 manometers On delivery of compressors using other re frigera
290. r temp iesu tete K ET eee SE 92 Cooling ead T TT NN 86 Cooling with Thermo Pump ice re recreo De kx es 94 Coupling 140 GA AA AA 138 Crankshaft pee gc ANAKAN aa 248 ERR 248 NA rS 249 aanib MEC 249 EE 40 Cylinder lining a 258 Checking clearance Gogia a 258 Lifting gt LES 259 MOnitoring 258 With suction valv 240 Danger Texts Marked with Danger 17 Description Pe 83 Additional unloading 69 Analogue Reading ama AA AGA 77 By pass handa 49 Capacity Regulation cep oeste a e Lee EEE 63 Solenoid Valves 65 Capacity Stages Et 68 Conversion of TSMC Mk2 to 50 Cooling of the Intermediate Gas 49 Cooling system er nor M utet t no ee 86 NANANA NANANG E LANA AA 86 Determining the Intermediate Pressure 84 Discharge P
291. regulations can lead to personal injury or even death Moreover the equipment can be damaged or destroyed 227 342 Service manual SMC TSMC 100 Mk4 13 Service Instructions General Preparations before Service Ventilation Before servicing the unit always check that the ventilation system used in the area where the re ciprocating compressor unit is located machine room is functional and operating at full capacity The safety instructions explain the risks associat ed with the refrigerant and oil being used Pay close attention to the fact that large amounts of escaped or released refrigerant entail risk of suf focation The safety instructions also explain the risks gen erally associated with refrigerants Body contact with leaking liquid refrigerant entails high risk of in juries caused by intense cold Pressure A reciprocating compressor unit comprises a pressurized system Never loosen threaded joints such as a union nut while the system is under pressure and never open pressurized system parts Hot and Cold Surfaces A reciprocating compressor unit contains both hot and cold system parts Always wear and use the recommended safety items Never use your hands or other body parts to search for leaks 228 342 Qualification Requirements Before carrying out the measures set forth in this manual all personnel must have studied the in structions issued for the reciprocating compressor unit carefully
292. ressure cut out differential is Increase differential pressure see also special too small between stopping and instructions starting 2 13 Compressor capacity too high Check operating conditions and if need be re duce capacity 0178 933 ENG Rev 2005 12 09 SABROE 217 342 Service manual SMC TSMC 100 Mk4 12 Fault finding Instructions 2 41 Filter in suction line clogged Check suction filters on compressor 2 43 Solenoid valve in liquid line does not Check direction of flow close Replace defective valve 2 52 discharge valves compressor are Atcompressor stop pressure equalizes relatively leaky quickly between suction and discharge side Clean or change discharge valves 3 Compressor starts but stops again immediately 3 5 Motor protection cuts Look for cause of overloading If star delta start set starting time to minimum tion of foam in oil 3 10 Low pressure cut out has cut Open any suction stop valve which is closed 3 12 Defective oil pressure cut out Replace cut out see special instructions 3 15 Oil charge insufficient Top up with oil and investigate cause of oil short age 3 18 Oil pressure failing owing to forma Reduce capacity See 17 and 18 4 Compressor operates continuously 4 10 Thermostat or low pressure cut out Adjust operating points does not cut at too low temp
293. ribed later in this section under Charging Compressor with Lubricating Oil Only use the recommended oil When the oil level is too low check the plant for leaks If it is not possible to find the error call for service assistance 0178 933 ENG Rev 2005 12 09 11 maintenance instructions fm Service manual SMC TSMC 100 Mk4 11 Maintenance Instructions General Rules for Use of Lubricating Oil in Refrigeration Compressors Only fresh clean refrigeration machine oil may be charged Oil tapped from the evaporator system in an ammonia plant must not be reused in the compressor Use grade of oil originally prescribed for compressor As far as possible avoid mixing different types of oil Mixed oil is generally inferior to the two original oils Mixing various types of oil may give rise to formation of sludge which will lodge in valves and filters If it is necessary to switch to another brand of oil please contact the supplier of the new oil for instructions Note that some of the old oil may be left in the piping system 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 be used for a single or at most two top ups The oil con 0178 933 ENG Rev 2005 12 09 tainers must be kept carefully sealed If all the oil in a container
294. rigerant into the intermediate pipe This can be achieved with the following two systems 1 Intermediate Cooling with Thermostatic Expansion Valve Type TEA R717 or TEX R22 Fig 4 56 TSMC Oil separator Opt P4 Solenoid valve Filter In the system in Fig 4 56 the liquid refrigerant conveyed to the intermediate pipe is regulated by a thermostatic expansion valve type TEA R717 or TEX R22 with a sensor placed on the intermediate pipe close to the HP stage 0178 933 ENG Rev 2005 12 09 Connection pos B pipe dimension OD 10 mm emerges from receiver or priority vessel as de scribed in Cooling with thermopump R717 later in this section The intermediate discharge pipe is built onto the compressor on delivery as a block or a unit On delivery of a compressor block the liquid system including the expansion valve must be mounted on site 2 intermediate Cooling with Thermostatic Injection Valve Type TEAT HCFC The intermediate cooling system is designed as il lustrated in Fig 4 57 Here the intermediate cool ing is carried out by a thermostatic injection valve of the TEAT type and the subcooling takes place in a HESI heat exchanger Fig 4 57 From receiver z To evaporator HESI The sensor of the TEAT valve is placed in a sen sor pocket at the HP discharge branch of the com pressor and a proper thermal contact is obtained by means of the heat cond
295. rities which may have accumu lated in the valve or the piping from mixing with the oil sample Analytical Evaluation Naturally the oil sample can be analysed by the oil company which supplies the oil As a special offer to our customers Sabroe Refrigeration has developed an analytical concept in cooperation with Mobil Oil which is able to analyse all oil makes This will mean a uni form reporting of the results The analysis allows the following to be deter mined Whether the oil is still usable if nec essary after filtering Whether solid particles possibly present the oil originate from the bearings or other components exposed to wear and tear in 208 342 which case the compressor must be in spected Each report will include the corresponding measuring results from the previous 3 oil analyses In this way it is possible to follow up on the state of both the oil and the com pressor from one analysis to the next Procedure A form set with a plastic sampling bottle and a dispatching envelope can be requested from the local Sabroe Refrigeration repre sentative The oil sample must be drained from the cleaned oil drain valve into the sample bot tle Screw the lid loosely on and let the bottle stand for a few hours to enable refrigerant contained in the oil sample to evaporate be fore sending it to the laboratory Please follow the Sampling and Shipping In structions encl
296. rm water Remove tape from centre hole Refit gauge Fig 13 30 Compensator 41 20 C 10 C Balancing screw Blowout 60 0178 933 ENG Rev 2005 12 09 13 service instructions fm Service manual SMC TSMC 100 Mk4 13 Service Instructions x SABROE Fitting and alignment of coupling type AMR 4 Installation and alignment In principle alignment involves manoeuvring the motor to make the shaft form an extension of the crankshaft Fig 13 31 Important Before performing any work on the coupling make sure that the compressor motor cannot start inadvertently a Table 13 1 Distance mm Torque Nm Coupling Compressor Sio C F A B D Nominal SMC 104 106 108 3125 105 25 147 55 43 SMC 112 116 350 5 116 27 147 128 43 See final installation 0178 933 ENG 263 342 Rev 2005 12 09 Service manual SMC TSMC 100 Mk4 13 Service Instructions Preliminary installation Note Never tighten the cone screws D unless there is a shaft inside the bore Otherwise it might damage the cone system Degrease the compressor shaft and hub bore surfaces Any lubricant here will re duce the transferred torque Place the hub at the compressor side ob serving the measurement F Tighten the screw
