04.

02

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

The CMO/TCMO-type piston compressor can instruction manual, even if they are not fea-
be fitted with a range of equipment, depend- tured on your particular unit.
ing on the function and requirements it is
The variants featured on the unit are marked
called on to meet.
with an ’x’ in the following diagram, with the
Some of these variants are discussed in this serial number stated below.
Compressor type
Designation
Serial number

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

UNISAB II Control- and regulating system
Control
Analogous control system
Water cooled top and side covers
Thermopump
Compressor Air-cooled top covers and water-cooled side covers
cooling
Air-cooled top- and side covers + oil-cooling
Air-cooled top- and side covers
Coupling
Drive type
V-belts
Explosion-proof electrical design
Additional suction filter
With capacity regulation system
Capacity regulation
Without capacity regulation system
Oil return on parallel systems
With solenoid valve controlled oil return
Oil separator
With float valve controlled oil return
Compressor used for air conditioning

Intermediate With internal intermediate cooling system

cooling system With external intermediate cooling system

0171-370-EN 1
Preface

The aim of this instruction manual is to pro- this instruction manual to ensure a safe, reli-
vide the operators with a thorough knowl- able and efficient operation of the product as
edge of the compressor and the unit and at Sabroe Refrigeration is unable to provide a
the same time provide information about: guarantee against damage of the product oc-
curring during the warranty period as a
S the function and maintenance of the indi-
result of incorrect operation.
vidual components;
Dismantling and assembly of compressors
S service schedules;
and components should only be carried out
S procedure for dismantling and reassem- by authorized personnel to prevent
bling of the compressor. accidents.

This instruction manual draws attention to The contents of this instruction manual must

00.07
typical errors which may occur during opera- not be copied or passed on to any unautho-
tions. The manual states causes of error and rized person without Sabroe
explains what should be done to rectify the Refrigeration’s permission.

0171-500-EN
errors in question.
Sabroe Refrigeration’s General Conditions
It is imperative that the operators familiarize for the Supply of Components and Spare
themselves thoroughly with the contents of Parts will apply.

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

2 0171-370-EN
Contents

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

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Description of compressor CMO 24-26-28 & TCMO 28 Mk 2 . . . . . . . . . . . . . . . . . . . . . . 6
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Reciprocating compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
General safety instructions and considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Handling of the compressor, areas of application,
safety equipment and symbols, safety at servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Safety equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Safety symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
First Aid for accidents with Ammonia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
First aid for accidents with HFC/HCFC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Protecting the operator as well as the environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Sound data for compressor units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Vibration Data for Compressors - All Compressor Types . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Compressor data for reciprocating compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Operating limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
General operating instructions for
CMO/TCMO, SMC/TSMC reciprocating compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Starting up compressor and plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Stopping and starting-up compressor during a short period of standstill . . . . . . . . . . . . . 40
Stopping plant for brief periods (until 2-3 days) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Stopping plant for lengthy periods (more than 2-3 days) . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Automatic plants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Pressure testing refrigeration plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Pumping down refrigeration plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Operating log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Servicing the reciprocating compressor Reciprocating compressors . . . . . . . . . . . . . . . . 45
Pressure drop test: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Removing refrigerant from compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Lubricating oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Lubricating oil requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
General rules for use of lubricating oil in refrigeration compressors . . . . . . . . . . . . . . . . . 50
Instructions for choosing lubricating oil for refrigeration compressors . . . . . . . . . . . . . . . 50
Charging refrigeration compressor with lubricating oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Changing oil in refrigeration compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

0171-370-EN 3
Charging the compressor with oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Assessing the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Visual assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Analytical evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Pressure and temperature settings for SABROE compressor . . . . . . . . . . . . . . . . . . . . . 57
Expected discharge gas temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Servicing the Refrigeration Plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Maintenance of reciprocating compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Pump-down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
1. If the compressor is operational . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2. If the compressor is inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Top covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Discharge valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Cylinder lining with suction valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Main bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
By-pass valve pos. 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Suction filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Cleaning of extra suction filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Stop valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Compressor lubricating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Oil pressure valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Capacity regulation and unloaded start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Capacity stages and regulating sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Pilot solenoid valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
The TCMO 28 compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
TCMO with capacity regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
TCMO without capacity regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Cooling of intermediate discharge gas on the TCMO 28 compressor . . . . . . . . . . . . . . . 90
Heating Rods, pos. 30, Element for Oil Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Stop valves pos. 23 and 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Sundry clearances and check dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Undersize Bearing Diameters for Crankshaft
Reciprocating Compressors with 4 to 8 Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Torque moments for screws and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

4 0171-370-EN
Refrigeration Plant Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Operational Reliability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Pumping down of Refrigeration Plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Dismantling of plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Tightness Testing and Pumping down of Refrigeration Plant . . . . . . . . . . . . . . . . . . . . . . . 98
Trouble-shooting on the Reciprocating Compressor Plant . . . . . . . . . . . . . . . . . . . . . . . . . 99
Remedying malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Selecting Lubricating Oil for SABROE Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Data Sheet for Listed Sabroe Oils
Typical data for lubricating oils for Sabroe compressors . . . . . . . . . . . . . . . . . . . . . . . . . . 117
List of Major Oil Companies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Alignment of unit, AMR coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Fitting and alignment of AMR-type coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Boring of motor flange for AMR coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
V-Belt Drive for CMO/TCMO Reciprocating Compressors . . . . . . . . . . . . . . . . . . . . . . . . . 148
Transmission Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Power Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Servicing and Alignment of the V-Belt Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Dismantling of the Belt Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Control of V-Belts and Belt Pulleys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Mounting and Adjusting of the V-Belt Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Mounting of the V-Belt Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Thermo pump cooling of R717 reciprocating compressors . . . . . . . . . . . . . . . . . . . . . . . . 157
Principle drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Oil return in parallel operation for reciprocating compressors . . . . . . . . . . . . . . . . . . . . . . 166
Refrigerant cooled oil cooler for CMO reciprocating compressor . . . . . . . . . . . . . . . . . . . 169
Oil return to the compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Connections on CMO/HPO 24-26-28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Connections on TCMO 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Water cooling of the reciprocating compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Reciprocating compressors used for air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Cooling of intermediate gas on TCMO and TSMC 100 and 180 . . . . . . . . . . . . . . . . . . . . 186
Ordering Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Spare parts sets for compressors and units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Compressor block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Spare part set for Basic Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
List of parts for CMO/TCMO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0662-215
Tools for compressor CMO/TCMC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0662-147
Spare Parts drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0662-213/-217
Spare Parts drawing (in detail) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0662-212
Piping diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . order specific
Wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . order specific
Dimension sketch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . order specific
Cooling water diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . order specific
Foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . order specific
Positioning of vibration dampers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . order specific

0171-370-EN 5
Description of compressor
CMO 24-26-28 & TCMO 28 Mk 2

T0177142_0 V16

97.03
The CMO 2 is a reciprocating compressor Similarly, the name-plate indicates the com-
with several cylinders in the same block. pressor’s serial number, which is also
The first digit in the type number indicates stamped into the compressor housing at the

0171-351-EN
the stage of development of the compressor. top by the end cover facing away from cou-
The compressor comes in 4-, 6- and 8-cylin- pling/belt drive.
der versions, indicated by the last digit in the
Whenever contacting SABROE about the
type number.
compressor, its serial number should be
stated.
The TCMO 28 is a 8-cylinder version, which
compresses the gas in two stages, with 6 The pistons of the compressor have a diame-
low-pressure cylinders and 2 high-pressure ter of 70 mm and a stroke of 70 mm.
cylinders. The type can be determined by the
The pistons work in replaceable cylinder lin-
compressor’s name-plate which is located at
ings, inserted in the frame and located with
the bottom on one side of the compressor.
two cylinders under each top cover.
The suction valve, which is a ring plate valve,

SABROE is mounted at the very top of the cylinder lin-

ing. The discharge valve forms the top of the
AARHUS DENMARK cylinder and is kept in place by a powerful
Type Refrigerant safety spring. This spring allows the dis-
Shop no Year
charge valve to rise slightly by liquid strokes.
Max. speed r.p.m.
This prevents overloading of the connecting
Swept volume m3/h
Working pressure bar rod bearings.
Test pressure bar The crankshaft is embedded in slide bearings
Able to assimilate both radial and axial
T0177093_2
forces. The oil pressure for the bearings and

6 0171-370-EN
the capacity regulating system is supplied The TCMO 28 compressor is available with
from the gearwheel oil pump built into the either a built-in intermediate cooling system
compressor. or an external intermediate cooling system,
which may be seen from the table on page 1
At the shaft end, the crankshaft is equipped as well as from the description further on in
with a balanced shaft seal of the slide-ring this instruction manual.
type, consisting of a cast-iron ring rotating The compressor can be delivered without
with the crankshaft and a stationary spring-- capacity regulating functions but still with the
loaded carbon ring. start unloading function for totally unloaded
start-up.
As standard equipment the compressors
The capacity regulation is controlled by sole-
have a hydraulic capacity unloading system
noid valves, mounted in one of the compres-
that forces the suction valves open, thus pre-
sor side covers.
venting compression. This unloading system
is designed in such a way to ensure that the The following table shows the capacity
compressor always starts totally unloaded. stages at which the compressor can operate.

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

CMO 24 x x x x
CMO 26 x x x x
CMO 28 x x x x
TCMO 28 x x x x

0171-370-EN 7
Safety Precautions

Reciprocating compressors safety procedures are a vital part of their job.

Accident prevention must be one of the prin-
cipal objectives of the job regardless of what
WARNING activity is involved.
Read related safety precautions be-
Know and respect your machinery. Read and
fore operating this machine. Failure to
practice the prescribed safety and checking
follow safety instructions may result in
procedures. Make sure that everyone who
serious personal injury or death.
works for, with, or near you fully understands
and -- more importantly -- complies with the
following safety precautions and procedures
Important
when operating this machine.
The safety precautions for this Sabroe Re-
frigeration machine have been prepared to Observe and follow safety warnings on the
assist the operator, programmer and mainte- compressor/unit.
nance personnel in practicing good shop

98.03
safety procedures. Use safety protective equipment. Wear clear
approved eye or face protection as you work
Operator and maintenance personnel must when operating parts containing refrigerant.

0170-123-EN
read and understand these precautions com- Safety-toe shoes with slip-proof soles can
pletely before operating, setting up, running, help you avoid injury. Keep your protective
or performing maintenance on the machine. equipment in good condition.
These precautions are to be used as a guide
Never operate or service this equipment if
to supplement safety precautions and warn-
affected by alcohol, drugs or other sub-
ings in the following:
stances or conditions which decrease alert-
a. All other manuals pertaining to the ma- ness or judgement.
chine.
Work area safety
b. Local, plant, and shop safety rules and
Always keep your work area clean. Dirty
codes.
work areas with such hazards as oil, debris,
c. National safety laws and regulations. or water on the floor may cause someone to
fall to the floor, into the machine, or onto oth-
er objects resulting in serious personal injury.
General safety instructions and
considerations Make sure your work area is free of hazard-
ous obstructions and be aware of protruding
Personal safety
machine members.
Machine owners, operators, setup men,
maintenance, and service personnel must be Report unsafe working conditions to your su-
aware of the fact that constant day-to-day pervisor or safety department.

8 0171-370-EN
Tool safety Never exceed the safety rated capacity of
Always make sure that the hand tools are in cranes, slings, eyebolts, and other lifting
proper working condition. equipment. Follow standards and instructions
Remove hand tooling such as wrenches, applicable to any lifting equipment you use.
measuring equipment, hammers, and other
Before inserting an eyebolt, be certain that
miscellaneous parts from the machine im-
both the eyebolt and the hole have the same
mediately after usage.
size and type threads. To attain safe working
Lifting and carrying safety loads, at least 90% of the threaded portion of
a standard forged eyebolt must be engaged.
Contact Sabroe Refrigeration if you have any
questions or are not sure about the proper
procedures for lifting and carrying.
WARNING
Before lifting or carrying a compressor/unit or
other parts, determine the weight and size by Failure to follow safety instructions
referring to such things as tags, shipping on this page may result in serious
data, labels, marked information, or manuals. personal injury or death.

Use power hoists or other mechanical lifting

and carrying equipment for heavy, bulky, or Installation and relocation safety
hard to handle objects. Use hookup methods
Before lifting the compressor, unit or other
recommended by your safety department
parts of the plant consult the machine manu-
and know the signals for safely directing a
al or Sabroe Refrigeration for proper meth-
crane operator.
ods and procedures.
Never place any part of your body under a
suspended load or move a suspended load An electrician must read and understand the
over any part of another person’s body. Be- electrical schematics prior to connecting the
fore lifting, be certain that you have a safe machine to the power source. After connect-
spot for depositing the load. Never work on a ing the machine, test all aspects of the elec-
component while it is hanging from a crane trical system for proper functioning. Always
or other lifting mechanism. make sure the machine is grounded properly.
Place all selector switches in their OFF or
If in doubt as to the size or type of lifting
neutral (disengaged) position. The doors of
equipment, method, and procedures for lift-
the main electrical cabinet must be closed
ing, contact Sabroe Refrigeration before pro-
and the main disconnect switch must be in
ceeding to lift the compressor, motor, unit or
the OFF position after the power source
its components.
connection is complete.
Always inspect slings, chains, hoists, and
other lifting devices prior to use. Do not use When the compressor is installed, be sure
lifting devices found to be defective or ques- that the motors rotate in the proper indicated
tionable. direction.

0171-370-EN 9
 Never bypass or wire around any safety de-
WARNING vice.

Failure to follow safety instructions Keep all parts of your body off the compres-
on this page may result in serious sor/motor/unit during operation. Never lean
personal injury or death. on or reach over the compressor.

During operation, be attentive to the com-

Setup and operation safety pressor unit process. Excessive vibration,
Read and understand all the safety instruc- unusual sounds, etc., can indicate problems
tions before setting up, operating or servicing requiring your immediate attention.
this compressor. Assign only qualified per-
sonnel, instructed in safety and all machine Maintenance safety
functions, to operate or service this compres- Do not attempt to perform maintenance on
sor. the compressor unit until you read and un-
derstand all the safety instructions.
Operators and maintenance personnel must
carefully read, understand, and fully comply Assign only qualified service or maintenance
with all machine mounted warning and personnel trained by Sabroe Refrigeration
instruction plates. Do not paint over, alter, or to perform maintenance and repair work on
deface these plates or remove them from the the unit. They should consult the service
compressor/unit. Replace all plates which manual before attempting any service or re-
become illegible. Replacement plates can be pair work and when in doubt contact Sabroe
purchased from Sabroe Refrigeration. Refrigeration. Use only Sabroe Refrigeration
Safety guards, shields, barriers, covers, and replacement parts; others may impair the
protective devices must not be removed safety of the machine.
while the compressor/unit is operating. Before removing or opening any electrical
All safety features, disengagements, and in- enclosure, cover, plate, or door, be sure that
terlocks must be in place and functioning cor- the Main Disconnect Switch is in the OFF
rectly prior to operation of this equipment. position and the main fuses are dismantled.