297. roe Oils We recommend that you use these oils which can be delivered in 20 litre pails or 208 litre drums When ordering use the part no stated in List of Part Numbers for Availa ble Sabroe Oils It is of course possible to use similar oils from oth er oil companies If this is the case use the table Data for Sabroe Oils Please note that Sabroe Refrigeration has not tested other oils than our own brand Thus we cannot guarantee the quality stability or suitability of other oils The respective oil companies are thus responsible for the quality and suitability of the oil delivered and if there are any problems with these oils in the compressor or the refrigera tion plant contact the oil supplier directly When selecting oils from other oil companies special attention should be paid to the suitability of 175 342 Service manual SMC TSMC 100 Mk4 6 Technical Data the oil in the compressor and the refrigeration plant as a whole Please note in particular the following points Oil type Refrigerant type Compressor type Miscibility between refrigerant oil Operating data for the compressor Discharge gas temperature Oil temperature Normal temperature in the crank case is 50 60 C Max permitted oil temperature set point for alarm Min permitted oil temperature set point for alarm if there is any The viscosity of the oil in the compressor during operation and under
298. ry See point 2 2 Checking lifting reserve When fitting a new cylinder or if changing refrig erant on the compressor from R717 to another one or vice versa or in the event of any major overhaul of the compressor the lifting reserve must be checked Note The lifting reserve must not be checked until the clearance volume has been adjusted Start by checking that the mutual height of the rocker arms is the same as described in the fol lowing 1 Having removed the cylinder lining meas ure distance Y from the contact face of the cylinder lining in the frame to the top of the two rocker arms which interact on either side of the cylinder lining see Fig 13 27 0178 933 ENG Rev 2005 12 09 Fig 13 27 2 3 Block er Rocker arms The rocker arms must be in their vertical po sition i e with the short screw pos 12D and gasket 12E fitted The measured distances Y1 and Y2 may not vary more than max 0 25mm If this difference is greater a shim Pos 15E must be placed under the lowest rocker arm bearing pos 15B or a shim removed from the highest bearing Normally there is no shim or max 2 shims under the rocker arm bearing Check lifting reserve The lifting reserve of the rocker arm is im portant in order to make sure that the rocker arm in its upright position can keep the suc tion valve ring plate open while the cylinder is unloaded However it must not be
299. s 112 116 0662 040 SMC 104 106 108 0662 020 4 TSMC 116 0662 050 TSMC 108 0662 030 Common drawings 0662 060 Table 18 1 Compressor SMC Designation Compressor frame 1A 1 Frame SMC 104 1A 2 Frame SMC 106 1A 3 Frame SMC 108 1A 4 Frame TSMC 108 1A 5 Frame SMC 112 1A 6 Frame SMC 116 1A 7 Frame TSMC 116 1B 1 1226 015 Oil level glass 1C 1 O ring Included Gasket kit in 3188 111 and 3188 141 1D 1 1424 148 Hexagon head M6 x 18 Top cover air cooled 2A 1 3113 263 Top covers S L E SMC 100 Mk 4 2A 2 3113 264 Top cover with flange S L E SMC 100 Mk 4 2E 1 1424 083 Hexagon head M14x90 2F 1 1424 090 Hexagon head M14x120 Top cover water cooled 2A 1 3113 263 Top covers S L E SMC 100 Mk 4 2A 2 3113 264 Top cover with flange S L E SMC 100 Mk 4 2B 1 3113 260 Water cover for cover with flange SMC 100 Mk 4 2B 2 3113 259 Water cover left SMC 100 Mk 4 2B 3 3113 258 Water cover right SMC 100 Mk 4 2E 1 1424 083 Hexagon head M14x90 2F 1 1424 090 Hexagon head M14x120 2G 1 1432 066 Nut M14 2H 1 2112 161 Staybolt M14 x 138 SMC HPC 100 Mk 4 272 342 0178 933 ENG Rev 2005 12 09 tool list fm 18 spare parts list Service manual SMC TSMC 100 Mk4 18 Part list 3184 380 Designation Kit assembly staybolts for top cover SABROE Compressor SMC
300. s sor unit Observe the safety warnings on the compres sor unit Use safety equipment Wear approved eye or face protection as well as gloves when working with parts containing refrigerant and or lubricating oil Safety shoes with slip proof soles can help you avoid injuries Keep your safety equipment in good condition Never operate or service this equipment if affect ed by alcohol drugs or other substances or if ina condition which decreases alertness or judgment Work Area Safety Always keep your work area clean Dirty work ar eas with such hazards as oil debris or water on the floor may cause someone to fall onto the floor 19 342 Service manual SMC TSMC 100 Mk4 3 Safety Precautions into the machine or onto other objects resulting in serious personal injury Make sure your work area is free of hazardous ob structions and be aware of protruding machine parts Always keep your work area tidy so that you can escape if a dangerous situation should arise Report unsafe working conditions to your supervi sor or safety department Tool Safety Always make sure that the hand tools are in prop er working condition Remove hand tools such as wrenches measuring equipment hammers etc from the compres sor unit immediately after use Transmission safety Coupling The coupling guard for directly driven compres sors is not designed to resist unintended load Therefore do not step on it or load it in
301. s D crosswise in two or three steps of torque Assembly is complet ed when no screw can be tightened any fur ther one by one with tightening torque Place the hub at the motor side Tighten the bolts A and the pointed screw loosely Mount the retaining plate from the coupling screen onto the compressor and insert a support ring for the coupling screen over the motor flange Assemble the intermediate piece and the la mella segments with the 8 screws applying the prescribed torque Remember the shaped washers facing the lamellas 264 342 Insert the coupling intermediate piece Cre ate space between the flanges either by shifting the entire motor or just the motor coupling flange The intermediate piece should only be secured to the compressor flange Do not insert the last four bolts in the motor flange until the coupling has been aligned As the compressor shaft rotates during the alignment procedure the motor must turn with it as the bolts in the intermediate piece engage in the free holes in the motor cou pling flange Line up the motor so that the free holes in the motor feet are right above the threaded holes in the base frame Shift the motor coupling flange to make up distance C in table See Table 13 1 Tighten the two bolts and the pointed screw in the hub Tighten the measuring pin on the coupling flange of the compressor as shown in the drawing 0178 933 ENG Rev 2005 12 09
302. s represented by the hatched fields in Table 4 5 0178 933 ENG Rev 2005 12 09 04 technical description fm Service manual SMC TSMC 100 Mk4 4 Technical Description Fig 4 45 Schematic drawings Additional Equipment SMC HPC 104 Compressor seen from the shaft end Relief cylinder Oil return Oil pressure 7 x SABROE SMC 188 SMC 112 0178 933 ENG Rev 2005 12 09 69 342 Service manual SMC TSMC 100 Mk4 4 Technical Description Table 4 5 Compressor Capacity per Stage in Type 25 33 37 50 SMC 104 63 67 75 83 87 100 SMC 106 SMC 108 SMC 112 SMC 116 TSMC 108 TSMC 116 As illustrated in Table 4 5 the SMC 100 standard compressors can only be capacity regulated in steps of two cylinders which is sufficient in most cases However it will occasionally be required to feature more stages and for this reason a system called extended unloading has been developed to ca 70 342 pacity regulate the compressor in steps of one inder per stage with the following capacity stages represented by the hatched fields in Table 4 6 Table 4 7 displays the numbers of the solenoid valves which must be activated to obtain the stat ed capacity stages load 0178
303. s are kept within certain per mitted operating limits The operating limits are specified in the following Operating Limits Diagrams Sabroe Refrigeration is only liable in so far as the operating limits con ditions of the compressor are kept within the limi tation of the curvas Similary the recommenda tion concerning the number of revolutions and cooling of the compressor must be observed The limitation curves have been determined on the basis of both constructional and operating conditions 1 Max Permissible Condensing Pressure The pressure limit corresponds to the test pressure which is applied to all compressors and as indicated under Test Pressure in this section Fig 6 7 TC TE 114 342 2 Max Permissible Differential Pressure across the Pistons Fig 6 8 TC TE 3 Permissible Compression Ratios The compression ratio is calculated into the diagram with the following values Max value for R717 8 7for SMC 100 R134a 12 R22 10 R407C 10 R404A 14 R507 14 Fig 6 9 Limitation of the Compressor rpm The limitation has been introduced in order to avoid excessive discharge gas and oil temperatures 0178 933 ENG Rev 2005 12 09 Service manual SMC TSMC 100 Mk4 6 Technical Data SABROE Fig 6 10 Fig 6 12 3a TE TE 06 technical data fm The Lowest Permissible Suction Pressure The limit has been fixed at approx 0 5 bar and 5 6 bar
304. s cut 40 Expansion valve produces excessive superheating 10 Low pressure cut out has cut 41 Filters in liquid suction line clogged 11 Low pressure cut out differential too small 42 Solenoid valve in liquid suction line closed 12 Oil pressure cut out has cut 43 Solenoid valve leaky 13 Capacity regulator incorrectly set 44 Evaporator iced up or clogged 14 Defrosting timer breaks current 45 Cooling air being recirculated short circuited 15 Oil charge insufficient 46 Excessive load on plant 16 Compressor capacity too high during start up 47 Refrigerant collecting in cold condenser close off by pass 17 Oil pressure too low 48 Coupling misaligned or loose bolts adjust oil pressure regulating valve 18 Oil foaming in crankcase 49 Oil pump defective 19 Oil overcharge 50 Bearings worn out or defective 20 Poor oil return oil in evaporators 51 Defective piston rings or worn cylinder 21 Restricted supply of refrigerant 52 Discharge valves defective or leaky 22 Refrigerant charge insufficient 53 Suction valves defective or leaky 23 Refrigerant vapour in liguid line 54 Compressor by pass open leaky safety valve 24 Leaky refrigeration plant 55 Compressor oil filter clogged 25 Refrigerant overcharge 56 Capacity regulator defective 26 Liquid in suction line 57 Solenoid valve in oil return clogged defective 27 At low temperature operation degree of charge in 58 Filter in oil return clogged evaporators rises 28 Insufficient coolant air to condenser 59 Compressor
305. s on a regular basis This will also give an indication of the con dition of the plant This service can be supplied by Sabroe Refrigeration or the oil supplier Max oil concentration in liquid phase at 2 W Max oil concentration in liquid phase contact Sabroe Refrigeration Min suction temperature 50 C At TE lt 50 C superheating must be introduced Dry expansion systems only Flooded systems to be considered individually contact Sabroe Refrigeration Suction gas superheat K Kelvin Zone in which both oils are useable SH N 0178 933 ENG Rev 2005 12 09 Calculation must be performed using COMP1 167 342 Service manual SMC TSMC 100 Mk4 6 Technical Data Data Sheet for Listed Sabroe Oils Typical data for lubricating oils for Sabroe compressors Sabroe Viscosity Viscosity Spec Flash p Pour p Anilin Acid no code cSt cSt Index grav at COC C C mg 40 C 100 C 15 C NG point KOH g M1 63 6 4 14 0 91 202 36 81 0 02 A3 97 8 1 13 0 86 206 32 78 0 05 AP1 64 9 3 121 0 858 195 51 121 0 04 66 10 1 136 0 835 266 lt 45 138 0 03 5 94 13 7 147 0 838 255 lt 45 144 0 03 9 208 25 149 0 846 260 lt 39 154 0 03 E3 ES Due to the great difference between polyolester based lubricants from various suppliers it is not pos 9 sible to present any typical data for these oils When using another oil brand than the one recommend
306. s page may result in serious personal injury or death Installation and Relocation Safety Before lifting the compressor unit or other parts of the plant consult the Engineering manual or Sabroe Refrigeration for proper methods and pro cedures An electrician must read and understand the elec trical diagrams prior to connecting the machine to the power source After connecting the machine test all aspects of the electrical system for proper functioning Always make sure that the machine is grounded properly Place all selector switches in their OFF or neutral disengaged position The doors of the main electrical cabinet must be closed and the main disconnect switch must be in 0178 933 ENG Rev 2005 12 09 x SABROE the position after the power source connec tion is complete Before starting the compressor for the first time make sure that all the motors rotate in the indicat ed direction Set Up and Operation Safety Read and understand all the safety instructions before setting up operating or servicing this com pressor Assign only qualified personnel instruct ed in safety and all machine functions to operate or service this compressor Operators and maintenance personnel must care fully read understand and fully comply with all warnings and instruction plates mounted on the machine Do not paint over alter or deface these plates or remove them from the compressor unit Replace all p
307. s resting on rocker arms Pos 15A on the by pass valve because the valve cone does not fit tightly against the seat or outer O ring Pos 24B or inner O ring Pos 24C is defective During pressure drop testing pay attention to any piping connections to the discharge side of the compressor which may influence the test result 229 342 Service manual SMC TSMC 100 Mk4 13 Service Instructions Removing refrigerant from compressor Before the compressor can be dismantled the refrigerant must be removed from the compressor which can be done in the following ways Step Activity Remark 1 Run compressor at lowest capacity stage and then throttle suction stop valve slowly until completely closed 2 The compressor will then stop on the low pressure cut out This can be adjusted to stop compressor lower than normal 3 Close discharge stop valve and other piping connections to compressor Remove remaining refrigerant gas using pump down compressor connected to purge Only HFC and valve pos 42 see Fig 13 1 HCFC 5 Connect the purge valve pos 42 see Fig 13 2 to a sealed empty vessel which in turn is Only R717 connected to an open tank containing water The water will absorb the refrigerant which can then be dispatch for proper destruction The moment the pressure is equalized the valve must be closed in order to prevent that water is being sucked back into the compressor 6 In connection with R744
308. s section remove long threaded plug and screw in short plug after having checked the aluminium gasket Pos 12E and found it fit for use Connecting rod The connecting rod pos 17 is made of two parts carefully adapted to each other The two parts are held together by means of two bolts secured with lock nuts Procedure for removing piston and connecting rod Bleed compressor of oil and refrigerant safeguard against any unintended start up Disconnect any water hoses and other pip ing connections to top and side covers Dismantle top and side covers Remove spring Pos 21 discharge valve and cylinder liner Remove nuts Pos 17D following this the bottom part of the connecting rod can be taken out by hand 0178 933 ENG Rev 2005 12 09 x SABROE Piston and connecting rod can then be lifted out through the top cover opening on the frame The connecting rod Pos 17 is equipped with inde pendent bearings at both ends The big end is fit ted with two bearing half bushes Pos 17A con sisting of a half cylindrical steel plate internally coated with white metal These bearing half bush es are secured in the connecting rod partly through their fit in the connecting rod bore and partly by a spring which fits into a milled groove in the connecting rod The opposite end of the con necting rod is fitted with the gudgeon pin bearing Pos 17B of which the following two types are found
309. s too high Fig 4 15 Valves and filter on oil pump cover Differential pressure monitoring of the oil filter is carried out using a differential pressure switch mounted directly on the pump housing as stand ard The signal serves as a warning to indicate that the filter must be changed The filter has extra capacity in order to avoid using the signal for an alarm which forces the compressor to stop If required the above mentioned switch can be re placed by a different type or by direct measure ment of the oil differential pressure above the filter 0178 933 ENG Rev 2005 12 09 04 technical description fm Service manual SMC TSMC 100 Mk4 4 Technical Description by connecting to port BT inlet pressure and BN discharge pressure Port BP must be blocked Regarding port connections see chapter 5 The shaft seal pos 10 is a sealing component which prevents oil and refrigerant from the com pressor interior from leaking into the atmosphere The shaft seal is of the slide ring type consisting of a plane lapped cast iron slide ring which ro tates with the crankshaft and seals against a sta tionary spring loaded slide ring made of special Fig 4 16 Oil diagram x SABROE carbon The shaft seal is of the balanced type and consequently serves a universal purpose in view of operating conditions refrigerants and oil types used for the compressor The design of the shaft seal and coupling o
310. sher Intermediate bearing 49 1 3113 146 Intermediate bearing complete 49A 1 Housing 49B 1 1413 389 Socket cap screw M12x45 49C 1 1437 081 Spring washer 49D 1 1446 022 Guide pin 5x26 49 1 1424 199 Hexagan head screw M10x65 49G 1 1437 033 Spring washer 49H 1 2314 027 Threaded plug 3 4 BSP Capacity regulation 50A 1 3143 383 Valve body with 1 solenoid valve 50A 2 3143 384 Valve body with 2 solenoid valves 50A 3 3143 385 Valve body with 3 solenoid valves 50A 4 3143 386 Valve body with 4 solenoid valves 50B 1 1372 537 Coil 10W 220 230V 50 60Hz 50B 2 1372 538 Coil 10W 110V 50 60Hz 50B 3 1372 539 Coil 10W 240V 50Hz 50C 1 1372 424 Service Kit for one solonoid valve Crankcase heater 1 1 4 BSP 3184 375 Kit assembly crankcase heater 270W 115V Heater Sealing ring 3184 376 Kit assembly crankcase heater 270W 230V Heater Sealing ring 3184 377 Kit assembly crankcase heater 270W 250V Heater 298 342 Sealing ring 0178 933 ENG Rev 2005 12 09 tool list fm 18 spare parts list Service manual SMC TSMC 100 Mk4 18 Part list Designation Compressor SMC 57B 1 Sealing ring Included in Gasket kit 3188 141