10 0171-370-EN
If any tool is required to remove a guard, cov- disconnect is not locked, tag all start button
er, bracket, or any basic part of this compres- stations with a ”DO NOT START” tag. Ade-
sor, place the Main Disconnect Switch in the quate precautions, such as warning notices,
OFF position, lock it in the OFF position. or other equally effective means must be tak-
If possible, post a sign at the disconnect en to prevent electrical equipment from being
switch indicating that maintenance is being electrically activated when maintenance work
performed. is being performed.

When removing electrical equipment, place

Dismantle main fuses to the unit.
number or labeled tags on those wires not
marked. If wiring is replaced, be sure it is of
the same type, length, size, and has the
DANGER: same current carrying capacity.
HIGH VOLTAGE
Close and securely fasten all guards, shields,
Before working on any electrical cir- covers, plates, or doors before power is re-
cuits, turn the machine Main Dis- connected.
connect Device ”OFF” and lock it.
Dismantle the main fuses to the An electrial technician must analyse the elec-
compressor unit. trical system to determine the possible use of
Unless expressly stated in applica- power retaining devices such as capacitors.
ble Sabroe Refrigeration documen- Such power retaining devices must be dis-
tation or by appropriate Sabroe Re- connected, discharged, or made safe before
frigeration Field Service Represen- maintenance is performed.
tative, do NOT work with electrical
power ”ON”. If such express state- Working space around electrical equipment
ment or advice exists, working with must be clear of obstructions. Provide ade-
electrical power ”ON” should be quate illumination to allow for proper opera-
performed by a Sabroe Refrigera- tion and maintenance.
tion Field Service Representative.
The customer and subsequent Materials used with this product
transferees must determine that any Always use Sabroe Refrigeration original
other person performing work with spare parts.
electrical power ”ON” is trained and
technically qualified. Please, note the type of refrigerant on which
FAILURE TO FOLLOW THIS the compressor is operating and the precau-
INSTRUCTION MAY RESULT IN tions that you need to pay attention to as de-
DEATH OR SERIOUS PERSONAL scribed in the following sections:
SHOCK INJURY.

S First aid for accidents with Ammonia.

S First aid for accidents with HFC/HCFC.
Whenever maintenance is to be performed in S Protecting the operator as well as the en-
an area away from the disconnect and the vironment.

0171-370-EN 11
Handling of the compressor, areas of application,
safety equipment and symbols, safety at servicing

Direction of rotation The unit is lifted by catching the lifting eyes

In order to reduce the noise level from the welded onto the unit frame. These have been
clearly marked with red paint. The weight of
electric motors these are often executed with
the unit can be seen from the shipping docu-
specially shaped fan wings, thus determining
ments.
a particular direction of rotation.
During transportation and handling care
In case you yourself order a motor you should be taken not to damage any of the
should take into consideration whether the components, pipe or wiring connections.
motor is intended for direct coupling or for
belt drive of the compressor. Areas of application of the recipro-
cating compressors
The direction of rotation of the compressor
Compressor types:
for compressors CMO-TCMO and SMC-
BFO 3-4-5
TSMC is indicated by an arrow cast into the CMO-TCMO,
compressor cover, near the shaft seal. SMC 100-TSMC 100 Mk3, S, L, E
On the BFO compressors the direction of SMC 180-TSMC 180,
rotation is not indicated by an arrow but is HPO-HPC
standard as illustrated by the following Application
sketch:
In view of preventing any unintended applica-
tion of the compressor, which could cause
injuries to the operating staff or lead to tech-
nical damage, the compressors may only be
used for the following purposes:

The compressor may ONLY be used:

Seen towards shaft end
S As a refrigeration compressor with a num-
ber or revolutions and with operating limits
Handling of compressor and unit as indicated in this manual or according to
For lifting of the compressor the large models a written agreement with SABROE.
are equipped with a threaded hole for mount-
S With the following refrigerants:
ing of the lifting eye. As to the weight of the
R717 -- R221 -- R134a1 -- R404A1 -- R5071
compressor, this can be seen from the ship-
-- R6001 -- R600A1 -- R2901 -- LPG1
ping documents. 1) Exempted are the following compres-

sors:
WARNING SMC-TSMC 100 E (only R717)
HPO and HPC (only R717)
The compressor block alone may
All other types of gas may only be
be lifted in the lifting eye.
used following a written approval from
The same applies to the motor.
SABROE.

12 0171-370-EN
S As a heat pump: It should only be possible to set back the
emergency device by a deliberate act, and
-- BFO 3-4-5
this set back must not cause the compressor
CMO - TCMO and SMC - TSMC may to start operating. It should only make it pos-
be used with a max. discharge pressure sible to restart it.
of 25 bar.
Other demands to the emergency device:
-- HPO -- HPC may be used with a max.
S It must be possible to operate it by means
discharge pressure of 40 bar.
of an easily recognizable and visible
S In an explosion-prone environment, pro- manual handle, to which there is free ac-
vided the compressor is fitted with ap- cess.
proved explosion-proof equipment. S It must be able to stop any dangerous si-
tuation, which may occur, as quickly as
possible without this leading to any further
WARNING danger.

Combustion motors
The compressor must NOT be
If combustion motors are installed in rooms
used:
containing refrigeration machinery or rooms
S For evacuating the refrigera-
where there are pipes and components con-
tion plant of air and moisture,
taining refrigerant, you must make sure that
S For putting the refrigeration the combustion air for the motor is derived
plant under air pressure in
from an area in which there is no refrigerant
view of a pressure testing,
gas, in case of leakage.
S As an air compressor.
Failure to do so will involve a risk of the lubri-
cating oil from the combustion motor mixing
with the refrigerant; at worst, this may give
rise to corrosion and damage the motor.
Safety equipment

Emergency device Safety symbols

The compressor control system must be Before putting a compressor/unit into opera-
equipped with an emergency device. tion they must be provided with warning
signs corresponding to the actual design of
In case the compressor is delivered with a
compressor/unit and in accordance with the
SABROE control system this emergency de-
rules and regulations in force.
vice is found as an integrated part of the con-
trol. The CAUTION sign
The emergency device must be executed in A CAUTION tag is fixed on the compressor
a way to make it stay in its stopped position, like the one illustrated below. This sign im-
following a stop instruction, until it is deliber- poses upon the users to read the Safety Pre-
ately set back again. It must not be possible cautions section in the manual before han-
to block the emergency stop without a stop dling, operating or servicing the compressor
instruction being released. and unit.

0171-370-EN 13
 ”ON” should be performed by a Sabroe Re-
frigeration Field Service Representative. The
customer and subsequent transferees must
CAUTION determine that any other person performing
work with electrical power ”ON” is trained and
technically qualified.

WARNING
Before handling, installing, operating or
servicing the compressor and unit, read Failure to follow this instruction
the Safety Precautions section in the
may result in death or serious
Instruction Manual.
personal shock injury.
It is the responsibility of the operator or
his employer that the instruction manual
is always available. Explosion-proof electrical execution
This sign must not be removed nor be If the compressor is delivered in an explo-
damaged in any way. sion-proof electrical execution it will, further
to the SABROE name plate, be equipped
Antes de manejer, instalar, poner en mar- with an Ex-name plate like the one illus-
cha o dar servicio al compresor y la uni- trated below.
dad, leer la sección Precauciones de
seguridad en el Libro de Instrucciones.
Es respondabilidad del operarío o de su
patrón, que el libro de instrucciones
permanezca siempre al alcance de la
mano.
Esta señal no debe de ninguna manera
suprimirse o dañarse.
2516-297

T2516273_0
DANGER: The high voltage sign
The temperature of tangible surfaces
DANGER: When a compressor is working, the surfaces
HIGH VOLTAGE that are in contact with the warm discharge
gas also get warm. However, the temperatu-
re depends on which refrigerants and under
Before working on any electrical circuits, turn
which operating conditions the compressor
the machine Main Disconnect Device ”OFF” is working. Often, it exceeds 70°C which for
and lock it. Dismantle the main fuses to the metal surfaces may cause your skin to be
compressor unit. burnt even at a light touch.
Unless expressly stated in applicable Sabroe
Consequently, the compressors will be equip-
Refrigeration documentation or by appropri- ped with yellow warning signs informing
ate Sabroe Refrigeration Field Service Rep- you that pipes, vessels and machine parts
resentative, do NOT work with electrical po- close to the warning signs during operation
wer ”ON”. If such express statement or ad- are so hot that your skin may be burnt from 1
vice exists, working with electrical power second’s touch or longer.

14 0171-370-EN
 pressor and other parts of the refrigeration
plant.

S Make sure that the motor cannot start up

inadvertently. It is recommended to re-
move all main fuses.

S Switch off all electric components on the

compressor/unit before the dismantling.
Internal protection
S Make sure that there is neither overpres-
Compressor blocks and units are usually de-
sure nor any refrigerant in the part to be
livered without any refrigerant or oil content
dismantled. Close all necessary stop
in the crankcase.
valves.
In order to protect the compressors against S Use gloves and protective glasses and
internal corrosion, they are delivered eva- make sure to have a gas mask ready to
cuated of all athmospheric air and charged be used in connection with the current re-
with Nitrogen (N2) to an overpressure of frigerant.
0.2 bar.
S Use the prescribed tools and check that
In such cases a yellow label like the one they are properly maintained and in good
shown below are stuck on the compressor working condition. In explosion-proof
surface. areas use tools specially suited for this
specific purpose.

S On dismantling top covers attention

Påfyldt beskyttelsesgas N2
Charged with inert gas
Enthält Schutzgas 0,2 bar
should be paid to the very considerable
Chargé du gaz protecteur
Contiene gas protector
3 PSI spring force beneath the covers. When
1534-169
screws a are loosened the cover must lift
itself from the frame as described in the
instruction manual.
Safety at servicing
Springs
Top cover
WARNING
Read related safety precautions be-
fore operating this machine. Failure to •
follow safety instructions may result in
•
serious personal injury or death. •

Before dismantling a compressor or unit

attention should be paid to the following
S Before dismantling the side covers empty
points:
the crankcase of its oil content.
S Read related Safety Precautions section S Check that the heating rod in the crank-
in this manual before opening the com- case is de-energized.

0171-370-EN 15
First Aid for accidents with Ammonia
Chemical formula: NH3 - refrigerant no.: R717)

Inhalation
WARNING 1. Move affected personnel into fresh air im-
mediately, and loosen clothing restricting
No plant can ever be said to be
breathing.
too safe.
Safety is a way of life. 2. Call a doctor/ambulance with oxygen
equipment immediately
General 3. Keep the patient still and warmly wrapped
Ammonia is not a cumulative poison. It has a in blankets.
distinctive, pungent odour that even at very 4. If mouth and throat are burnt (freeze or
low, harmless concentrations is detectable by acid burn), let the conscious patient drink
most persons. Since ammonia is self-alarm- water, taking small mouthfuls.
ing, it serves at its own warning agent, so 5. If conscious and the mouth is not burnt,
that no person will voluntarily remain in con- give hot, sweet tea or coffee (never feed
centrations which are hazardous. Since am- an unconscious person).
monia is lighter than air, adequate ventilation
6. Oxygen may be administered, but only
is the best means of preventing an accu-
when authorized by a doctor.
mulation.
7. If breathing fails, apply artificial respira-
Experience has shown that ammonia is ex- tion.
tremely hard to ignite and under normal
conditions is a very stable compound. Under Eye injuries from liquid splashes or con-
extremely high, though limited concentra- centrated vapour
tions, ammonia can form ignitable mixtures 1. Force the eyelids open and rinse eyes im-
with air and oxygen, and should be treated mediately for at least 30 minutes with the
with respect. salt water solution just mentioned
2. Call a doctor immediately.
Basic rules for first aid
Skin burns from liquid splashes or con-
1. Call a doctor immediately.
centrated vapour
2. Be prepared: Keep an irrigation bottle
1. Wash immediately with large quantities of
available, containing a sterile isotonic
water and continue for at least 15 minutes,
(0.9%) NaCl-solution (salt water).
removing contaminated clothing carefully
3. A shower bath or water tank should be while washing.
available near all bulk installations with 2. Call a doctor immediately.
ammonia.
3. After washing, apply wet compresses
4. When applying first aid, the persons as- (wetted with a sterile isotonic (0.9%)
sisting should be duly protected to avoid NaCl-solution (salt water)) to affected
further injury. areas until medical advice is available.

16 0171-370-EN
First aid for accidents with HFC/HCFC
Refrigerant no.: R134a - R505A - R507 - R22, etc

2. Adrenalin or similar heart stimuli must not

WARNING be used.

No plant can ever be said to be Inhalation

too safe. 1. Move affected person into fresh air im-
Safety is a way of life.
mediately. Keep the patient still and warm
and loosen clothing restricting breathing.
General
2. If unconscious, call a doctor/ambulance
HFC/HCFC form colourless and invisible with oxygen equipment immediately.
gasses which are heavier than air and smell
faintly of chloroform at high concentrations 3. Give artificial respiration until a doctor au-
only. They are non-toxic, non-inflammable, thorizes other treatment.
non-explosive and non-corrosive under nor-
Eye injuries
mal operating conditions. When heated to
above approx. 300°C they break down into 1. Force eyelids open and rinse with a sterile
toxic, acid gas components, which are isotonic (0.9%) NaCl-solution (salt water)
strongly irritating and aggessive to nose, or pure running water continuously for 30
eyes and skin and generally corrosive. Be- minutes.
sides the obvious risk of unnoticeable, heavy 2. Contact a doctor, or get the patient to a
gases displacing the atmospheric oxygen, hospital immediately for medical advice.
inhalation of larger concentrations may have
an accumulating, anaesthetic effect which Skin injuries -- Freeze burns
may not be immediately apparent. 24 hours 1. Wash immediately with large quantities of
medical observation is, therefore, recom- luke warm water to reheat the skin.
mended. Continue for at least 15 minutes, removing
contaminated clothing carefully while
Basic rules for first aid washing.
1. When moving affected persons from low-
2. Treat exactly like heat burns and seek
lying or poorly ventilated rooms where
medical advice.
high gas concentrations are suspected,
the rescuer must be wearing a lifeline, and 3. Avoid direct contact with contaminated oil/
be under continuous observation from an refrigerant mixtures from electrically burnt-
assistant outside the room. out hermetic compressors.

0171-370-EN 17
Protecting the operator as well as the environment

High concentrations of refrigerant vapours

WARNING are suffocating when they displace air; if high
concentrations of refrigerant vapours are in-
No plant can ever be said to be haled they attack the human nerve system.
too safe.
Safety is a way of life. When halogenated gasses come into contact
with open flame or hot surfaces (over approx.
Increasing industrialisation threatens our en- 300°C) they decompose to produce poiso-
vironment. It is therefore absolutely impera- nous chemicals, which have a very pungent
tive that we protect nature against pollution. odour, warning you of their presence.

To this end, many countries have passed le- In high concentrations, R717 causes respira-
gislation in an effort to reduce pollution and tory problems, and when ammonia vapour
preserve the environment. These laws apply and air mix 15 to 28 vol. %, the combination
to all fields of industry, including refrigeration, is explosive and can be ignited by an electric
and must be complied with. spark or open flame.

Be especially careful with the following sub- Oil vapour in the ammonia vapour increases
stances: this risk significantly as the point of ignition
falls below that of the mixture ratio stated.
S refrigerants
S cooling media (brines etc) Usually the strong smell of ammonia will
give ample warning of its presence before
S lubricating oils.
concentrations become dangerous.
Refrigerants usually have a natural boiling
point which lies a good deal below 0°C. This The following table shows the values for refri-
means that liquid refrigerants can be extre- gerant content in air, measured in volume %.
mely harmful if they come into contact with Certain countries may, however, have an offi-
skin or eyes. cial limit which differs from those stated.

Halogenated refrigerants Ammonia

R134a R404A R507 R22 R717

Unit

TWA
Time weighted ave- vol.% 0,1 0,1 0,1 0,1 0,005
rage during a week

Warning smell vol.% 0,2 0,002

18 0171-370-EN
Further, it may be said about Halogenated refrigerants must never be
refrigerants: mixed. Nor must R717 ever be mixed with
halogenated refrigerants.
S If halogenated refrigerants are released
directly to the atmosphere they will break
Purging a refrigeration plant
down the ozone stratum in the strato-
If it is necessary to purge air from a refrige-
sphere. The ozone stratum protects the
ration plant, make sure you observe the follo-
earth from the ultraviolet rays of the sun.
wing:
Halogenated refrigerants must, therefore,
never be released to the atmosphere. Use S Refrigerants must not be released to the
a separate compressor to draw the refrig- atmosphere.
erant into the plant’s condenser/receiver
or into separate refrigerant cylinders. S When purging an R717 plant, use an ap-
proved air purger. The purged air must
S Most halogenated refrigerants are mis- pass through an open container of water
cible with oil. Oil drained from a refrigera- so that any R717 refrigerant remaining
tion plant will often contain significant can be absorbed. The water mixture must
amounts of refrigerant. Therefore, reduce be sent to an authorized incinerating plant.
the pressure in the vessel or compressor
as much as possible before draining the S Halogenated refrigerants can not be ab-
oil. sorbed by water. An approved air purger
must be fitted to the plant. This must be
S Ammonia is easily absorbed by water: checked regularly using a leak detector.
At 15°C, 1 litre of water can
absorb approx. 0,5 kg liquid Cooling media
ammonia (or approx. 700 litres Salt solutions (brines) of calcium chloride
ammonia vapour). (CaCl2) or sodium chloride (NaCl) are often
used.
S Even small amounts of ammonia in water
(2-5 mg per litre) are enough to wreak In recent years alcohol, glycol and halogena-
havoc with marine life if allowed to pollute ted compounds have been used in the brine
waterways and lakes. production.

S As ammonia is alkaline it will damage In general, all brines must be considered as

plant life if released to the atmosphere in harmful to nature and must be used with
large quantities. caution. Be very careful when charging or
purging a refrigeration plant.
Refrigerant evacuated from a refrigerant
plant shall be charged into refrigerant cylin- Never empty brines down a sewer or into
ders intended for this specific refrigerant. the environment.

If the refrigerant is not to be reused, return it The brine must be collected in suitable con-
to the supplier or to an authorized incinerat- tainers, clearly marked with the contents, and
ing plant. sent to an approved incinerating plant.

0171-370-EN 19
Lubricating oils -- alkyl benzene-based synthetic oil

Refrigeration compressors are lubricated by -- polyalphaolefine-based synthetic oil

one of the following oil types, depending on
-- glycol-based synthetic oil.
the refrigerant, plant type and operating con-
ditions. When you change the oil in the compressor
or drain oil from the refrigeration plant’s ves-
-- mineral oil sels, always collect the used oil in containers
marked “waste oil” and send them to an ap-
-- semi-synthetic oil proved incinerating plant.

NOTE
This instruction provides only general information. The owner of the refrigeration plant is
responsible for ensuring that all codes, regulations and industry standards are complied
with.

20 0171-370-EN
 Sound data for compressor units

In the following tables the noise data of the be calculated provided that the acoustic data
compressors is stated in: of the machine room is known.
-- A-weighted sound power level LW
For screw compressors the average values
(Sound Power Level)
are indicated in the tables for the following
-- A-weighted sound pressure level LP components.
(Sound Pressure level)
The values for LW constitute an average of a Dimension tolerances are :
large number of measurings on various units.
1 ±3 dB for SAB, SV and FV screw com-
The measurings have been carried out in ac-
pressors
cordance with ISO 9614-2.
±5 dB for SAB 283 L/E and SAB 355 L
The values are further stated as average screw compressors
02.07

sound pressure in a free field above a re-

flecting plane at a distance of 1 meter from
As to the reciprocating compressors the
a fictional frame around the unit. See fig. 1.
values are stated for the compressor block
0170-114--EN

Normally, the immediate sound pressure only. The dimensional values are stated for
lies between the LW and LP values and can 100% capacity.

Fig. 1.1

Fictional frame

Dimensional plane

Reflecting plane
1 meter 1 meter

0171-370-EN 21
Note the following, however: stated -- e.g. near the compressor and
motor.
S at part load or if the compressor works
S the acoustics is another factor that can
with a wrongly set Vi the sound level can
change the sound level in a room. Please
sometimes be a little higher than the one
note that the sound conditions of the site
indicated in the tables.
have not been included in the stated
S additional equipment such as heat ex- dimensional values.
changers, pipes, valves etc. as well as S by contacting Sabroe Refrigeration you
another motor type can increase the noise can have sound data calculated for other
level in the machine room. operating conditions.

S as already mentioned, the stated sound Tables for Noise Data

pressures are only average values above The following tables show the operating
a fictional frame around the noise source. conditions of the compressor during the
Thus, it is sometimes possible to measure noise measurements as well as the applied
higher values in local areas than the ones refrigerant.

22 0171-370-EN
RECIPROCATING COMPRESSORS Two-strage
Evaporating temperature = --35°C
One-stage
Condensing temperature = +35°C
Evaporating temperature = --15°C
Refrigerant = R22/R717
Condensing temperature = +35°C
Number of revolutions = 1450 o/min.
Refrigerant = R22/R717
Number of revolutions = 1450 o/min.
Compressor block LW LP

Compressor block LW LP TCMO 28 81 66

TSMC 108 S 95 79
CMO 24 84 69
TSMC 116 S 97 81
CMO 26 86 71
TSMC 108 L 96 80
CMO 28 87 72
TSMC 116 L 98 82
SMC 104 S 95 79
TSMC 108 E 96 80
SMC 106 S 96 80
TSMC 116 E 98 82
SMC 108 S 97 81
SMC 112 S 99 82
Evaporating temperature = --35°C
SMC 116 S 100 83
Condensing temperature = +35°C
SMC 104 L 96 80 Refrigerant = R22/R717
SMC 106 L 97 81 Number of revolutions = 900 o/min.
SMC 108 L 98 82
SMC 112 L 100 83 Compressor block LW LP
SMC 116 L 101 84
TSMC 188 100 82
SMC 104 E 96 80
SMC 106 E 97 81
SMC 108 E 98 82 Heat pump
SMC 112 E 100 83 Evaporating temperature = +20°C
SMC 116 E 101 84 Condensing temperature = +70°C
Refrigerant = R22/R717
Number of revolutions = 1450 o/min.
Evaporating temperature = --15°C
Condensing temperature = +35°C
Compressor block LW LP
Refrigerant = R22/R717
Number of revolutions = 900 o/min. HPO 24 91 76
HPO 26 93 78

Compressor block LW LP HPO 28 94 79

HPC 104 97 81
SMC 186 101 83
HPC 106 98 82
SMC 188 102 84
HPC 108 99 84

0171-370-EN 23
SCREW COMPRESSORS
Evaporating temperature = --15°C Evaporating temperature = --35°C
Condensing temperature = +35°C Condensing temperature = --5°C
Refrigerant = R22/R717 Refrigerant = R22/R717
Number of revolutions = 2950 o/min. Number of revolutions = 2950 o/min.
*Number of revolutions = 6000 o/min.
Compressor unit LW LP
Compressor block LW LP

SAB 110 SM 98 81 SAB 163 BM 106 88

SAB 110 SF 98 81 SAB 163 BF 110 92
SAB 110 LM 98 81
SAB 110 LF 98 81
SAB 110 SM Mk2 - -
SAB 110 SF Mk2 - -
SAB 110 LM Mk2 - -
SAB 110 LF Mk2 - -
SAB 110 LR* Mk2 - -
SAB 110 SR* Mk2 - -
SAB 128 M Mk3 100 82
SAB 128 F Mk3 104 86
SAB 128 R* Mk3 104 86
SAB 128 M Mk4 - -
SAB 128 F Mk4 - -
SAB 128 R* Mk4 - -
SAB 163 M Mk3 103 85
SAB 163 F Mk 3 105 87
SAB 163 R* Mk 3 105 87
SAB 163 M Mk4 - -
SAB 163 F Mk4 - -
SAB 163 R* Mk4 - -
SAB 202 SM 105 86
SAB 202 SF 106 87
SAB 202 LM 105 86
SAB 202 LF 107 88
SAB 283 L 107 87
SAB 283 E 108 88
SAB 355 L 109 89
SAB 81 103 84
SAB 83 104 85
SAB 85 105 86
SV 87 106 86
SV 89 108 87

24 0171-370-EN
 Vibration Data for Compressors - All Compressor Types
Vibration data for Sabroe Refrigeration’s Vibration data for Sabroe Refrigeration’s
Sabroe reciprocating compressors complies Sabroe screw compressors complies with:
with: the ISO 10816, standard, Part 6, ISO 10816 standard, part 1, Annex B,
Annex A, group 4, AB, which fixes max per- Class III, C, which fixes max permissible
missible operating vibrations at 17.8 mm/s. operating vibrations at 11.2 mm/s.
The measurements are made as illustrated in
the figure below (points A-D).
01.01
0170-115-EN

Pay attention to the following, however: -- motor and compressor have not been
aligned as described in the Instruction
S Motors comply with EN 60034-14 (CEI/ Manual.
IEC 34-14) Class N. -- the compressor runs at a wrong Vi ratio.
This applies to screw compressors.
S When placing the unit on vibration
-- the piping connections have been
dampers supplied by Sabroe Refrigeration
executed in a way that makes them force
(additional), the vibrations against the
pull or push powers on the compressor
foundation are reduced by: unit or transfer vibrations to the unit
caused by natural vibrations or con-
-- 85-95% for screw compressor units nected machinery.
-- 80% for recip. compressor units -- the vibration dampers have not been
fitted or loaded correctly as indicated in
S However, a higher vibration level may oc- the foundation drawing accompanying
cur if: with the order.

0171-370-EN 25
Compressor data for reciprocating compressor
CMO 4, CMO 24-28, TCMO 28, SMC 104-116,
TSMC 108-116, SMC 186-188, TSMC 188

Operating limits
SABROE prescribes operating limits within which the compressor and any additional equipment
must operate. These limits for R717, R22, R134a, R404A, R507 and R407C are shown in the
following tables, together with the main data for the compressor.
Bore Stroke Max/min Swept Weight
Compressor Number of Speed volume (max.)
type cylinders max RPM* compr. block
mm mm RPM m3/h kg
CMO 4 4 65 65 1800/900 93,2 200
CMO 24 4 70 70 1800/900 116 340
CMO 26 6 70 70 1800/900 175 380
CMO 28 8 70 70 1800/900 233 410
TCMO 28 2+6 70 70 1800/900 175 410

00.05
SMC 104S 4 100 80 1500/700 226 580
SMC 106S 6 100 80 1500/700 339 675
SMC 108S 8 100 80 1500/700 452 740

0171-476-EN
SMC 112S 12 100 80 1500/700 679 1250
SMC 116S 16 100 80 1500/700 905 1350
TSMC 108S 2+6 ♦ 100 80 1500/700 339 775
TSMC 116S 4+12 ♦ 100 80 1500/700 679 1400
SMC 104L 4 100 100 1500/700 283 580
SMC 106L 6 100 100 1500/700 424 675
SMC 108L 8 100 100 1500/700 565 740
SMC 112L 12 100 100 1500/700 848 1250
SMC 116L 16 100 100 1500/700 1131 1350
TSMC 108L 2+6♦ 100 100 1500/700 424 775
TSMC 116L 4+12♦ 100 100 1500/700 757 1400
SMC 104E 4 100 120 1500/700 339 600
SMC 106E 6 100 120 1500/700 509 700
SMC 108E 8 100 120 1500/700 679 770
SMC 112E 12 100 120 1500/700 1018 1300
SMC 116E 16 100 120 1500/700 1357 1400
TSMC 108E 2+6♦ 100 120 1500/700 509 800
TSMC 116E 4+12♦ 100 120 1500/700 1018 1450
SMC 186 6 180 140 1000/450 1283 2560
SMC 188 8 180 140 1000/450 1710 2840
TSMC 188 2+6♦ 180 140 1000/450 1283 2900
✶ The maximum speed permitted can be lower than stated here depending on operating
conditions and refrigerant; please see the following diagrams.
♦ Two - stage compressors (High Stage cylinders and Low Stage cylinders)

26 0171-370-EN
 TC
°F °C

R717
140 60
Operating Limits
122 50
Single--Stage
104 40
1
4 Compressor Type
Condensing temperature

86 30
CMO & SMC
68 20
3
2
50 10

32 0 BOOSTER
OPERATION
14 --10

--4 --20

--22 --30
--60 --50 --40 --30 --20 --10 0 10 20 30 40 °C
TE
--76 --58 --40 --22 --4 14 32 50 68 86 104 °F
Evaporating temperature
T0111123_1 VIEW 2

rpm
TYPE AREA max. min. COOLING NOTE
1--2 Air cooled top-- and side covers # or water cooled
CMO20 1800 900
3--4 Thermopump or watercooled
1--2 Air cooled top-- and side covers # or water cooled
SMC100S/L 3 1500 700
Thermopump or watercooled
4 1
1 750
SMC180 450 Water cooled
2--3--4 1000

SMC 188: 840--920 RPM not allowed

# Included refrigerant cooled oilcooler.
Thermopump: Water cooled:
Top and side covers are cooled Top and side covers are
by injected refrigerant. water cooled.
Oilcooling is included in the system Oil cooling is included
For Booster: liquid supply at in the system
intermediate pressure

NB: Discharge temperature must not exceed 150°C at full or part load

Min. 50% capacity (101) Min 50°C suction super heat

0171-370-EN 27
 TC
°F °C

140 60
R717
Operating Limits
122 50
Single--Stage
104 40
2 Compressor Type
30
Condensing temperature

86
1
SMC100E
68 20

50 10

32 0 BOOSTER
OPERATION
14 --10

--4 --20

--22 --30

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

TE
--76 --58 --40 --22 --4 14 32 50 68 86 104 °F
Evaporating temperature
T0111140_0 view 6

rpm
TYPE AREA max. min. COOLING NOTE
1
SMC100E 1500 700 Thermopump or water cooled
2 1

Thermopump: Water cooled:

Top and side covers are cooled Top and side covers are
by injected refrigerant. water cooled.
Oilcooling is included in the system Oil cooling is included
For Booster: liquid supply at in the system
intermidiate pressure

NB: Discharge temperature must not exceed 160°C at full or part load

Min. 50% capacity (101) Min. 50°C suction super heat

28 0171-370-EN
 R717
TC
°F °C
158 70

140 60
Operating limits
122 50
two-stage
compressors
104 40 1
TCMO
Condensing temperature

2
86 30
TSMC 100 S-L-E
68 20 TSMC 180
50 10

32 0

14 --10

--4 --20

--22 --30
0177128_0 VIEW 3,1

--40 --40
--70 --60 --50 --40 --30 --20 --10 0 10 20 30 40 °C
TE
--94 --76 --58 --40 --22 --4 14 32 50 68 86 104 °F

Evaporating temperature

Type Area rpm Cooling Note

max min top and side
TCMO 1--2 1800 900 Thermopump or water-cooled
TSMC 100 1-2 1500 700 Thermopump or water-cooled 1)
S-L-E
1 750
TSMC 180 450 Water-cooled 1)
2 1000

Oil cooling is always necessary.