311. specific applications the authorities may however de mand a higher test pressure level Within certain limits such requirements can be met for SABROE Table 6 17 compressors against an additional price Please contact Sabroe Refrigeration for further informa tion Units consist of components which have been pressure tested as described in the following ta ble This means that it is only necessary to leak test the unit Leak testing is carried out with pres surized air at the pressure stated in the table All weldings and connections are covered with a frothing liquid which will start foaming in case of a leak Allowable pressure The pressures given in Table 6 18 under allowa ble pressure shall always be observed during plant design and operation Pressure in the com pressor are not allowed to exceed these values Step Action Reference Description 1 Strength test See Table 6 18 The test is carried out with air 2 Leak test 1 See Table 6 18 The test is carried out with air 3 Test run Functional test of compressor 4 22 5 Charging of protective Charging of protective gas nitrogen N3 gas 0 2 bar 3 psi overpressure 0178 933 ENG Rev 2005 12 09 157 342 Service manual SMC TSMC 100 Mk4 6 Technical Data Table 6 18 Standard Test Pressure Levels Standard Test Pressure Levels Max allowable Max allowab
312. speed recommended by Sabroe Refrigeration See chapter 4 Description of compressor Providing the compressor operates within the specified pressures and temperatures and the prescribed periodic services are performed the compressor will have a long and efficient service life Consequently operating conditions must be checked on a daily basis and registered in an op erating log Pressure drop test Using the pressure drop test it is possible to check the internal tightness of the compressor from discharge to suction side The pressure drop test is performed with the compressor at standstill as described below 0178 933 ENG Rev 2005 12 09 x SABROE Immediately after stopping the compressor read the pressure on discharge and suction side of compressor Close the discharge stop valve quickly and from the moment of closure time how long it takes for the pressure to drop on the high pressure side of the compressor Normally the pressure drop should not be more than 3 bar over a period of approx 5 minutes If the pressure drops more quickly this is due to internal leakage which may occur where the pressure valve ring plates are in bad contact with their seats Pos 20C against Pos 20A and 19H with defective seal Pos 197 with defective seal Pos 19K because cylinder lining and top cover have been tightened without a long mount ing stopper being fitted Cylinder lining is thu
313. ssors Single stage compressor Compressor type Cylinder Diameter 100 mm Number of Cylinders 4 6 8 12 or 16 Stroke S Lor E Two stage compressor Compressor type Cylinder Diameter 100 mm Number of Cylinders 8 or 16 Stroke S Lor E An entire list of the compressor series can be seen in the table Technical Data for SMC 100 Se ries in chapter 6 Technical Data The type and version of the various compressors can be read from the name plate shown below A name plate is fixed on every compressor Christian X s 201 8270 H jbjerg Denmark SABROE Compressor Type Nominal speed Swept volume Max allowable pressure Max allowable pressure 0178 933 ENG Rev 2005 12 09 SMC 1081 TSMC 116 5 Similarly the serial number of each compressor is stamped into the compressor block The letter S L or E which refers to the compressor stroke is stamped into the end surface of the crankshaft Whenever contacting Sabroe Refrigeration about a compressor please state its serial number 35 342 Service manual SMC TSMC 100 Mk4 4 Technical Description Compressor Description With a few exceptions all compressors of the SMC 100 or TSMC 100 types use the same spare parts as the ones described in the following sec tion Fig 4 4 SMC 100 Cylinder Liner Complete
314. ssure PE PE Fig 4 37 To condenser 1X E Alternative Oil separator with float valve controlled oil return 6 8 12 14 9 H Table 4 4 A B Compressor 9 Oil vessel 2a 2b Level Switch 10 Non return valve 1 bar 3 Filter 11 Solenoid valve 4 Stop valve 12 Nozzle dia 3 3 mm 5 Oil separator 13 Filter 6a 6b Solenoid valve incl nozzle Fig 4 37 14 Heating cartridge 7 Non return valve 15 Oil charging valve 8 Float valve 16 Oil level glass 60 342 0178 933 ENG Rev 2005 12 09 04 technical description fm Service manual SMC TSMC 100 Mk4 4 Technical Description To be able to press the oil from the oil vessel pos 9 to the crankcase on the compressor pos A which is working at the highest suction pressure the pipeline with the non return valve 1 bar pos 10 is connected to the suction gas line for this compressor There is a risk however that the differential pres sure between the oil vessel pos 9 and the crank case on compressor B may become so great that the oil conveyed via the solenoid valve 6a starts foaming Usually this foaming does not cause any problems as the oil is supplied to the compressor 0178 933 ENG Rev 2005 12 09 x SAB
315. t two stage operation it is necessary to cool the discharge gas from the LP stage before it enters the HP stage This intermediate cooling is carried out with the systems described below depending on the type of refrigerant used Common for these intermediate cooling systems is that they must cool the intermediate pressure gas sufficiently and at the same time ensure that no liquid is admitted into the HP stage since liquid may result in liquid slugging in the HP cylinders and excessive wear on the moving parts It is therefore important to check the systems as de scribed below Intermediate Cooling System with Intermediate Cooler Type DVEA R717 The two stage R717 plant may consist of two compressors one low pressure compressor LP and one high pressure compressor HP as illus trated in Fig 4 54 The plant may also consist of one or more two stage compressors as shown in Fig 4 55 In both cases the compressors are connected to an intermediate cooler in which the warm gas from the LP stage is cooled down before it flows on to the HP stage In the intermediate cooler the liquid level of R717 is regulated by the float valve and the discharge gas from the LP stage is cooled by bubbling up through the refrigerant from the distributor at the bottom of the intermediate cooler 82 342 Fig 4 54 SMC 100 compressor Float valve Liquid subcooling Intermediate iral cooler type spira DVEA Oil drain off Fig 4
316. tes Fig 4 1 fixed on each unit Fig 4 1 T2516273 0 Please note that specially made tools which not cause any sparks must be used in connection with maintenance work on the compressor Warning 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 test ing an air compressor 31 342 Service manual SMC TSMC 100 Mk4 4 Technical Description AN Danger Sabroe Refrigeration does not take any responsi bility for injuries to personnel or damage to equip ment resulting from using this equipment for other purposes than the ones stated above Application of Combustion Engines If combustion engines are installed in rooms con taining refrigeration machinery or rooms where 32 342 there are pipes and components containing refrig erant make sure that in case of leakage the com bustion air for the engine comes from an area in which there is no refrigerant gas Failure to do so will involve a risk of lubricating oil from the combustion engine mixing with refriger ant at worst this may lead to corrosion and dam age of the engine 0178 933 ENG Rev 2005 12 09 04 technical description fm Service manual SMC TSMC 100 Mk4 4 Technical Description Marine application Special attention should be paid to the listing of the ship and
317. th screw compr type E 3183 145 4 4 2 Tools for shaft seal 3183 139 1 1 3 Tommy screw for cylinder liner 3183 041 2 2 4 Theaded plug for unloading cylinder 3 8 BSP 2314 017 2 2 5 Supporting plate for pistons 3183 115 8 8 6 Spanner for heating cartridge NV 55 3183 060 1 1 7 Trigger for coupling or belt pulley 3183 059 1 1 8 Adjusting jig for coupling 3183 105 1 9 1 Wrench for cylinder screw NV 4 1 9 2 Wrench for cylinder screw NV 5 1 9 3 Wrench for cylinder screw NV 8 1 9 4 Wrench for cylinder screw NV 10 1 9 5 Special wrench for shaft seal NV 4 1612 392 1 1 10 1 Retaining ring plier J 21 G 1 10 2 Retaining ring plier A 11 G 1 11 1 Open end and ring spanner NV 10 1 11 2 Open end and ring spanner NV 17 1 11 3 Open end and ring spanner NV 19 1 11 4 Open end and ring spanner NV 22 1 0178 933 ENG 305 342 Rev 2005 12 09 Service manual SMC TSMC 100 Mk4 18 Part list Line No a Designation Dimen part No A601 A602 A603 0 sion A B 11 5 Open end and ring spanner NV 24 1 11 6 Open end and ring spanner NV 27 1 13 1 Socket wrench NV 10 1 13 2 Socket wrench NV 13 1 13 3 Socket wrench NV 17 1 13 4 Socket wrench NV 19 1 13 5 Socket wrench NV 22 1 13 6 Socket wrench NV 24 1 1 1 13 7 Socket wrench NV 27 1 13 8 Socket wrench NV 30 1 13 9 Socket wrench NV 32 1 13 10 Socket wrench NV 9 16 1 13 11 Socket wr
318. th short strokes 80mm an L type for longer strokes 100mm and an E type for the longest strokes 120mm The crank shafts have an S L or E stamped into the connect ing end Dismantling crankshaft Dismantle the crankshaft through the pump end of the frame in the following way Bleed compressor of oil and refrigerant safeguard against inadvertent start up Dismantle top and side covers Dismantle all cylinder linings 248 342 Extract all pistons and connecting rods Pull off V belt pulley or coupling half Dismantle shaft seal cover and shaft seal Dismantle cut outs and pipes to manome ters or piping connections to UNISAB Dismantle end cover Pos 4A Dismantle oil filter Dismantle oil pump drive and oil pump On SMC TSMC 112 116 loosen the middle bearing by dismantling the plugs pos 49H as well as gasket pos 49J in both sides of the compressor Next dismantle screws pos 49F and lock ing plates pos 49G Rotate crankshaft to place connecting rod journals on horizontal level Dismantle bearing cover at pump end and support the crankshaft by means of a board inserted through the side openings After this the crankshaft can be drawn out of the frame The crankshaft must still be sup ported The middle bearing on SMC TSMC 112 116 can be dismantled by removing screws pos 49B and shims pos 49C as well as guide pins pos 49D 0178 933 ENG Rev 2005 12 09 13 service instruc
319. th the pins pos 19B are pressed up under the suction valve thus keeping the valve in open position as shown in Fig 4 40 63 342 Service manual SMC TSMC 100 Mk4 4 Technical Description Fig 4 40 Cylinder Liner Complete 19F 19B 19A The unloading ring pos 19B is activated by two rocker arms pos 15A Fig 4 41 one at each side of the cylinder liner The rocker arms which are placed in ball sockets pos 15B are moved back and forth by the unloading frame pos 13 64 342 The unloading frame which is controlled by two brackets with guiding pins does always activate two cylinders at a time The unloading frame is moving back and forth by means of the unloading cylinder pos 12 If oil pressure is put on the cylin der during operation the unloading frame will move to the left as shown in Fig 4 41 Thus the angle of slope of the rocker arms is changed so that the unloading ring pos 19F is able to move freely Consequently the cylinder is forced to work If the oil pressure to the unloading cylinder closes the unloading frame pos 13 will move to the right thereby raising the rocker arms The ing ring with pins pos 19B are pressed up under the ring plate and the suction valve is forced open thereby unloading the cylinder Fig 4 41 Unloading System 15 12 13 15 4 KAW MW Y LAN
320. the adjustment pres sures indicated in the table Pressure and temper ature settings The actual set pressure is stamped on the rating plate pos A The by pass valve is of the high lift type which makes it very sturdy and durable Further the by pass valve is independent of the pressure on the compressor suction side Conse quently it only opens when the pressure on the discharge side exceeds the set pressure in rela tion to atmospheric Fig 13 21 Therefore take care that the hole pos B does not get covered or clogged In case the pressure on the discharge side ex ceeds the set pressure so that the by pass valve opens the valve will remain open until the pres sure on the discharge side has fallen to approx half the set pressure The valve then closes auto matically However at great differential pressures across the compressor the valve may remain open In that case stop the compressor and close the discharge stop valve entirely The equalization of pressure in the compressor will then close the safety valve and the compressor can be restarted The by pass valve is supplied factory set and sealed and need normally not be disassembled and readjusted If necessary control of function and set pressure must be made in accordance with local regula tions for safety valves On the outside the by pass valve is sealed with two O rings pos 24B and 24C Fasten it to the compressor housing by means of screws pos 24D
321. the electric motor taking oil cooling system in account During the condensing process the refrigerant va pors are again transformed into liquid To give off the energy heat from the condenser the temper ature of the medium air water to which the heat is to be transferred must be lower than the con densing temperature Since there is a connection between the temperature and the pressure in the condenser there is a minimum value for how much the condensing temperature must fall a too low condensing pressure level will result in opera tional failures 205 342 Service manual SMC TSMC 100 Mk4 11 Maintenance Instructions Visual Inspection Inspect the reciprocating compressor unit in order to make sure that there are no refrigerant or oil leaks Oil Pressure Check that the oil pressure complies with the rec ommended cut out pressure see chapter 9 Set tings Oil level Check the oil level in the compressor It is of vital importance for the service life of the compressor that an optimal lubrication is maintained The oil level must always be visible in the oil level glass 206 342 Chapter 6 Technical Data Charging the Com pressor with Oil includes table values for oil charg ing and oil level If the oil level is below the lowest part of the oil level glass oil must be recharged Recharging of oil topping up can be carried out during operation either by means of a hand oper ated oil pump or as desc
322. the influence of Type of refrigerant and solubility of re frigerant in the oil Operating temperatures Vapour pressure in the oil reservoir Suction pressure and oil temperature in the crankcase Compatibility with neoprene O rings The aniline point indicates how the O ring material reacts to the oil At an aniline point less than approx 100 C the material has a tendency to swell and at an aniline point higher than approx 120 C it has a tendency to shrink Thus it cannot be recommended to change the oil type from M to PAO without changing the O rings at the same time as a leak may otherwise easily occur in the compressor or 176 342 the plant Sabroe Refrigeration recom mends therefore the use of the Sabroe AP68 oil since this type of oil in this case re duces considerably the risk of leaks Sabroe Refrigeration can supply a list of op erating data on request Please note the viscosity limits during oper ation e Optimum viscosity limits 20 to 50 cSt e Max permitted viscosity 100 cSt e Min permitted viscosity 10 cSt Max permitted viscosity during start up of the compressor 500 cSt e Max refrigerant concentration in the oil during operation 25 also in case the viscosity requirements have been met Use of Mineral Oil As described in the introduction mineral oil in par ticular causes serious problems especially in R717 plants When using mineral oil it is i
323. the local Sabroe Refrigeration representative it is possible to receive a list of the spare part sets recommended by Sabroe Refrigeration 0178 933 ENG Rev 2005 12 09 04 technical description fm Service manual SMC TSMC 100 Mk4 4 Technical Description Types of Spare Parts Set For the different compressor blocks Standard spare parts set Contains a suit able selection of O rings as well as valve ring plates and valve spring Extended spare parts set In addition to the parts included in the standard spare parts set the set contains a cylinder liner and discharge valve as well as an extended number and types of gaskets and fittings Certificate spare parts set In addition to the parts from the extended spare parts set this set contains a major number of components and wearing parts selected by the classification societies Special spare parts set This is a more comprehensive set than the extended 0178 933 ENG Rev 2005 12 09 spare parts set as almost all O rings and gaskets are included and for the most wear ing parts the number of parts have been ex tended For the different compressor units Standard spare parts set This is a set consisting mainly of O rings and gaskets for some of the components included in the unit Certificate spare parts set In addition to the parts from the standard spare parts set this set contains other components selected in accordance with the requirem
324. the spindle 5 turns clockwise NB Factory setting must always be increased by min 10 C Ad justment of the TEAT valve must be carried out with the thermopump out of operation For detailed descriptions concerning setting and adjustment of automatics see chapter 21 Appendices 196 342 0178 933 ENG Rev 2005 12 09 Service manual SMC TSMC 100 Mk4 9 Settings SABROE Expected Discharge GasTemperatures ig 9 1 9 sduiei seb 2 dua seb 9 sdwa seb 9 duwa seb 5 s G9IL 1694 180146 16 8 98 9006 665 82 211 801 66 S 9l 76 48 18 GGL 861 97 66 26 98 28 62 28 191 Ect ILE LOLI 26 97 66 68 68 62 ZZ FOL 91 9241 96 78 18 92 HL Z9 11 901 96 v8 L Sh 76 78 BZ 74 Z 88 96 961 SLL 20 4011 LE 68 97 2 69 86 98 GZ FLH 98 8 162 OZ 69 44 06 921 901106 16 28 8 29 v9 081 0 16 84 69 lt 6 672 22 89 99 V9 99 7611411 96 84 91 4 99 29 09 0 16 146 68 OL 6S 28 SZ 89 19 88 ZS OC F VSL 9EL 10116911 66 48 18 GL FOZ 6011 86 06 99 Z6 v8 ZZ EL IZ ISLE St 1G9L
325. the surfaces which are in contact with the warm discharge gas will also get warm However the temperature de pends on the refrigerants used as well as the op erating conditions of the compressor Often the temperature exceeds 70 C 158 F which for metal surfaces may cause skin burns even at a light touch Consequently the compressors are equipped with yellow warning signs signalling that pipes vessels and machine parts will become so hot during operation that your skin will get burnt if you touch them for one second or more The sign Internal protection Compressor blocks and units are usually deliv ered without any refrigerant or oil To protect the compressors against internal corro sion they are delivered evacuated of all atmos pheric air and charged with Nitrogen N to an overpressure of 0 2 bar 3 psi In such cases a yellow sign is affixed to a visible spot on the compressor Pafyldt beskyttelsesgas No Charged with inert gas Enthalt Schutzgas 0 2 bar Charg du gaz protecteur 3 PSI Contiene gas protector 1534 169 0178 933 ENG Rev 2005 12 09 Other warning signs A Hazardous substance Dangerous noise level use hearing protectors Internal overpressure Cold surfaces 15 342 Service manual SMC TSMC 100 Mk4 2 Signs and Warnings Emergency Stop Fig 2 5 Emergency stop on the reciprocating compressor unit Electromechanical control