Thermopump: Part-load operation:
Only the HP Stage top covers are cooled 1)Depending on the operating conditions
by a thermo pump and the presure on the compressor a by-
Oil cooling included in the system pass system may be required.
Water-cooled:
Top- and side covers.
Oil cooling included in the system.

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

0171-370-EN 29
 TC

R22
°F °C
158 70

140 60 Operating Limits

122 50 1 Single stage
2
CMO & SMC
104 40

86 30
4

68 20
3
50 10

32 0

14 --10

--4 --20

--22 --30
--60 --50 --40 --30 --20 --10 0 10 20 30 40 °C
TE
--76 --58 --40 --22 --4 14 32 50 68 86 104 °F
T0111--127_0 view 2

rpm 1)
TYPE AREA max. min. OIL COOLING REQUIRED REMARKS
1 1500 No
2 1500 No
CMO20 900
3 1800 At less than 50% capacity
4 1800 yes
1 1000 No
2 1200 No
SMC100S 700
3 1800 At less than 50% capacity
4 1800 yes
1 2)
2 1000 No
SMC100L
3 1200 700 At less than 50% capacity
4 1200 yes
1--2 2)
SMC180 3 At less than 50% capacity
4 750 450 yes

Top covers: Air cooled only

1) When required there is a free choice between A or B
-- except SMC 180 where only A may be selected.
A: Water cooled side covers
B: Built in refrigerant cooled oil cooler with thermostaticexpansion valve
2) Not applicable

30 0171-370-EN
 TC
°F °C

140 60
R22
Condensing temperature

122 50
1
Operating Limits
104 40
2 two--Stage
86 30
3 Compressortype
68 20 TCMO & TSMC
50 10

32 0
--60 --50 --40 --30 --20 --10 0 °C
TE
--76 --58 --40 --22 --4 14 32 °F
Evaporating temperature
T0111139_0 view 1

rpm OIL COOLING

TYPE AREA 1) REMARKS
max. min. REQUIRED
1--2 1500
TCMO 3 900 no
1800
1 1000
TSMC100S 2 1200 700 yes 2)
3 1800
1 Not applicable
TSMC100L 2 1000 700 yes 2)
3 1200
1--2 Not applicable
TSMC180
3 750 450 yes 2)

Top covers: Air cooled only

1) When required there is a free choice between A or B
-- except SMC 180 where only A may be selected.
A: Water cooled side covers
B: Built in refrigerant cooled oil cooler with thermostatic
expansion valve
2) By--pass equipment required to maintain intermediate
temperature at minimum load.
(see price list specification)

0171-370-EN 31
 °F
TC
°C R134a
176 80 Operating limits
158 70
1
single stage
140 60
2 compressors
122 50
CMO
SMC 100 S-L
104 40
3
Condensing temperature

86 30

68 20

50 10

32 0

14 --10

--4 --20

--22 --30

--40 --40
--70 --60 --50 --40 --30 --20 --10 0 10 20 30 40 °C
T0177128_ V8,1

TE
--94 --76 --58 --40 --22 --4 14 32 50 68 86 104 °F
Evaporating temperature

Type Area rpm Oil-cooling Note

max min required 1)

1200 no
1-2
1500 At less than 50% capacity
CMO 900
1500 no
3
1800 At less than 50% capacity
1 1000 no
2 1200 no
SMC 100 S 700
1200 no
3
1500 At less than 50% capacity
1 Not applicable
2 1000 no
SMC 100 L
1000 700 no
3
1200 At less than 50% capacity

Top covers: Air-cooled design only. A: Water-cooled side covers

1) When oil cooling is required there is a B: Built-in refrigerant-cooled oil cooler with
free choice between A and B. thermostatic expansion valve.

32 0171-370-EN
 °F
158
TC
°C
70
R134a
1
Operating limits
140 60
2 two-stage
122 50
compressors
104 40 3 TCMO
TSMC 100 S-L
Condensing temperature

86 30

68 20

50 10

32 0

14 --10

--4 --20

--22 --30

--40 --40
--70 --60 --50 --40 --30 --20 --10 0 10 20 30 40 °C
TE
T0177128_0 V8,1

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

Evaporating temperature

Type Area rpm Oil-cooling Note

max min required 1)

1-2 1500 1)
TCMO 28 900
3 1800
1 1000
TSMC 2 1200 700 1) 2)
100 S
3 1500
1 Not applicable
TSMC 2 1000
100 L 700 1) 2)
3 1200

1) Oil cooling: 2) Part-load operation:

Not required. By-pass equipment required to maintain i
Top- and side covers: termediate temperature at minimum load.
Only air-cooled.

0171-370-EN 33
 °F
TC
°C R404A
140 60 Operating limits
122 50 single stage
1
compressors
104 40
CMO
Condensing temperature

86 30
SMC 100 S-L
68 20
2
50 10

32 0

14 --10

--4 --20

--22 --30
--70 --60 --50 --40 --30 --20 --10 0 10 20 30 °C
TE
274263.1 Rev. 0

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

Evaporating temperature

Type Area rpm Oil-cooling Note

max min required 1)

1200 no
1
1500 At less than 50% capacity
CMO 20 900
1500 no
2
1800 At less than 50% capacity
1 1000 no
SMC 100 S 1200 700 no
2
1500 At less than 50% capacity
1 1000 no
SMC 100 L 700
2 1200 no

Top covers: Air-cooled design only. A: Water-cooled side covers

1) When oil cooling is required there is a B: Built-in refrigerant-cooled oil cooler with
free choice between A and B. thermostatic expansion valve.

34 0171-370-EN
 °F
TC
°C R404A
140 60 Operating limits
two-stage
122 50
compressors
TCMO
Condensing temperature

104 40
1
TSMC 100 S-L
86 30

2
68 20

50 10

32 0

14 --10
--70 --60 --50 --40 --30 --20 --10 0 °C
TE
--94 --76 --58 --40 --22 --4 14 32 °F
274263.3 Rev. 0

Evaporating temperature

Type Area rpm Oil-cooling Note

max min required 1)

1 1)
TCMO 28 1800 900
2
TSMC 1 1200
700 1) 2)
100 S 2 1500

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

1) Oil cooling: 2) Part-load operation:

Not required. By-pass equipment required to maintain i
Top- and side covers: termediate temperature at minimum load.
Only air-cooled.

0171-370-EN 35
 °F
TC
°C R507
140 60 Operating limits
122 50 single stage
1
104 40
compressors
CMO
Condensing temperature

86 30
SMC 100 S-L
68 20
2
50 10

32 0

14 --10

--4 --20

--22 --30

--40 --40
--70 --60 --50 --40 --30 --20 --10 0 10 20 30 °C
TE
--94 --76 --58 --40 --22 --4 14 32 50 68 86 °F
274263.2 Rev. 0

Evaporating temperature

Type Area rpm Oil-cooling Note

max min required 1)
1200 no
1
1500 At less than 50% capacity
CMO 20 900
1500 no
2
1800 At less than 50% capacity
1200 no
1
SMC 100 S 1200 700 no
2 1500 At less than 50% capacity
1 1000 no
SMC 100 L 700
2 1200 no

Top covers: Air-cooled design only. A: Water-cooled side covers

1) When oil cooling is required there is a B: Built-in refrigerant-cooled oil cooler with
free choice between A and B. thermostatic expansion valve.

36 0171-370-EN
 R507
TC
°F °C
140 60
Operating limits
two-stage
122 50
compressors
TCMO
Condensing temperature

104 40
1
TSMC 100 S-L
86 30

2
68 20

50 10

32 0

14 --10
--70 --60 --50 --40 --30 --20 --10 0 °C
TE
274263.4 Rev. 0

--94 --76 --58 --40 --22 --4 14 32 °F

Evaporating temperature

Area rpm Oil-cooling Note

Type
max min required 1)
1 1)
TCMO 28 1800 900
2
TSMC 1 1200 1) 2)
700
100 S 2 1500
TSMC 1 1000 1) 2)
700
100 L 2 1200

1) Oil cooling: 2) Part-load operation:

Not required. By-pass equipment required to maintain i
Top- and side covers: termediate temperature at minimum load.
Only air-cooled.

0171-370-EN 37
 TC
R407C
°F °C Operating Limits
140 60
one-Stage
122 50
Compressor type
104 40 1 CMO & SMC
Condensing temperature

86 30
2
68 20
3
50 10

32 0

14 --10

--4 --20

--22 --30
--70 --60 --50 --40 --30 --20 --10 0 10 20 30 °C
TE
--94 --76 --58 --40 --22 --4 14 32 50 68 86 °F
Evaporating temperature
T245411_0 view 2

Type Area rpm Oil-cooling Note

max min required 1)
1 1500 no
CMO 2 900 At less than 50% capacity
1800
3 yes
1 1200 no
SMC 100 S 2 1500 700 At less than 50% capacity
3 1200 yes
1 1000 no
SMC 100 L 2 1200 700 At less than 50% capacity
SMC 100 L 3 1000 yes
SMC 1 NOT APPLICABLE
SMC 180 2 At less than 50% capacity
750 450
3 yes

Top covers: Air-cooled design only. A: Water-cooled side covers

1) When oil cooling is required there is a free
B: Built-in refrigerant-cooled oil cooler with
choice between A and B - However, for thermostatic expansion valve.
SMC 180 only A may be selected.

38 0171-370-EN
 General operating instructions for
CMO/TCMO, SMC/TSMC reciprocating compressors

Starting up compressor and plant For pre-lubrication use a clean new refriger-
ant machine oil of the same type as the
S Before the initial start-up of the compres-
one found in the compressor, and pump as
sor following a lengthy stand-still period of
follows:
several months, the compressor must be
prelubricated. Hereby, the bearings are Pump strokes w. Estimated
lubricated and the oil system filled up Compressor SABROEs oil quantity
type hand-operated
with oil before the compressor is set run- oil pump Liters
ning.
CMO
Carry out the prelubrication by connect- TCMO appr. 25 2.5
ing the oil pump to the prelubricating HPO
SMC 104
valve which in the more recent SMC- 106-108 appr. 35 3.5
TSMC-HPC compressors is connected to TSMC 108
96.06

HPC
the shaft seal housing pos. 6A and on the
CMO-TCMO-HPO to the cover pos. 86H SMC 112-116
appr. 45 4.5
TSMC 116
0171-461-EN

or 87K. As prelubricating pump we recom-

mend SABROE’s hand-operated oil pump SMC 186-188
TSMC 188 appr. 50 5.0
part no 3141-155, which is mounted as
shown in fig. 1.
S The heating rod in the crankcase must be
energized at least 6-8 hours before start-
ing up the compressor in order to boil any
Fig. 1 refrigerant out of the compressor oil. At
the same time, the suction check valve
To compressor must be open.
valve for prelubrication

S Check oil level in crankcase. The oil level

Gasket
Cap
must always be visible in the oil sight
Optional hand---
operated oilpump glass. See section: Charging the compres-
sor with oil.

S Start condenser cooling, brine pumps,

fans at air coolers as well as any com-
pressor cooling device.

S Check correct setting of safety auto-

matics on compressor.
T0177131_0 V15 S Open discharge stop valve at compressor.

S Set capacity regulator to minimum capa-

city.

0171-370-EN 39
S In order to avoid excessive pressure re- Stopping and starting-up com-
duction in the compressor on start--up, the pressor during a short period of
suction stop valve must be opened a few
standstill
turns, as there is otherwise a risk of oil
foaming in the crankcase. Before stopping the compressor, its capacity
must be reduced to the lowest capacity stage
S Open all other stop valves except for the for a few minutes, before it stops.
main valve in the liquid line and possible
During short periods of standstill, it is not
by-pass valves serving other purposes.
necessary to shut off the suction stop valve
and the discharge stop valve. The heating
S Check that the time relay 3K13 keeps the
rod must be energized.
solenoid valve in the oil return line closed
for 20-30 mins. after start-up of the com- If the compressor is cooled by means of cool-
pressor. ing water, the water flow must always be
stopped during periods of standstill.
S Start compressor motor and check suction This is normally done by means of a solenoid
and oil pressures. valve in the water inlet line to the compres-
sor.
S Carefully continue opening suction stop Connect the solenoid valve to the start/stop
valve to its full open position. relay of the compressor motor.

S Open main valve in liquid line. Compressor start-up must always take place
at the lowest capacity stage, after which ca-
S If the oil in the crankcase foams, or knock- pacity is increased stepwise at suitable inter-
ing noises are heard from the compressor vals, in order to avoid that a sudden exces-
because droplets of liquid are being fed in sive pressure reduction in the evaporation
with the suction gas, throttle suction stop system causes liquid hammering in the com-
valve immediately. pressor and oil foaming in the crankcase.

S The compressor is now operating. Stopping plant for brief periods

Increase capacity stepwise, allowing the
(until 2-3 days)
compressor to adjust to new conditions
before switching to next stage. S Shut off liquid supply to evaporators for a
Check carefully whether oil is foaming and few minutes before stopping the plant.
whether oil pressure is correct.
S Stop compressor and shut off suction and
discharge stop valves. Close valve in oil
S Check whether oil return from oil separa-
return.
tor is working. (Pay attention to any clog-
ging of filter and nozzle.) S Stop condenser cooling, pumps, fans and
The pipe should normally be warm. any compressor cooling.

S Do not leave plant for first 15 minutes after S Cut off power supply to both master and
start-up and never before it has stabilized. control currents.

40 0171-370-EN
Stopping plant for lengthy periods -- correct setting of safety automatics.
(more than 2-3 days)
S Shut off main valve after receiver and Pressure testing refrigeration plant
pump down evaporators. If necessary, ad- Before charging the plant with refrigerant, it
just low-pressure cut-out on unit to a lower must be pressure tested and pumped down.
pressure during evacuation.
Pressure test the plant with one of the follow-
S Allow temperature in evaporators to rise, ing:
then repeat evacuation.
S dry air - pressurized cylinders containing
S When suction pressure has been reduced dry atmospheric air may be used - but
to slightly over atmospheric, stop com- never oxygen cylinders;
pressor. Shut off suction and discharge
S air compressor for high pressure;
stop valves and close off stop valve in oil
return. S nitrogen.

S Shut off condenser cooling. If there is a

risk of freezing, draw off coolant. Important
The plant compressors must not be
S Cut off power supply to master and control used to pressurize the plant.
currents.
Water or other fluids must not be used
S Inspect receiver, condenser and pressure for pressure testing.
vessels as well as piping connections and
apparatus for leakage. If nitrogen is used, it is important to place a
reducing valve with a pressure gauge be-
tween the nitrogen cylinder and the plant.
Automatic plants
S Refrigeration plant should normally be put During pressure testing, it is important to en-
into operation as described in the Start-up sure that pressure transducers and other
section.Once started, switch over to auto- control equipment are not exposed to the
matic operation. testing pressure. The compressor stop
valves must also be closed during pressure
S Special instructions for automatic plant in testing.
question should be followed to the letter.
Plant safety valves must normally be blanked
S The following should be checked daily, off during pressure testing, as their opening
even on automatic plants: pressure is lower than the testing pressure.

-- correct oil charging,

Important
-- automatic oil return,
During this pressure testing, no person
-- correct oil pressure, should be allowed to be present in
rooms housing plant parts or in the vicin-
-- suction and condenser pressures, ity of the plant outside the rooms.
discharge pipe temperature,

0171-370-EN 41
S The entire unit must be pressure tested in atmospheric air and moisture. Evacuation
accordance with the local regulations for must be carried out on all types of refrigera-
pressure testing. tion plant, regardless of the type of refriger-
ant with which the plant is to be charged.
S The test pressure must never exceed the
disign pressure.
Observe that HCFC and HFC refrigerants
S If it is required that the compressor should mix only minimally with water, and it is there-
be pressure tested together with the unit fore necessary to effect evacuation of such
or with the plant, the testing pressure must systems with particular care.
not exceed:
For reciprocating compressors: The boiling point of a fluid is defined as the
HP side: 24 bar temperature at which the steam pressure
LP side: 17.5 bar equals atmospheric pressure. For water, the
boiling point is 100°C. Lowering the pressure
S Please observe that manometers, pres- also lowers the boiling point of the water.
sure controls, pressure transmitters and
other control equipment are not exposed The table sets out the boiling point of water
to testing pressure. at very low pressures:
S Afterwards, reduce pressure to 10 bar for
a period of 24 hours - as an initial tight-
Boiling point of At pressure
ness test - as a tightly sealed plant will water °C mm HG
maintain this pressure throughout the peri-
od. 5 6,63
10 9,14
During the tightness test, it is permitted to
15 12,73
enter the room and approach the plant.
20 17,80
S By way of a second tightness test, ex-
amine all welds, flange joints etc. for leak-
age by applying soapy water, while main- For evacuation, use a vacuum pump which
taining the 10 bar pressure. bleeds the plant of air and steam.

When pressure testing, compile a pressure The vacuum pump must be able to lower the
test report containing the following: pressure to approx. 0.1 mm Hg (mercury col-
S date of pressure testing, umn) and must be fitted with a gas ballast
valve. This valve should be used wherever
S person carrying out the test, possible to prevent water vapours condens-
ing in the vacuum pump.
S comments.

Important
Pumping down refrigeration plant
Never use the refrigeration compressor
Following pressure testing, the refrigeration to evacuate the plant.
plant must be evacuated in order to eliminate

42 0171-370-EN
For a satisfactorily performed evacuation, the S Blow dry air or nitrogen into system to a
final pressure must be lower than 5 mm Hg. pressure corresponding to atmospheric.
Attention is drawn to the fact that there may Never use OXYGEN cylinders.
be a risk of any water left in the refrigeration
S Repeat evacuation to reduce pressure to
plant freezing if ambient temperatures are
less than 5 mm Hg.
lower than 10°C. In such instances, it will be
necessary to supply heat to the component S Shut the vacuum pump off from refrigera-
surroundings, as ice evaporates with difficul- tion plant and check that the pressure
ty. does not rise for the next couple of hours.
If the system still contains water, this will
It is recommended to carry out evacuation as
evaporate and cause the pressure to rise,
follows:
thereby indicating unsatisfactory evacua-
S Evacuate to a pressure lower than 5 mm tion and necessitating a repetition of the
Hg. procedure.

0171-370-EN 43
Operating log This operating log should be kept at regular
intervals, thus providing important informa-
In order to keep tabs on the operating state tion about the cause of any undesired
of the refrigeration plant, it is recommended changes in the operating state.
that an operating log be kept. (See following page)

Observation Measuring point Measurement unit

Time Date and time

Suction pressure • Compressor pressure gauge
°C or bar
• UNISAB II Control
Discharge pressure • Compressor pressure gauge
°C or bar
• UNISAB II Control
Oil pressure • Compressor pressure gauge
bar
• UNISAB II Control
Oil temperature • UNISAB II Control °C

Suction gas temp. • Thermometer in suction pipe

immediately °C
before compressor
• UNISAB II Control
Discharge gas temp. • Thermometer in discharge pipe
immediately after compressor but
°C
before oil separator
• UNISAB II Control

Oil level in • Oil level sight glass Must be visible in oil

compressor in compressor sight glass
Recharding of oil on • See section on oil Number of litres
compressor charging
Compressor motor’s • Electrical panel
• UNISAB II (additional) Amps
consumption in amps.

At the same time, attention should be paid to the following:

(tick these off in the log, if you wish)
S whether the compressor’s cooling system is functioning correctly,
S whether any unusual noise is coming from the compressor,
S whether there are unusual vibrations in the compressor.

44 0171-370-EN
 Servicing the reciprocating compressor
Reciprocating compressors CMO/TCMO, SMC/TSMC
100 and SMC/TSMC 180

In order to ensure problem-free operation, it sure drop test is performed with the compres-
is advisable to carry out regular servicing to sor at standstill, as described below:
the refrigeration plant. In this section,
SABROE indicates some periodic services S Immediately after stopping compressor,
fixed on the basis of the number of operating read off pressure on discharge and suc-
hours from the first start-up or after over tion side of compressor.
hand of the compressor. S Close discharge stop valve quickly and,
from moment of closure, time how long it
The servicing schedules also depend on the
takes for pressure to drop on high pres-
speed of the compressor. If the compressor
sure side of compressor. Normally, the
is running at less than 1200 rpm, SABROE
pressure drop should not be more than 3
permits extended service intervals. However,
bar over a period of 5 minutes or so.
the compressor must always operate within
the speed recommended by SABROE. See If the pressure falls more quickly, this is
Description of compressor. Providing the due to internal leakage, which may occur:
99.05

compressor operates within the specified

pressures and temperatures and the pre- S where pressure valve ring plates are in
scribed periodic services are performed, the bad contact with their seats (Pos. 20C
0171-462-EN

compressor will have a long and efficient ser- against Pos. 20A and 19H);
vice life.
S with defective seal Pos. 19T; ( not CMO)

S The following must therefore be checked S with defective seal Pos. 19K;
daily:
Operating pressure, S because cylinder lining and top cover
Operating temperatures, have been tightened without long mount-
Oil level and pressure, ing stopper having been fitted. Cylinder
Abnormal noise and vibrations. lining is thus resting on rocker arms, Pos.
15A; (not CMO).
The actual operating conditions should be
S on safety valve, because valve cone does
entered in an operating log daily. See the Op-
not fit tightly against seat, or outer O-ring
erating log section.
Pos. 24B or inner O-ring Pos. 24C is de-
fective. (See Safety valve section.)
Pressure drop test: During pressure drop testing, pay attention to
Using the pressure drop test, it is possible to any piping connections to the discharge side
check the internal tightness of the compres- of the compressor, which may have an influ-
sor from discharge to suction side. The pres- ence on the test result.

0171-370-EN 45
Removing refrigerant from
compressor 42
Before the compressor can be dismantled,
the refrigerant must be removed from the
compressor, which can be done in the follow- Water
ing ways:
R717
1. Run compressor at lowest capacity stage
and throttle suction stop valve slowly until
Connect the purge valve Pos. 42 to a sealed,
completely closed.
empty vessel which in turn is connected to an
2. The compressor will then stop on the low open tank containing water.
pressure cut-out. This can be adjusted to The water will absorb the refrigerant, which
stop compressor at a pressure lower than can then be dispatched for proper destruc-
normal. tion. The moment the pressure is equalized,
the valve must be reclosed in order to pre-
3. Close discharge stop valve and other pip-
vent water being sucked back into the com-
ing connections to compressor.
pressor.
4. On HFC and HCFC compressors, remove
Note:
remaining refrigerant gas using a pump-
The following instructions apply to the
down compressor connected to purge val-
compressor only. Servicing of the refrig-
ve Pos. 42.
eration plant is described in a separate
section. Service the compressor motor ac-
42 cording to your own instructions. For the
various scheduled services, SABROE can
supply ready-made spare-part sets, which
it would be an advantage to have before
Evacuating pump carrying out the scheduled service.

R22 In the event that the compressor cannot op-

erate, start evacuation as described under pt.
S On the R717 compressor, adopt the fol- 3, and remember also to close the suction
lowing method: stop valve.

46 0171-370-EN
 Scheduled services

No. Operating Operating Activity

hours hours
< 1200 rpm > 1200 rpm
1.1 Remove and discard filter bag in suction filter.
Clean suction filter. Following major repair work or
in event of severe soiling of filter bag, it is recom-
1 75 50 mended that a new filter bag be fitted for another
period of 50 operating hours.
1.2 Check tension of driving belts.

2.1 Check or change oil. When changing oil, change oil

filter cartridge, too. See following section:
Assessing the oil.
2.2 Clean suction filter.
2.3 Check that following function correctly:
Solenoid valves
Compressor cooling
2 300 200 Thermopump
Safety automatics
Heating rod
V-belt drive.
2.4 Retighten external piping connections.
2.5 Check oil return system from oil separator.
2.6 Retighten coupling.

3.1 Check or change oil. When changing oil, change

oil filter cartridge, too. See following section:
Assessing the oil.
3.2 Clean suction filter.
3.3 Check that following function correctly:
Solenoid valves
Compressor cooling
Thermopump
Safety automaitcs
3 7500 5000 Heating rod
V-belt drive
Oil return system from oil separator.
3.4 For heat pump operation, inspect:
Valve seats
Cylinder linings
Pistons, gudgeon pins and gudgeon pin bearings
Piston and oil scraper rings.
Change suction and discharge valve ring plates.
3.5 Finish off with a pressure drop test.

0171-370-EN 47
 Operating Operating
No. hours hours Activity
< 1200 rpm > 1200 rpm

4.1 Check or change oil. When changing oil, change oil

filter cartridge, too. See following section: Assessing
the oil.
4.2 Clean suction filter.
4.3 Check following:
Solenoid valves
Oil cooling system
Water cooling system for any deposits and clogging
4 15000 10000 Thermopump
Safety automatics
Heating rod
V-belt drive
Coupling and alignment
Oil return system from oil separator
Valve seats
Cylinder linings
Pistons, gudgeon pins and gudgeon pin bearings
Piston and oil scraper rings
Unloading mechanism
Seal for tightness
4.4 Change:
Suction and discharge valve ring plates
V-belts
4.5 Finish off with a pressure drop test.

5.1 Check V-belt drive

5.2 For heat pump operation, inspect:
Valve seats
5 22500 15000 Cylinder linings
Pistons, gudgeon pins and gudgeon pin bearings
Piston and oil scraper rings.
Change:
Suction and discharge valve ring plates.

48 0171-370-EN
 Operating Operating
No. Hours Hours Activity
< 1200 rpm > 1200 rpm

6.1 Change compressor oil,

Change oil filter cartridge,
Clean crankcase.
6.2 Clean suction filter.
6.3 Check following:
Solenoid valves
Oil cooling system
Water cooling system for any deposits and clogging
Thermopump
6 30000 20000 Safety automatics
Heating rod
V-belt drive
Coupling and alignment
Valve seats
Cylinder linings
Pistons, gudgeon pins and gudgeon pin bearings
Piston and oil scraper rings
Unloading mechanism
Seal for tightness
Oil pump and drive
Check valves.
6.4 Change:
Suction and discharge valve ring plates
V-belts
Half-sections of bearing for connecting rod
(does not apply to CMO compressors)
6.5 Finish off with a pressure drop test.
7 37500 25000 As for service no. 5
8 45000 30000 As for service no. 4

9 52500 35000 As for service no. 3

10 60000 40000 Major overhaul; contact SABROE Refrigeration

Then repeat scheduled services from no. 3 inclusive.