326. therefore recommended to adhere to 0178 933 ENG Rev 2005 12 09 Sabroe Refrigeration s recommendations as to the cooling of the compressor These recommen dations can be found in the Operating Limits dia grams Variable speed drive VSD Further the compressor can be driven by VSD as long as the rpm limits are not exceeded see Op erating limits For the standard and total unloading compressor UNISAB II is able to control the VSD combined with the mechanical capacity control in the most efficient way taking into consideration both energy consumption and wear 75 342 Service manual SMC TSMC 100 Mk4 4 Technical Description Compressor Units The compressor units can be delivered as stand ard units with base frames adapted to IEC electric motors Against additional payment base frames can also be delivered for non standard electric motors On the base frame one oil separator can Fig 4 49 SMC 100 Unit Direct Couple The compressors can be connected to an electric driving motor or a combustion motor The trans mission can be either direct through a coupling that is flexible in both radial and longitudinal direc tion but which is also rigid in its contorsion there by stabilising the compressor rotation The trans mission can also take place by means of a V belt drive which through the selection of st
327. three versions of pistons For compressors with 80mm stroke lengths type S 100mm stroke lengths type L and with 120mm stroke lengths type E The difference is clearly seen from Fig 13 12 L n 170 120 The same piston and piston pin are used irre spective of whether the connecting rod contains a sleeve or a needle bearing e Fitting piston rings in piston Before mounting the piston rings in the piston their fit in the cylinder lining should be checked by measuring the ring gap See section entitled Various clearances and ad justment measurements Assembling and stripping down piston and connecting rod Adopt the following procedure when assembling piston and connecting rod 0178 933 ENG Rev 2005 12 09 Le On Piston Type E L z 60 60 10 G 100 50 40 L one of the circlips pos 18D into bore served for piston pin Heat piston to 70 158 F in oil on hot plate After inserting bearing bush or needle bear ing guide connecting rod into place in heat ed piston The piston pin can now be posi tioned without using tools It is sometimes possible to fit the piston rod by hand without a preliminary heating of the piston Fit last Seeger ring To strip reverse sequence however do not heat piston but press piston pin o
328. ting compressors Code no E5 Area no 1 A Condensing temperature 76 40 22 4 14 32 50 68 F Evaporating temperature A Very suitable in case of a new plant Min suction temperature 50 C At TE lt 50 C superheating must be introduced 192 342 0178 933 ENG Rev 2005 12 09 06 technical data fm Service manual SMC TSMC 100 Mk4 6 Technical Data R744 single stage reciprocating compressors Code no E 85 Area no 1 A SABROE TE F C 68 20 50 10 32 0 2 KA HPO defrost S 4 10 X j HPO HP Le 9 4 20 22 30 o c 9 40 40 58 50 o 76 60 94 70 112 80 90 80 70 60 50 40 30 20 10 0 C 130 112 94 76 58 40 22 4 14 32 F 10111160 6 Evaporating temperature Very suitable in case of a new plant 0178 933 ENG Rev 2005 12 09 193 342 Service manual SMC TSMC 100 Mk4 6 Technical Data List of Major Oil Companies The oil from the companies listed below are not tested by Sabroe Refrigeration and are therefore not ap proved by Sabroe Refrigeration The following list includes the information provided by the oil companies The oil companies are responsible for the information concerning the durabilit
329. ting quality is carefully monitored Sabroe Refrigeration recommends however that you use synthetic oils for modern high capacity 0178 933 ENG Rev 2005 12 09 06 technical data fm Service manual SMC TSMC 100 Mk4 6 Technical Data plants where a long service life for both lubricant and moving parts is expected The advantage of using synthetic lubricating oils is a much lower oil consumption and longer oil changing intervals Improved viscosity at low tem peratures facilitates furthermore drainage at the cold parts of the plants How to Use the Diagrams in the Oil Recommendation To find the correct code number select refriger ant and compressor type in the oil recommenda tion diagram Then insert the estimated operating conditions in the diagram Example reciprocating compressors Refrigerant R717 Condensing temperature TC 35 C Evaporating temperature TE 20 C Note Sometimes plants operate under different conditions e g different evaporating tempera tures due to variations in the plant or different condensing temperatures as a result of seasonal changes By inserting TC and TE in the oil recom mendation diagram the recommended area is found In this case it is oil area 1 If the intersection is outside the area contact Sabroe Refrigeration for a detailed calculation by means of the calcula tion program COMP1 0178 933 ENG Rev 2005 12 09 SABROE
330. tion Suction Filters In the TSMC compressors the two suction filters vary in design The suction filter for the LP stage is of the same type as the ones for the SMC com pressors and is characterised by square holes in the shell and openings at both ends Fig 4 23 TSMC 108 gt Closed end and O ring 4 sealing 4 Depending the type of refrigerant and the tion and discharge pressures a by pass system is sometimes used to regulate the intermediate pressure PI in order to prevent it from falling below the specified pressure The system is either built onto the compressor at the factory or mounted on the refrigeration plant if several two stage compressors work in parallel 0178 933 ENG Rev 2005 12 09 SABROE In the high pressure stage a suction filter of the same size as the one for the LP stage has been fitted but this has round holes in the shell and is closed at one end The by pass system is described in detail later in this section under Cooling of the Intermediate Dis charge Gas on TSMC Compressors The TSMC 100 compressors can be delivered with one or two oil separators depending on the type of refrigerant and area of application Other wise the terms of delivery are the same as the ones described for single stage compressors 49 342 Service manual SMC TSMC 100 Mk4 4 Technical Description Conversion of TSMC Compressors from Two stage to Single stage If n
331. tion of poor maintenance or lack of thoroughness at installation 0178 933 ENG Rev 2005 12 09 03 safety precautions fm Service manual SMC TSMC 100 Mk4 3 Safety Precautions Cooling media Salt solutions brines of calcium chloride CaCl or sodium chloride NaCl are often used In recent years alcohol glycol and halogenated compounds have been used in the production of brine In general all brines must be considered harmful to nature and they must be used with caution Be very careful when charging or purging a refrigera tion plant Never empty brines down a sewer or into the environment The brine must be collected in suitable containers clearly marked with the contents and sent to an approved incineration plant Lubricating oils A Warning When charging oil follow the safety instructions given by the oil supplier MSDS Material Safety Data Sheet Always avoid direcst contact with the oil as this may cause skin allergies Always use protective equipment goggles and gloves when charging oil Refrigeration compressors are lubricated by one of the following oil types depending on the refrig erant plant type and operating conditons Mineral oil M oil Hydro treated mineral oil H oil Semi synthetic oil mix of M oil and syn thetic oil Alkyl benzene based synthetic oil A oil Polyalphaolefine based synthetic oil PAO oil Mixed A and PAO oil AP oil
332. tion process Failure to comply with safety precautions may cause death or injury to person nel It may also cause damage to or destruction of the equipment 9 342 Service manual SMC TSMC 100 Mk4 2 Signs and Warnings Identification of Sabroe Refrigeration Equipment All Sabroe Refrigeration equipment can be identified by one or several name plates placed as illustrated by the following drawing Fig 2 1 q 1 Compressor name plate 2 Vessel name plate 3 Unit pipe system name plate 10 342 0178 933 ENG Rev 2005 12 09 02 signs and warnings fm Service manual SMC TSMC 100 Mk4 2 Signs and Warnings Unit pipe system name plate Fig 2 2 X Unit pipe system name plate y Christian X s Vej 201 2516 328 8270 H jbjerg Denmark SABROE Unit pipe system Identification No Design code Approval No Pressure system Fluid group Allowable pressure Max Leak test pressure Design temperature in max CE 0062 The unit pipe system name plate is positioned on the frame The name plate contains the following information Manufacturer s type designation Year of manufa