0171-370-EN 49
Lubricating oil

Lubricating oil requirements S The refrigeration oil must be free of mois-

ture, which may give rise to operating mal-
Above all, the refrigerator oil must provide
functions and attacks of corrosion.
satisfactory lubrication of the compressor,
even at the relatively high temperatures oc- The oil should therefore be purchased in con-
curring during compression. It must be inca- tainers corresponding to the quantity to be
pable of coking at such high temperatures used for a single, or at most, two top-ups.
and must not precipitate solid constituents The oil containers must be kept carefully
such as paraffin or wax at the lowest occur- sealed. If all the oil in a container is not used
ring temperatures. The oil must not have any in one go, the container should be tightly
corrosive effect, whether alone or mixed with sealed and stored in a warm place to prevent
refrigerant. According to the oil companies the absorption of moisture.
the oils mentioned in the Oil Recommenda-
Note:
tion in this instruction manual comply with
It is inadvisable to reuse oil which has
these conditions. See section on Choice of
been drawn from a compressor or plant.
lubricating oils.
This oil will have absorbed moisture from
the air and may cause operating prob-
lems.
General rules for use of lubricating Always switch off the power to the heating
oil in refrigeration compressors rod before drawing off the oil.
S Only fresh, clean refrigeration machine oil If, after reading the above, any doubt exists
may be charged. Oil tapped from the as to the type of oil which has been used on
evaporator system in an ammonia plant your compressor, you are recommended to
must not be reused in the compressor. contact SABROE, rather than risk charging
with unsuitable oil.
S Use grade of oil originally prescribed for
compressor. Instructions for choosing
lubricating oil for refrigeration
S As far as possible, avoid mixing different
compressors
types of oil. Mixed oil is generally inferior
The instructions in Choice of lubricating oils
to the two original oils. Mixing various
offer more detailed guidelines for choosing
types of oil may give rise to formation of
the lubricating oil best suited to each individ-
sludge, which will lodge in valves and fil-
ual case on the basis of the anticipated oper-
ters.
ating conditions.
S If necessary to switch to another brand of
oil, this must be done at the same time as
Charging refrigeration compressor
completely changing the oil in the com- with lubricating oil
pressor and tapping off all oil from the re- Since all SABROE piston compressors are
frigeration plant. supplied with a special oil-charging valve on

50 0171-370-EN
the crankcase, refrigeration oil may be therefore, it is necessary to refill with re-
topped up while the compressor is in opera- frigeration oil after starting up for the first
tion. time and after charging with fresh refriger-
ant.
For this purpose, use a manual oil pump or
adopt the following procedure: For a while after the plant is started for the
first time, keep an extra sharp eye on the oil
Note: level in the compressor, therefore.
When charging for the first time, use the
oil pump; it goes without saying that the
Changing oil in refrigeration com-
compressor must not be started unless
already charged with oil. pressor
S Cut off power to heating rod.
S Reduce pressure in crankcase, e.g. by
throttling suction stop valve, until suction S Close compressor stop valves and valve
pressure gauge shows pressure slightly in oil return line from oil separator.
below atmospheric.
S Reduce pressure in compressor crank-
S Fill pipe connected to oil charging valve case to slightly above atmospheric by
with refrigerator oil and insert free end of throttling suction stop valve while com-
pipe down into a receptacle containing pressor is running at its lowest capacity
fresh refrigerator oil. stage. Alternatively, raise to slightly above
atmospheric pressure by stopping com-
S Open oil charging valve carefully, thereby pressor and closing suction stop valve.
causing external air pressure to force oil Pressure in crankcase will then rise gradu-
into crankcase. ally.
S Avoid getting air or other impurities S Oil in the crankcase can then be forced
sucked into compressor. out through drain valve Pos. 23 when
compressor is at a standstill.
Note:
In order to achieve pressure below atmo- S Equalize pressure in compressor to atmo-
spheric, it will sometimes be necessary to spheric through purge valve pos. 42. See
reset the low-pressure cut-out so that the section on Environmental protection.
compressor can aspirate down to this
S Dismantle side covers.
pressure. Remember to reset the pressure
cut-out to its normal setting after charging S Replace oil filter cartridge with a new one.
with oil.
S Clean crankcase thoroughly, wiping with a
When in operation, the compressor may be clean, dry linen cloth (not cotton waste).
refilled with oil using the manual oil pump.
S Reassemble side covers.
Note:
S Charge to correct level with fresh, clean
Since halocarbon refrigerants such as
refrigerator oil according to SABROE’s oil
R22 mix with refrigeration oils, there will
recommendations.
always be a good portion of oil blended
with the refrigerant in the plant. Often, S Connect heating cartridge.

0171-370-EN 51
S Connect vacuum pump to compressor and 42 is open. See section on Environmental
pump down to 5-7 mm Hg; close off con- protection, however. When smelling R717,
nection. close purge valve.

Then open suction stop valve a few turns,

filling compressor with refrigerant gas. In S Open discharge stop valve and valve in oil
the case of R717, it will suffice to blast the return line; compressor is then ready for
compressor through by carefully opening start-up as described in section
suction stop valve while purge valve Pos. General operating instructions.

52 0171-370-EN
Charging the compressor with oil

Compressor Volume of oil The oil level must be checked with extreme
in crankcase care, particularly when starting and charging
Type Size
Litres with refrigerant.
3 1,5 The oil level must always be visible in the
BFO 4 4
oil level sight glass. The below table illus-
5 5
trates, how many litres of oil a drop in the
24 14 oil level of 10 mm is approximately equal
CMO 26 16 to.
TCMO 28 18
4 13

104 26
SMC 100 106 28
TSMC 100 108 30
Mk 3 112 47
S-L-E
116 50

SMC 180 186 80

TSMC 180 188 90
T0177162_0

The volume of oil stated in the table is the Compressor 10 millimeter

amount which must always be present in the type size difference in
oil levels equals
crankcase. CMO/ 24
26 ~1 litre of oil
TCMO 28
As a rule, the compressor should be charged
with oil after the plant is started for the first 104
SMC / 106 ~2 litres of oil
time, as some of the oil -- especially on an 108
TSMC
HCFC installation -- will be absorbed by the
100 112
refrigerant in the plant. 116 ~6 litres of oil
S-L-E
SMC /
The following determinants decide the total 186
TSMC 188 ~6 litres of oil
volume of oil a refrigeration plant should con- 180
tain:
Assessing the oil
S type of refrigerant
Refrigeration machine oil is a vital part of the
compressor, as it not only lubricates and
S refrigerant charge (volume)
cools the movable parts of the compressor, it
also prevents abrasive particles from en-
S size of plant
tering the bearings.
S temperature range in which refrigeration An analysis of the oil can give important in-
plant is to operate. formation on how the compressor is running.

0171-370-EN 53
We would, therefore, advise that the oil anal- As a special offer to our customers
yses be carried out at the intervals prescri- SABROE has developed an analytical con-
bed. cept, which is able to analyse all oil makes.
This will mean a uniform reporting of the re-
An oil sample must be drawn off while the
sults.
compressor is in operation, which gives a
representative sample. Before taking the
The analysis allows the following to be deter-
sample, clean the drain valve and tap a little
mined:
oil off, to prevent any impurities which may
have accumulated in the valve or the piping S Whether or not the oil is still usable, if nec-
from mixing with the sample. essary after filtering.

Visual assessment S Whether solid particles possibly present in

If you pour the sample into a clean, transpar- the oil originate from the bearings or other
ent glass bottle or a test-tube and hold it up components exposed to wear and tear in
to a clear light source, it will be easy to as- which case the compressor must be in-
sess the quality. You can also compare the spected.
sample with the fresh oil of the same make
and grade. S Each report will include the corresponding
measuring results from the previous 3 oil
An oil which you approve on the grounds of a analyses. In this way you will be able to
visual assessment must: follow up on the state of both the oil and
S be clear and shiny the compressor from one analysis to the
next.
S not contain any visible particles

S feel viscous, smooth and greasy when a

drop is rubbed between two fingers. Procedure

If you don’t feel that you can approve the oil S A form set with a plastic sampling bottle
by visual assessment, charge with new oil or and a dispatching envelope can be re-
send a sample to a laboratory for analysis. quested from the local Sabroe Refrigera-
tion representation.
Warning
If the oil sample is poured into a glass bottle, S The oil sample must be drained from the
this must not be hermetically sealed until all cleaned oil drain valve into the sample
the refrigerant in the oil sample has evapora-
bottle. Screw the lid loosely on and let the
ted. Refrigerant in the oil may produce ex-
cess pressure in the bottle with subsequent bottle stand for a few hours to enable re-
risks of explosion. Never fill a bottle up com- frigerant contained in the oil sample to
pletely. Do not send glass bottles through evaporate before sending it to the labora-
the postal service -- use purpose-made plas-
tic bottles. Please see below. tory.

S Please follow the Sampling and Shipping

Analytical evaluation Instructions enclosed in the form set in
Naturally, the oil sample can be analysed by which the addresses of the laboratory in
the oil company which supplies the oil. Holland are also mentioned.

54 0171-370-EN
The analysis the results of the analyses approach these
The following table states some average values. In some cases the water content of
values that can be applied in practice. How- 100 ppm in HCFC plants may be too much
ever, you should be on the alert whenever and thus lead to Cu--plating in the shaft seal.

Limiting values
Sabroe Oil PAO 68 Sabroe Oil AP 68 Sabroe Oil A 100
Parameter Unit Method Target Target Target
Spec. Max. Min. Spec. Max. Min. Spec. Max. Min.
Viscosity @ 40°C cSt ASTM D 445 66 76 53 64 74 51 100 115 80
TAN *1) mg KOH/g ASTM D 664 0.03 0.2 -- 0.01 0.2 -- 0.05 0.2 --
SAN * 2) mg KOH/g ASTM D 665 -- 0 -- -- 0 -- -- 0 --
Water ppm Karl Fisher -- 100 -- -- 100 -- -- 100 --
Appearance -- -- report report report
Colour -- ASTM D report report report
1500
Pentane Insolubles W% MM 490 -- 0.05 -- 0.05 -- -- 0.05 --
(5μm)
Oxidation abs/cm IR,1700-1720 -- 5 -- -- 5 -- -- 5 --
/cm
Nitration abs/cm IR,1627-1637 -- 5 -- -- 5 -- -- 5 --
/cm
Nitro Compounds abs/cm IR,1547-1557 -- 0.5 -- -- 0.5 -- -- 0.5 --
/cm

Maximum values for metal content in the oil

Lead ppm ICP -- 10 -- -- 10 -- -- 10 --

Copper ppm ICP -- 10 -- -- 10 -- -- 10 --
Silicium ppm ICP -- 25 -- -- 25 -- -- 25 --
Iron ppm ICP -- 100 -- -- 100 -- -- 100 --
Chromium ppm ICP -- 5 -- -- 5 -- -- 5 --
Aluminium ppm ICP -- 10 -- -- 10 -- -- 10 --
Tin ppm ICP -- 10 -- -- 10 -- -- 10 --

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

0171-370-EN 55
A report is drawn up for every sample re- through a 3 micron filter and back to the
ceived. This report indicates: unit. The system must be completely
closed, to prevent the oil being affected by
S Whether the oil can still be used -- without moisture in the air.
taking any further action.
S Whether the oil is no longer fit for use.
S Whether the oil can be used after it has
been filtered through a very fine filter. The report will always be sent to the address
stated on the sample label included in the
If this is necessary, the oil must be form set. A copy will be sent to SABROE Re-
pumped directly from the compressor unit frigeration, so that we are in a position to ad-
vise you, if required.

56 0171-370-EN
 Pressure and temperature settings for SABROE
compressor types SMC -TSMC and CMO - TCMO
Refrigerant

R404A
R134a

R507
R717
R22
24 bar (standard)
HP x x x x x
Safety valve 22 bar (special)
on the compressor
IP x x x x x 12 bar

High and intermediate KP 5 Set so that the compressor stops at a pres-

Safety equipment

cut-out x x x x x sure 2 bar lower than the safety valve set-

(KP15) ting.

KP 1 Set to a pressure with saturation temp. 5°K

Low-pressure
(KP15) x x x x x lower than the lowest evaporating temper-
cut-out ature.
96.04

Oil pressure cut-out MP 55 x x x x x 3,5 bar 1)

Discharge pipe x x x x * 120 ° C

0170-012-EN

thermostat KP 98
x * 150 ° C

Oil thermostat KP 98 x x x x x 80 ° C
Thermostat for KP 77 x x x x x 55 ° C
compressor cooling
Thermo valve for T(E) X Normally set at 4 ° C superheat.
compressor cooling T(E) Y x x x x Change to min. 10° C superheat
T(E) F
Control equipment

x x x x Factory set. 45 ° C See below.

TEAT
Injection valve for x x Factory set. ** 75 ° C See below.
intermediate cooling T(E) X x Adjust to min 10°C superheat
TEA x Adjust to min 10°C superheat

PMC + x
x x x -25 ° C
By-pass valve CVC x -15 ° C
Oil pressure x x x x x 4.5 bar 2)
regulating valve

* Factory setting - can be adjusted, if required, to a breaking point 20°C higher than the
highest normal discharge pipe temperature.
** For TCMO, R717 TEAT 20-2 spec., the factory setting is 85°C.
Adjust the TEAT valves so that the expected discharge pipe temperature (-5°C/+10°C) is achie-
ved at 100% compressor capacity.
Increase the opening temperature 10°C by turning the spindle 5 turns clockwise.
NB: Factory setting must always be increased by min. 10°C.
Adjustment of the TEAT valve must be carried out with the thermopump
out of operation
1) SMC - TSMC - CMO2 - TCMO2 3.5 bar 2) SMC - TSMC - CMO2 - TCMO2 4.5 bar
CMO4 0.8-1.2 bar CMO4 1.3 bar

0171-370-EN 57
58
HFC - HCFC

R134a R22 R404A/R507 R717

Evaporating temperature Evaporating temperature Evaporating temperature Evaporating temperature
or or or or
intermediate temperature intermediate temperature intermediate temperature intermediate temperature
C° C° C° C°

Condensing pressure bar

Condensing pressure bar
Condensing pressure bar

Condensing pressure bar

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

Suction gas superheat ° C

Condensing temp. ° C
20 5.7 38 41 43 48 55 8
8.2 37 48 61 76 91 11.0 40 42 46 53 62 7.6 53 71 91 110 131
25 6.6 44 45 48 52 59 9
9.5 47 57 69 84 101 12.5 44 47 51 58 67 9.1 65 83 102 121 142
30 7.7 49 50 53 58 66 11.
11.1 55 65 77 92 108 14.3 49 52 56 63 71 10.7 77 95 113 133 151
10 35 8.8 53 54 58 64 74 12.7 68 74 85 99 115 16.2 54 57 61 67 75 12.6 89 106 123 141 160
40 10.1 57 59 63 69 79 14
14.5 72 82 94 106 120 18.2 59 62 66 72 79 14.6 101 117 133 151 170
45 11.5 61 63 67 74 82 16.5 81 90 100 112 126 20.5 65 67 71 77 83 16.9 110 126 143 161 --
20 5.7 48 51 53 58 65 8
8.2 48 59 72 88 103 11.0 50 52 56 63 72 7.6 65 83 103 122 143
25 6.6 54 55 58 62 69 9
9.5 57 68 80 95 110 12.5 54 57 61 68 77 9.1 77 95 114 132 153

20 30 7.7 59 60 63 68 76 11
11.1 65 76 88 102 117 14.3 59 62 66 73 81 10.7 89 106 125 142 162
35 8.8 63 64 68 74 84 12
12.7 73 84 96 109 123 16.2 64 67 71 77 85 12.6 100 116 134 152 --
40 10.1 67 69 73 79 89 14
14.5 82 92 103 115 128 18.2 69 72 76 82 89 14.6 111 127 144 162 --
45 11.5 71 73 77 84 92 16
16.5 90 98 109 121 133 20.5 75 77 81 87 93 16.9 121 136 154 171 --
Expected discharge gas temperatures

20 5.7 58 61 63 68 75 8
8.2 59 70 83 97 113 11.0 60 62 66 73 82 7.6 78 96 115 134 153
25 6.6 64 65 68 72 79 9
9.5 69 78 91 105 120 12.5 64 67 71 78 87 9.1 90 106 126 144 163
30 7.7 69 70 73 78 86 11
11.1 75 86 98 111 125 14.3 69 72 76 83 91 10.7 102 118 136 154 --
30
35 8.8 73 74 78 84 94 12
12.7 84 95 106 118 131 16.2 74 76 81 87 95 12.6 112 128 146 163 --
40 10.1 77 79 83 89 99 14
14.5 92 101 111 123 135 18.2 79 82 86 92 99 14.6 123 138 155 -- --
45 11.5 81 83 87 94 102 16
16.5 99 108 117 128 139 20.5 85 87 91 97 103 16.9 132 148 165 -- --
Discharge gas temp.° C Discharge gas temp.° C Discharge gas temp.° C Discharge gas temp.° C

0171-370-EN
0170-105-EN 96.02
 Servicing the Refrigeration Plant

Both during start-up and operation it must be S the condenser pressure is not excessively
made sure that the plant is working correctly. high and

Compressor and condenser must be able to

work satisfactorily, safety devices must be S the plant works as it is supposed to.
intact and the evaporator must function under
load, ie: The service instructions outline some general
guidelines for servicing the refrigeration plant
S the desired temperatures are observed,
with some references to the instruction
S the oil pressure and discharge pipe tem- manual. The service instructions should
perature on the compressor are correct, therefore be read and followed carefully.
97.07

Check Interval Activity

0171-470-EN

Condensing pressure Excessively high pressure may be

due to:
• reduced cooling effect
Pressure • air in the condenser.
and temp. Too low condensing pressure
Daily
implies a risk of restricting the re-
frigerant supply to the evaporator.

Discharge pipe temperature Normal discharge pipe tempera-

ture according to instructions.

Filter in Accumulated dirt causes reduced

-- liquid line refrigerant supply to the evapor-
-- thermostatic valve Clean when ator.
Filters -- suction line required If a filter has a hot inflow and cold
-- oil return
discharge, this may be due to
clogging of the component.

Moisture in the sight glass Some installations are provided

(on HFC/HCFC installations) with a sight-glass featuring mois-
ture indicator. If the indicator co-
Dehumidi- lour switches from green to yel-
fier When re-
low, there is moisture in the re-
quired
frigerant.
Replace the drying filter regularly.

0171-370-EN 59
 Check Interval Activity

Refrigerant charge Inadequate charge results in re-

duced plant capacity and often
leads to an excessively high dis-
Refrigerant charge pipe temperature.

Periodically The plant must be searched reg-

Leak detection
ularly for leaks. Flanges and joints
settle during the initial operation
period of the plant. They must
therefore be tightened and
checked.

Automatic Safety pressure controls Adjust operating point and check

Automatic operating controls Periodically the function. Replace switch sys-
controls
Alarms tem if sticking.

Lubrication of electric mo- Clean and lubricate according to

tors supplier’s instructions. At tem-
peratures lower than -25°C, use
special lubricant.
Electric Periodically
motor Alignment of coupling Check in accordance with the in-
V belt drive structions of the instruction manual.
Tighten loose V belts or replace
with new ones.

Condenser Corrision Periodically Marine condensers are normally

-- normally protected against galvanic corro-
min. 4 sion by the mounting of corrosion
times a plugs in the condenser covers.
year
Metallic contact between corro-
sion plug and cover is essential to
proper functioning.

Frosting-up Unproblematic operation is condi-

When re- tional on the evaporator being
Evaporator quired kept free of ice. Defrost as and
when required.
Oil draining (ammonia plant) Check evaporator, intermediate
Periodically cooler, receiver, etc. for oil accu-
mulation. Exercise caution; use a
gas mask.

60 0171-370-EN
 Maintenance of reciprocating compressor
CMO 24-26-28 Mk2, TCMO 28 Mk2

General running on HFC/HCFC. An ammonia com-

When the compressor requires maintenance, pressor can stand having the pressure re-
it is important to follow the instructions given duced somewhat more quickly without the oil
below. In order to make sure that the com- foaming.
pressor is working correctly, the gauge Once the pressure is down to approx. 0.1
measurements and screw torques must be bar, stop the compressor and perform the
strictly adhered to. following steps in the order specified:
Before opening the compressor, it is expedi-
S Close suction stop valve.
ent to ensure that you have spares of those
seals and gaskets to be stripped down or dis- S Cut off power to compressor motor.
mantled. An O-ring which has been exposed S Close discharge stop valve.
to oil and heat for any length of time may S Draw off last remains of refrigerant gas
have expanded so much as to prevent it through purge valve Pos. 42.
98.07

being refitted.
S Having ensured that power to compressor
All seals used are resistant to oil, HFC/HCFC motor cannot be inadvertently connected,
0171-358-EN

and ammonia. All O-rings are made of neo- compressor is ready for opening.
prene rubber.
S Remove all fuses, if any.

Pump-down
2. If the compressor is inoperative
Before opening up the compressor for in-
S Leave heating rod in crankcase connected
spection, the pressure inside must be low-
for a couple of hours before compressor
ered to slightly above atmospheric. This can
is due to be opened in order to heat up oil.
be done in the following way, depending on
whether the compressor is operational or de- Warm oil does not contain as much re-
fective. frigerant.
S Suction stop valve must be open while
1. If the compressor is operational heating rod is connected.

Run the compressor at minimum capacity at S Keep discharge stop valve closed.
normal operating temperature. S Close suction stop valve and disconnect
Adjust the low-pressure cut-out so that the heating rod.
compressor stops at a suction pressure of S Equalize pressure in compressor through
approx. 0.1 bar. purge valve Pos. 42.
Throttle the suction stop valve very slowly. S Once pressure has been equalized to at-
Keep an eye on the suction pressure gauge. mospheric, compressor is ready for
opening. Remember to make sure that
The suction pressure must be lowered slowly
enough to give the refrigerant dissolved in power cannot be inadvertently connected,
the oil time to escape without the oil foaming. thereby starting the motor.
This is of great importance in compressors S Remove all fuses, if any.

0171-370-EN 61
Dismantling and assembly fitted. Pay attention to the powerful spring
The following sections describe the individual pressure under the top cover. After dismantl-
components. When dismantling and assem- ing of the two screws -- unscrew alternately --
bling, parts should generally be fitted in the the top cover can be removed.
same position from which they were taken,
Mounting of top cover
and should therefore be marked as they are
removed. Further, they should be thoroughly Check that gasket pos. 2B is intact and -- if
cleaned, checked and lubricated prior to necessary -- check that the clearance vol-
being reassembled. ume has been adjusted as described later in
this instruction.

Top covers If the gasket Pos. 2B needs to be replaced,

the graphitized side must face the com-
Dismantling of top cover
pressor frame. After placing the top cover
Loosen and dismantle screws Pos. 2C, how-
loosely on top of the springs pos. 21, it is rec-
ever with exception of the two screws shown
ommended that all screws be fitted by hand,
on drawing.
as the bolts will jointly guide the top cover
into position. Now tighten the top cover with
the two screws mentioned above, then with
the remaining ones.

Finally, cross-tighten all screws with the pre-

scribed torque in the following sequence:

7 1 3 5
T0177142_0 V9 11 9

12 10
8 4 2 6
Loosen these screws approx. 1 mm and
check that the cover lifts off the gasket.
But if the cover remains fastened to the
gasket, loosen it by a blow on the side with a
T0177142_0 V9
soft hammer while keeping the two screws

62 0171-370-EN
Discharge valve

Pos. 20
21

20F
20E
20D
20H

20C
20A
T0177142_0 V2

As shown in the drawing, the function of the Liquid strokes are heard as a distinct
discharge valve Pos. 20 is partly to allow the hammering in the compressor; the cause
compressed gas to pass from the compres- must be found immediately and the mal-
sion chamber of the cylinder to the discharge function corrected.
chamber beneath the top covers and partly to
create a seal from the discharge chamber to Discharge valve types:
the cylinder. Depending on which refrigerant the com-
pressor is operating on, various discharge
Furthermore, the discharge valve acts as a valves must be used in order to achieve opti-
safety device in the event of liquid refrigerant mum function.
passing the valve together with the discharge
gas, also called liquid stroke. Such strokes Marking
should normally not occur, as liquid cannot
All pressure valves supplied from SABROE
pass the valve as quickly as the compression
today are marked as described below and
gas. This produces a violent increase in pres-
shown in the sketch.
sure in the compression chamber.
Refrigerant R717:
In order to avoid pressure of such intensity All discharge valves are marked with one
as to damage the bearings in the com- groove.
pressor, the discharge valve is retained in
position by the safety spring Pos. 21, which Refrigerants HFC/HCFC:
allows it to lift a little bit under the strain of All discharge valves are marked with two
increased pressure. grooves.

0171-370-EN 63
 If necessary, exert counterpressure with 3
mm Allen key on bolt head.
S Fit spring guide Pos. 20F and tighten top
nut to same torque: 3,2 Kpm ≅ 31 Nm.

Leak testing of discharge valve

This is done by means of the pressure drop
test, as described elsewhere in this instruc-
tion manual. Please see list of contens.
Marked with
one groove for R717 Service life of discharge and
two grooves for HFC/HCFC
suction valves
In order to ensure that the compressor al-
Dismantling ways works perfectly, it is advisable - at suit-
S When top cover has been removed, spring able intervals - to replace the suction and dis-
Pos. 21 and discharge valve Pos. 20 can charge valve ring plates.
be lifted out by hand.
It is difficult to give altogether precise times
S Tighten discharge valve in a soft-jawed for such replacements, as the durability of
vice, then dismantle two nuts Pos. 20E the valve ring plates depends on the follow-
together with spring guide Pos. 20F. ing factors:
S Bolt Pos. 20D, discharge valve seat Pos. S If the compressor is exposed to liquid
20A and ring plate Pos. 20C can now be stroke or humid refrigerant gas, service
disassembled by hand. life is reduced.
S Remove valve springs Pos. 20H by hand.
S Speed of the compressor:
Assembling At 900 rpm, the service life of the valve
S Before assembling the discharge valve, ring plates is considerably longer than at
you must make sure that the valve springs 1500 rpm.
Pos. 20H are in good order and are firmly
S The compressor ratio at which the com-
fixed in their apertures.
pressor operates:
Assemble the discharge valve in reverse At high compression ratios, the load on
order to that described above. Note the fol- valve ring plates and springs is apprecia-
lowing, however: bly larger than at low compression ratios.

S Tighten bottom nut Pos. 20E to torque of When the valve ring plates are changed, the
3,2 Kpm ≅ 31 Nm. valve springs should also be replaced.

64 0171-370-EN
Cylinder lining with suction valve Pos. 19F to be removed from the cylinder
lining.
Marking of suction valve stop

Mounting suction valve

19J 19H 19K 19G 19K
Before reassembling the suction valve, you
must ensure that the valve springs Pos. 19G
are in good order and are positioned firmly in
their apertures.

1 groove for R717

Perform the assembly in reverse order to
2 grooves for HFC/HCFC
that described above. Note the following,
however:

T0177142_0 v1
S Before tightening screws 19J, ensure suc-
tion valve plate can be moved freely in its
In order to gain access to the cylinder lining guide. Tighten screws Pos. 19J to a
or suction valve, the top cover, spring Pos. torque of 7.6 Nm.
21, and discharge valve Pos. 20 need to be
Inserting cylinder lining
dismantled.
S Rotate crankshaft to position piston at top
The cylinder lining and suction valve form an dead centre.
integral unit and can be dismantled by re-
S Check that gasket Pos. 19K is in position
moving screws Pos. 19J.
on frame.
Extracting cylinder lining S Lubricate piston, piston rings and cylinder
S Rotate crankshaft to position relevant pis- face with clean refrigerating machine oil.
ton at top dead centre. Likewise, grease O-ring Pos. 19M on HP
cylinder of TCMO compressor with clean
S Fit the two T-shape extractors no. 3 from
refrigerant oil.
tool kit into threaded holes in guide ring
Pos. 19H. S Rotate piston rings on piston so as to
stagger ring gaps at 180° to each other.
S Carefully pull out cylinder lining with suc-
Press cylinder lining down over piston
tion valve, checking that gasket Pos. 19K
carefully. The chamfering on the cylinder
remains in frame.
interior will catch the piston rings and
S Insert protective plate no. 5 (from tool kit)
squeeze them to the diameter of the cylin-
between piston and frame so the piston
der. If possible, fit cylinder in same place
can rest on it. This makes it possible for
from which it was taken.
piston and piston rings to slide onto the
protective plate without being damaged S Press cylinder lining down by hand and
when the crankshaft is turned. without using rotating movements, how-
ever, it will not bear against gasket Pos.
Dismantling suction valve 19K until discharge valve pos. 20, safety
Dismantling the screws Pos. 19J enables the spring Pos. 21 and top cover have been
suction valve stop Pos. 19H and ring plate mounted.

0171-370-EN 65
S In order to be able to check the size of the Connecting rod
clearance volume. However, it is neces- Connecting rod Pos. 17 consists of a light
sary to press cylinder lining down against metal alloy which, besides its excellent
gasket Pos. 19K, using of 2 tightening strength properties, is also well-suited as
bars no. 1 to be mounted diagonally bearing material.
above the cylinder lining. To be used as
shown on the following drawing. Thus, the bearing surfaces of the connecting
rod work directly on the crankshaft and the
bearing surfaces of the gudgeon pin.

At the HP cylinder in the TCMO compressor

1 X a needle bearing Pos. 17K is fitted. The
needle bearing can -- in a vice or hydraulic
press -- be squeezed out from into the con-
necting rod. Apply soft jaws in the vice and
use tools that do not damage the parts.

As indicated in the parts lists the connecting

rods for the HP and LP stages each have
their own part number and can further be de-
19K T0177142_0 V3 livered with short measures on the big end
bearing, for use at repairs, if any. See section
on: Undersize bearing diameters for crank-
shaft.
S Using a depth gauge, measure the dis-
tance ”x” from discharge valve seat to the Fitting connecting rod
top of the piston, with this in its top posi-
Before fitting the connecting rod in the com-
tion.
pressor stand, piston and piston rings must
be fitted onto the connecting rod. See the fol-
The correct ”x” measure must be be-
lowing sections. In addition, the two connect-
tween:
ing rod bolts Pos. 17C must be fitted as
x min. = 0.8 mm
shown in the spare parts drawing.
x max. = 1.2 mm
S Introduce connecting rod down through
Adjustment of ”x” measure is done by insert- top cover opening in frame and guide into
ing one or more gaskets Pos. 19K which, as position on crankshaft manually. Take care
indicated in the parts lists, come in two sizes, so that connecting rod bolts do not leave
0.5 and 0.8 mm. marks in crankshaft journals.

Next, mount discharge valve Pos. 20, spring S Position connecting rod interior through
Pos. 21, and top cover. Before this, check lateral opening on frame, and fit nuts Pos.
gasket Pos. 2B. 17H.