333. tion valves is also used when starting up the compressor The system works as follows At compressor standstill all the suction valves are forced into an open po 0178 933 ENG Rev 2005 12 09 x SABROE sition and cannot be closed until the compressor is in operation and the oil pump has built up the oil pressure in the lubricating system With an open suction valve there is no compression resistance in the compressor and this reduces its starting torque considerably Thus a motor dimensioned to suit the operating conditions of the compressor can easily start up the compressor also by using the star delta starting system For compressors fitted with extra capacity stages extended unloading one cylinder SMC 104 106 108 or two cylinders SMC 112 116 will be in operation all the time also at start up See extended unloading Capacity Regulation and Unloading of Compressor Capacity Regulation As mentioned in the introduction to this section all SMC and TSMC compressors are fitted with a hy draulic capacity regulating system by means of which the compressor capacity can be adjusted to the refrigerating requirements of the plant When reducing the compressor capacity two or more suction valves on compressors with ex tended unloading one or more suction valves are forced open so that compression does not occur in the cylinders in question The suction valve is forced open when the unload ing ring together wi
334. tions fm Service manual SMC TSMC 100 Mk4 13 Service Instructions Inspection Check bearing journals on connecting rods for wear and tear and if necessary measure diame ter of journals The maximum wear on the bear ings is shown in the section Various clearances and adjustment measurements In most instances the permissible play in the bearing can be obtained by replacing the bearing half bushes The bearing journals on the main bearings are normally subject to very little wear but should be check measured during main over hauls If wear and tear exceeds the play stated the crankshaft can normally be ground to 0 5 mm undersize For the ground crankshaft main bear ings and connecting rod bearings with an under size of 0 5 mm can be supplied as stated in the part list The drawing for grinding the crankshaft to under size is found in this instruction manual Note After grinding the crankshaft all lubricating channels must be thoroughly cleaned with an ap proved cleansing fluid and blasted with com pressed air Remember to refit the blind plugs Check sealing face for O ring seal Pos 10D on shaft seal The surface must be bright and free of scratches and marks Refitting crankshaft Refit the crankshaft in the reverse order of that for dismantling Note the following however After the crankshaft has been inserted into the housing mount main bearing cover Pos 5A using gasket Pos 5D as a shim 017
335. types design M Mineral oil A Synthetic oil based on Alkylbenzene PAO Synthetic oil based on Polyalphaolefin AP Mixture of A and PAO oils E Synthetic ester based lubricants In the oil recommendation diagrams it is possible to find the code number best suited for the ing conditions in question With the code number itis possible to select the correct Sabroe oil for the application in question 0178 933 ENG Rev 2005 12 09 Oil Types and Oil Companies Due to the large number of oil companies offering oil for refrigeration plants it has not been possible for Sabroe Refrigeration to test all the different oil brands on the global market It is our experience that certain oil brands can change character during use and thus no longer correspond to the specifications stated by the oil companies on delivery We have thus experi enced changes in specifications as well as formu la and performance without having received infor mation on this beforehand from the oil company This makes it extremely difficult for Sabroe Refrigeration to give a general approval of other oil brands In co operation with a large respected oil compa ny Sabroe Refrigeration has therefore developed a series of three different oils covering most de mands Furthermore a list of the oils which can be supplied through Sabroe Refrigeration has been prepared Data for these oils is included in the ta ble Data for Sab
336. ucting compound The solenoid valve is opened by the KP77 thermostat whenever the temperature of the pressure pipe exceeds 55 C 131 F 83 342 Service manual SMC TSMC 100 Mk4 4 Technical Description Automatic Regulation of Intermediate Pressure IP In two stage plants with reciprocating compres sors it should be pointed out that the intermediate pressure is not allowed to drop excessively A low intermediate pressure reduces the damping effect of the gas on the valve plates in the LP stage discharge valves The danger is that a breakdown may occur in the form of broken valve plates In order to prevent this it may be necessary to mount a by pass system between the HP side and IP side Thus a suitable amount of gas is led back to the IP side The system is illustrated in Fig 4 58 The lower limits for IP have been fixed at 15 C 5 F for R717 plants 25 C 13 F for HFC and HCFC plants The by pass system is additional equipment and is usually mounted by Sabroe Refrigeration di rectly on the internal pipe connections on the com pressor block The diagrams Fig 4 54 to Fig 4 57 do only show the principle of the different systems and must not therefore be used directly Fig 4 58 TSMC PM main valve a pilot valve 0 75 gt 7 bar 7 lt Oil separator 5 LP Opt pal _ 84 342 Determining the Intermediate Pressure I
337. ue eade sie ai cse iet o Gd E GN 209 Charging Compressor with Lubricating Oil 210 Searching Tor ESSKS Gee Baw eevee BEL ot nn Gane 211 Method of Searching for Leaks 211 Motor Lubrication zu oes ife me ERI AER PES a dvo uc 211 Fault finding Instructions 52 REA RE HARE RR ew OR AT eee dees 213 PreCAUNONS gt TD IET 213 Qualification Requirements III 213 How to Carry Out Fault findiDg champ wx AA ANT ewe Ra esa es 214 Reciprocating Compressor Unit as Part of the Overall System 214 Sysiemiatic Fa ltfindiN g uod 3 Su eta os els end p 214 Operating Condition 214 Using the Troubleshooting Chart eh 214 Remedying Malfunctions 217 Service Instructions oos annaua eo ee antt ee dI sep EE i RS QN Sei ig ds 227 Safety Measure ot ete etr a Pu tati rue et 227 General Preparations before Service 228 a atate d bo dias et pu Gee Bod Waah edb e ALNG 228 Pressures ATE bob RP USA ERU S Sarg SAD LENG OS MALA 228 Hot and Cold Surfaces avos man epp eR E
338. uide ring for discharge valve O ring 107 55 x 3 53 1413 343 Socket cap screw M6 x 30 Gasket 3184 361 Kit assembly springs for unloading ring Washer dia 8 4 3 x 0 5 Spring for unloading ring 286 342 Tesion spring 0178 933 ENG Rev 2005 12 09 tool list fm 18 spare parts list Service manual SMC TSMC 100 Mk4 18 Part list 3188 039 Designation Service kit pair of unloading rings SMC 100 S L Compressor SMC Unloading ring with pins S 8 L 3188 010 Gasket kit pair of cylinder liners SMC 100 3184 361 Kit assembly springs for unloading ring 3188 040 Service kit pair of unloading rings SMC 100 E Unloading ring with pins E 3188 010 Gasket kit pair of cylinder liners SMC 100 3184 361 Kit assembly springs for unloading ring Discharge valve 20 1 3136 090 Discharge valve HP R717 20A 1 3133 028 Discharge valve seat 20B 1 Retatining plate 20C 1 Ring plate 20E 1 1432 033 Nut 20H 1 1437 066 Lock washer 20G 1 Valve spring 20 2 3136 091 Discharge valve LP R717 20A 1 3133 028 Discharge valve seat 20B 2 plate 20C 1 Ring plate 20E 1 1432 033 Nut 20H 1 1437 066 Lock washer 20G 2 Valve spring 20 3 3136 092 Discharge valve HP HFC 20A 1 3133 028
339. uirements include a knowledge of refrigeration engineering and famili arity with the system in question 213 342 Service manual SMC TSMC 100 Mk4 12 Fault finding Instructions How to Carry Out Fault finding Fault finding is necessary in three general situa tions When acute problems arise To find out what caused the reciprocating compressor unit to malfunction Maintenance During scheduled maintenance to detect operational deficiencies that can lead to fu ture disturbances or uneconomical operation Starting up after repairs After a damaged component has been re placed for example to find external rea sons why the component failed Reciprocating Compressor Unit as Part of the Overall System The functions performed by a reciprocating com pressor unit and thus the errors that may occur are often linked to the overall system plant in which it is operating On the low pressure side the reciprocating com pressor unit is connected to an evaporator as well as to a system used for distributing the chilled me dium On the high pressure side it is connected to a condenser as well as to a system used for the coolant Acontrol system performs monitoring control and regulation Most of the errors which occur are in dicated by the control system Personnel who carry out fault finding must take into account all of the above mentioned system parts to obtain a clear picture of what is happen
340. uld be mounted in suction pipe 8 Liquid stroke in compressor during operation 8 23 Refrigerant gas in liquid line Expansion valve is oscillating 8 39 Superheating of expansion valve is set too low Adjust superheating which should normally be 5 8 220 342 0178 933 ENG Rev 2005 12 09 12 fault finding instructions fm Service manual SMC TSMC 100 Mk4 12 Fault finding Instructions 9 Excessive condenser pressure In the event of abnormally high pressures in the refrigeration system there is a risk of damage to the compressor At very high pressures see pressure testing the risk of the components in the refrigeration plant exploding can constitute a threat to life Abnormally high pressures can occur in the case of extreme heating of plant parts fire solar radiation or other abnormal heating volumetric expansion of fluids in sealed off premises 9 25 Overfilling with refrigerant Refrigerant fills condenser and reduces its effec tive area Draw off coolant 9 28 Insufficient condenser cooling e g if cooling water fails fan coling water pump clogs soiling scaling or foul ing of heat transmitting surfaces Regulate water air supply or reduce compressor capacity if called for Check condenser as per in structions for same 9 30 Presence of non condensable gas es especially air in condenser Blow air out at con
341. ult diagnosis in case of a com pressor shut down the UNISAB II immedi ately stores the alarm situations in its mem ory which can be displayed and analyzed on the display at any time Instrumentation Depending on compressor type the UNISAB II is equipped with a number of 0178 933 ENG Rev 2005 12 09 x SABROE pressure and temperature transducers as well as position transmitters on the com pressor On single stage reciprocating com pressors three pressure and three tempera ture transducers are mounted while two stage reciprocating compressors are equipped with four pressure and tempera ture transducers Screw compressors are fitted with four pres sure and three temperature transducers as well as one or two slide position transmit ters Furthermore a thermistor input is available for motor protection Factory Test Every UNISAB II is tested during the pro duction process and when it is mounted on the compressor A computer test is per formed including a test certificate before the compressor leaves the factory Please note that UNISAB II cannot directly combine the capacity of compressors with extended capacity control only SMC 104 can be controlled directly by UNISAB II when it is equipped with a simple box this has to be configured as a HPC 108 or SMC 108 81 342 Service manual SMC TSMC 100 Mk4 4 Technical Description Cooling of the Intermediate Discharge Gas on TSMC Compressors A
342. ut using a punch or mandrel 243 342 Service manual SMC TSMC 100 Mk4 13 Service Instructions Shaft seal Fig 13 13 777 10 1 10E 1 8 1 8 1 ANY A 8 1 YZ 8H 1 Ly 10F 1 2 8F 1 6 4 Ew ee 10G 1 55 10 1 8G 1 10H 1 10J 1 100 1 10A 1 10H 1 10 1 100 1 8G 1 10F 1 10G 1 8B 1 8H 1 8A 1 8C 1 ien 8F 1 244 342 0178 933 ENG Rev 2005 12 09 13 service instructions fm Service manual SMC TSMC 100 Mk4 13 Service Instructions The purpose of the shaft seal is to create a tight seal along the crankshaft between the inside of the compressor and the atmosphere It comprises a slide ring Pos 10E manufactured from special purpose cast iron which is secured to the crankshaft by means of the locking ring Pos 10H tightening flange Pos 10A and the four screws Pos 10J with spring washers Pos 10K The carbon slide ring Pos 10F is pressed against the flat machined lapped slide ring at the end of Pos 10E by a series of springs Pos 10B The car bon slide ring is prevented from rotating by means of the retention pin Pos 8H The spring pressure combined with the flat lapped faces of the two slide rings ensures an optimal seal between the faces either when rotat ing or stationary It is recommended to exercise great care with the lap
343. which can be blocked by means of solenoid valve pos 98G is used to lower the pressure in the pump vessel pos 98 This is part of the pumping cycle 0178 933 ENG Rev 2005 12 09 98 98 x SABROE from the oil bath in the crankcase The cooling cover is equipped with cooling fins in order to en sure a proper thermal contact with the oil Connection pos B emerges from the plant receiver or the priority tank will be de scribed later and goes right to the valve block pos 80 Connection pos C is connected to the bot tom of the pump vessel pos 98 as well as to the top covers and the oil cooler pos 98T through a number of nozzles pos 98M 95 342 Service manual SMC TSMC 100 Mk4 4 Technical Description Fig 4 72 SMC 108 96 342 Filling and evacuation of the pump vessel is con trolled by two level sensors pos 98C Fig 4 71 By means of the control box pos 98B the sen sors control the solenoid valves pos 98G and pos 98H so that they open and close simultane ously The thermo pump is safeguarded by the following systems as shown in Fig 4 71 Fig 4 72 and Fig 4 73 a A thermostat built into the control box pos 98B with sensors pos 98X fitted on the com pressor discharge pipe The thermostat is factory set to start up the thermo pump once the discharge gas tem perature is above 80 C 176 F An
344. with lig uid slugging for a short time only If liquid slugging occurs the sound of hard metal hammering the compressor must be stopped and the cause must be removed Connecting rod pos 17 Fig 4 6 is made of duc tile cast iron It has replaceable slide bearings pos 17A and B at both ends on single stage com pressors and on the first stage LP on TSMC On 0178 933 ENG Rev 2005 12 09 SABROE the second stage HP on TSMC the small end bearing is of the rolling element type The reason for this is that the top of the HP pistons are affected by the intermediate pressure which is higher than the suction pressure and thus gives a downward force during suction This is different from the top of the LP pistons which are affected by a pressure lower than the suction pressure which gives the piston an upward force during suction Fig 4 6 Connecting Rod SMC 100 17B TSMC HP 17B SMC and TSMC LP Suction filter All the compressors are equipped with very large built in suction filters pos 34A Fig 4 7 with great filtering capacity which effec tively filters off the dirt particles conveyed with the gas from the refrigeration plant to the compressor The suction filters are made of stainless steel and by dismantling the covers pos 34E they are easy to pull out and clean 37 342 Service manual SMC TSMC 100 Mk4 4 Technical Description When a compressor is delivered a fine meshed
345. y and suitability of their oils for specific purposes Oils tested and approved by Sabroe Refrigeration are included in the List of Part Numbers for Available Sabroe Oils 4 Oil Types Oil Company PAO AP E Aral Castrol Chevron UK Gulf Oil CPI Engineering Services Elf Lub Marine 1 Esso Exxon Fina FuchsDEA Hydro Texaco Kuwait Petroleum Q8 Mobil Petro Canada Shell Statoil Sun Oil 194 342 0178 933 ENG Rev 2005 12 09 09 settings fm Service manual SMC TSMC 100 Mk4 9 Settings 9 Settings The purpose of this chapter is to provide informa tion about the factory settings of the safety and control equipment how to change the settings and the effect of a change This chapter is primarily intended for installation and service engineers Safety Precautions Danger Risk of injury to personnel and damage to equip ment In addition to the safety precautions in this chapter always read the safety precautions be longing to this equipment before changing the set tings Failure to comply with safety precautions may cause death or injury to personnel It may also cause damage to or destruction of the equip ment Qualification Requirements Changes in the factory settings must only be car ried out by an authorised refrigeration company 0178 933 ENG Rev
346. y will decompose to produce poisonous chem icals These have a very pungent odour and will thus warn personnel of their presence At high concentrations R717 causes respiratory problems When the amount of ammonia vapour in air is between 15 and 28 vol the combination is explosive and can be ignited by an electric spark or open flame Oil vapour in the ammonia vapour increases this risk significantly as the point of ignition falls below that of the mixture ratio stated Usually the strong smell of ammonia will warn personnel before the concentration becomes dangerous The following table shows the values for the max permissible refrigerant content in air measured in volume Certain countries may however have official limits different from the ones stated Halogenated refrigerants Ein CO HFC HCFC R134a R404A R407C R410A R507 R22 R717 R744 TWA Unit 4 01 04 01 0 1 0 005 05 a week Vol Warning smell Vol 0 2 0 002 26 342 0178 933 ENG Rev 2005 12 09 03 safety precautions fm Service manual SMC TSMC 100 Mk4 3 Safety Precautions Furthermore it can be said about refrigerants HFC HCFC If released into the atmosphere halogenat ed refrigerants of the types CFC and HCFC e g R22 will contribute to the depletion of the ozone layer in the stratosphere The ozone layer protects the earth from the ul traviolet rays of the su

WDanger - coldfrio.com.br

Contents

Download Pdf Manuals

Related Search

Related Contents