66 0171-370-EN
Note: Assembling and stripping down piston
The two parts of the connecting rod are and connecting rod
numbered with the same number; this is
Adopt the following procedure when assem-
only of importance when assembling.
bling piston and connecting rod:
Parts with different numbers must not be
assembled and it is important that the
S Fit one of the circlips pos. 18E into bore
numbers are fitted in the same direction
reserved for piston pin.
as shown in Fig. 1.
S Heat piston to 70°C in oil or on hotplate.

Fig. 1 S Guide connection rod (TCMO - with in-

serted needle bearing) into place in the
Note: piston pin without using tools.
Stamped number on the same side
on assembly
S Fit the other circlip Pos. 18E.

Dismantling is done in opposite order. How-

916 916 ever, do not heat the piston, but press out the
piston pin using a punch.

T0177131_0 v2,b

Procedure for removing piston and con-

nection rod
S Tighten nuts Pos. 17H alternately with in-
creasing torque and finish off with torque S Bleed compressor of oil and refrigerant
wrench. and safeguard against any inadvertent
Torque: 20 Nm. start-up.

S Disconnect any water hoses and other

Piston
pipe connections to top and side covers.
The piston is made of aluminium and
equipped with a piston ring and an oil
scraper ring. S Dismantle top and side covers.

Fitting piston rings in piston S Remove spring Pos. 21, discharge valve
Before mounting the piston rings in the pis- and cylinder lining.
ton, their fit in the cylinder lining should be
checked by measuring the ring gap. See sec- S Remove nuts Pos. 17H; following this, the
tion entitled Various clearances and adjust- bottom part of the connecting rod can be
ment measurements. taken out by hand.
Note:
At the ring opening the oil scraper ring is S Piston and connecting rod can then be
marked TOP. This mark must face the pis- lifted out through the top cover opening on
ton top. the frame.

0171-370-EN 67
Shaft seal

Fig. 2
10H 10F 10C 10A 8E 8A 8H 8B 10D 8D 8C 16G

7A 10G 10B 10K

T0177142_0 V4

The purpose of the shaft seal is to create a

Pos. no. Shaft seal
tight seal along the crankshaft between the
inside of the compressor and the atmos-
7 A -1 Bearing cover
phere.
8 A -1 Shaft seal cover
8 B -1 O-ring dia. 98.02 x 3.53
8 C -1 Hexagon screw M8 x 30 It comprises a slide ring Pos. 10A, manufac-
8 D -1 Locking washer tured from special-purpose cast iron, which is
8 E -1 Circlip secured to the crankshaft by means of the
8 F -1 Retention pin
locking ring Pos. 10H, tightening flange Pos.
10 A -1 Slide ring (cast iron)
10 B -1 Slide ring (special carbon) 10F and the four screws Pos. 10G with
10 C -1 O-ring dia. 53.57 x 3.53 spring washers.
10 D -1 O-ring dia. 63.09 x 3.53
10 F -1 Tightening flange The carbon slide ring Pos. 10B is pressed
10 G -1 Allen screw M5 x 16
against the flat-machined, lapped slide ring at
10 H -1 Circlip
10 K -1 Spring
the end of Pos. 10A by a series of springs
16 G -1 Oil throw ring Pos. 10K, and the carbon slide ring is pre-
vented from rotating by means of the reten-
tion pin Pos. 8H.

68 0171-370-EN
The spring pressure, combined with the flat- 1.2. Dismantle shaft seal cover Pos. 8A by
lapped faces of the two slide rings, ensures alternately loosening bolts 8C so as to
an optimal seal between the faces, displace shaft seal cover outwards with-
both when rotating or stationary. out jiggling. This will avoid damage to
internal parts of the shaft seal.
1.3. Once the spring force is equalized and
It is recommended to exercise great care the bolts removed, the shaft seal cover
with the lapped slide surfaces. Even the can be taken off the shaft end by hand.
slightest scratch or other damage to the Take care so that no damage is done to
slide surfaces will result in leakage. the carbon slide ring Pos. 10B which
comes out with it.
1.4. The carbon slide ring Pos. 10B can be
The O-ring Pos. 10C creates a seal between
extracted by dismounting circlip pos. 8E
the slide ring Pos. 10A and the crankshaft.
as follows:
The O-ring Pos. 10D seals between the car-
Mount tool no. 2 as illustrated in fig. 3
bon slide ring Pos. 10B and the shaft seal
and tighten screw A so that the carbon
cover Pos. 8A.
slide ring does not touch the locking
ring.
When the shaft seal is operating, a tiny
Take care not to tighten screw A too
amount of oil drifts out between the slide
much as this could damage the car-
faces to lubricate them. An oil throw ring Pos.
bon ring.
16G has therefore been fitted to prevent this
oil migrating along the axle to the trans- Circlip pos. 8E is now easily extracted
mission linkage. by means of a screw driver without
damaging the slide surface of the car-
bon slide ring.
The oil splash ring ejects the oil into the
groove in the shaft seal cover Pos. 8A. Via After removing tool no. 2, the carbon
internal channels, the oil comes out under slide ring pos. 10B, O-ring pos. 10D
the shaft seal and through a plastic hose, it is and springs pos. 10K (see fig. 2) can
collected in a plastic bottle. now be dismantled.

Fig. 3
1. Dismantling and stripping down shaft
seal 8E 10B 10D 8A 8C

1.1. Once the gas pressure in the com-

pressor has been eliminated and the • •
motor safeguarded against inadvertent
start-up, dismantle coupling or V-belt
disk. •
•
Note: •
A
On units featuring coupling, there is no
•
need to move the motor, as the coupling
and the shaft seal can be taken out be-
tween the two shaft ends.

0171-370-EN 69
1.5. Dismantle slide ring 10A by turning the The torque is specified in the instruction
four Allen screws 10G a max. of 2-3 manual.
turns; the entire unit can then be taken
3. Unit with shaft seal cover Pos. 8A
out with the fingers or using two screw-
drivers inserted into the external groove 3.1. Mount O-ring 10D and the ten spiral
on the slide ring Pos. 10A and moved in springs 10K in shaft seal cover 8A,
the direction of the arrow as illustrated then position carbon slide ring 10B
in fig. 4. carefully. Rotate carbon slide ring so
slot fits in over retention pin 8H.

Fig. 4 3.2. With tool no. 2-1 fitted as shown fig. 3

press carbon slide ring 10B against
springs with your fingers and fit circlip
10A 8G. Take care that the surface of the
carbon slide ring remains undamaged.

3.3. Give the complete shaft seal cover an

extra oiling on the slide surface of the
carbon slide ring and guide it over the
• shaft. Pay attention to O-ring Pos. 8B.

3.4. By gently pressing the shaft seal cover

and the carbon ring against slide ring
Pos. 10A without compressing the
springs Pos. 10K, measure the distance
1.6. O-ring Pos. 10C can now be removed.
from shaft seal cover Pos. 8A to bearing
Assembling and mounting shaft seal cover pos. 7A (see sketch). By a subse-
After thoroughly cleaning the crankshaft, quent careful tightening of the screws
check that its sealing faces are smooth and Pos. 8C the shaft seal cover should only
be tightened about 3 mm before achiev-
free of scratches, blows and wear marks.
ing contact between Pos. 8A and 7A.
Then oil the crankshaft and the shaft seal
components thoroughly with the same type of
oil as used in the compressor.
10A 10B 7A 3 mm 8A 8C
2. Unit with slide ring, Pos. 10A
2.1. Before fitting slide ring 10A, tighten
screws 10G until there is approx. 2 mm •
•
spacing and parallelism between the
two flanges. Check also that locking ring • 10K
10H is mounted as shown in the draw-
10G
ing and O-ring 10C is in position.
2.2. Position slide ring 10A on shaft and en- •
• •
sure tightening flange makes contact •
with shaft shoulder.
2.3. Crosswise, tighten screws Pos. 10G al- T0177142_0 V4B

ternately with Allen wrench from tool kit.

70 0171-370-EN
 In case the movement is bigger, check S Extract all pistons and connecting rods.
whether the tightening flange Pos. 10F S Pull off V-belt pulley or coupling half .
has been pushed completely up against
the crankshaft shoulder as described in S Dismantle shaft seal cover and shaft seal.
sections 2.2 and 2.3. S Dismantle pressure cut-outs and pipes to
manometers, or piping connections to
3.5. Make sure that the screws Pos. 8C are
UNISAB.
evenly tightened cross-wise. Hereby
damage of the carbon slide ring is S Dismantle oil filter as well as its bracket
avoided. Tighten screws Pos. 8C to pre- Pos. 59A.
scribed torque, acc. to table in instruc- S Dismantle end cover, pos. 4A.
tion manual.
S Dismantle bearing cover with oil pump
3.6. Mount oil throw ring Pos. 16G, as
Pos. 5A at screws Pos. 5C, then pull out
shown in drawing.
bearing cover. It is not necessary to dis-
3.7. After mounting coupling half or V-belt mantle oil pump Pos. 11 from bearing
disk, it must be possible to turn the cover. it is also normally not necessary to
crankshaft easily by hand.
support the crankshaft.
Now pull out crank from the frame, sup-
Crankshaft
porting it by hand through one of the side
The crankshaft is made of heat-treated SG openings.
cast iron with fine strength and glide prop-
erties. The bearing journals are superfinished Inspection
and oil channels are bored for all lubricating
S Check bearing journals at connecting rods
points.
of wear and tear and, if necessary,
At the centre and end of the crankshaft, the measure diameter of journals. Max. wear
oil channels are blanked off with 3 blind of the journals appear from section Vari-
plugs. ous clearances and adjustment measure-
ments.
When fitting the crankshaft, it should be
checked that the plugs are mounted and tigh- In most instances, the permissible play in
tened. By way of bores in the counter- the bearing can be obtained by replacing
weights, the crankshaft is dynamically bal- the connecting rods.
anced with regard to 1st and 2nd order
Normally, the journals are only slightly
forces.
worn at main bearings, but during com-
Dismantling crankshaft plete overhauls they should be measured.
Dismantle the crankshaft through the pump By wear and tear beyond the plays stated,
end of the frame in the following way: the crankshaft can normally be ground to
S Bleed compressor of oil and refrigerant 0.5 mm undersize.
and safeguard against inadvertent start-
Main bearings and new connecting rods
up.
with a 0.5 mm undersize can be supplied
S Dismantle top and side covers. to the ground down crank, as stated in the
S Dismantle all cylinder linings. parts list.

0171-370-EN 71
 Drawing for grinding of crankshaft to un- Main bearings
dersize can be requested from SABROE.
Main bearings Pos. 5E and 6E consist of a
After grinding the crankshaft, all lubricat- steel bushing with collar, coated with a thin
ing channels must be thoroughly cleaned layer of white metal inside the bushing and
with an approved cleansing fluid and on the collar.
blasted with compressed air. Remember
The bushings can be squeezed out and re-
to refit the blind plugs.
placed by new ones and require no finishing
once assembled.
S Check sealing face for O-ring seal, Pos.
10D, on shaft seal. The surface must be When pressing in new bushings, the in- and
bright and free of scratches and marks. outlets of the lubricating duct for bushing at
shaft seal end, pos. 6E, should be positioned
Refitting crankshaft
as illustrated on the drawing. The cover is
Refit the crankshaft in the reverse order to shown from the inside and as fitted on the
that for dismantling. compressor.
Note the following, however:
The bushing at the oil pump end of the com-
S After positioning the crankshaft in the pressor, pos. 5E, must be placed so that the
frame, mount main bearing cover Pos. 5A in- and outlets of the lubricating duct are
with a gasket Pos. 5B as a shim. facing upwards.

S Before refitting bearing cover, position and Main bearing bushings can be supplied for
rotate oil pump coupling on pump shaft so ground down crankshaft.
that the retaining pins on the crankshaft See spare parts list.
engage the two nylon bushings.

S Check end play of crankshaft by pressing

the shaft against the main bearing Pos.
6E, and measure clearance in the other 45° In- and outlets
bearing, using a feeler gauge. of lubricating
duct
The permissible end play appears from
section Various clearances and adjust-
ment measurements.
Adjustment of end play is achieved by
means of the gasket Pos. 5B.
The gasket can be supplied in the follow-
ing thicknesses, as per the spare parts
list: T0177168_0

0.25 mm 0.50 mm 0.75 mm 1.0 mm

72 0171-370-EN
By-pass valve pos. 24
The compressor is equipped with a built-in In case the pressure on the discharge side
mechanical by-pass valve, fig. 1, which safe- exceeds the set pressure so that the by-pass
guards it against any inadvertent excess valve opens, the valve will remain open until
pressure if the electrical safety equipment the pressure on the discharge side has fallen
fails. The by-pass valve safeguards against to approx. half the set pressure. The valve
any excess pressure between the discharge then closes automatically. However, at great
and suction sides of the compressor. differential pressures across the compressor
the valve may remain open. In that case,
If the by-pass valve goes into action, the
stop the compressor and close the discharge
compressor must be immediately stopped
stop valve entirely. The equalization of pres-
and the cause established.
sure in the compressor will then close the
The by-pass valve is supplied ready-set and safety valve and the compressor can be re-
sealed in accordance with the adjustment started.
pressures indicated in the table Pressure and
The by-pass valve is supplied factory-set and
temperature settings. The actual set pressure
sealed and need normally not be disassem-
is stamped on the rating plate, pos. A.
bled and readjusted.
The by-pass valve is of the high-lift type
which makes it very sturdy and durable. If necessary, control of function and set pres-
sure must be made in accordance with local
Further, the by-pass valve is independent of regulations for safety valves.
the pressure on the compressor suction side.
Consequently, it only opens when the pres- On the outside the by-pass valve is sealed
sure on the discharge side exceeds the set with two O-rings, pos. 24B and 24C.
pressure in relation to atmospheric. Fasten it to the compressor housing by
Thus, watch out that hole pos. B does not means of screws pos. 24D and washers pos.
get covered or clogged. 24E.

Fig. 1 24C 24B

A B T3137T02I_1

0171-370-EN 73
Suction filter
On the inside of the end cover Pos. 7A the normally clean plants it may then be removed
compressor is equipped with a plate shaped together with the supporting spring.
suction filter Pos. 7G with a very large filter-
ing area. By non contaminated refrigeration In case the filter is badly soiled after the
50 operating hours mentioned, it is rec-
plants it is therefore not necessary to clean
ommended to fit a new filter bag for
suction filters between main overhauls.
another 50 operating hours. Similarly, a
If the plant is not completely clean, the com- filter bag should be fitted for a period of
pressor will normally be equipped with an ex- 50 hours after major repair works on the
tra suction filter as described below. refrigeration plant.

Extra suction filter

Cleaning of extra suction filters
66J 66G 66H 66F 66C 66B 66K After evacuation of the compressor, disman-
tle cover Pos. 66B, extract filter strainer Pos.
66F.

If filter bag Pos. 66B is fitted, it must be re-

moved and renewed as previously described.
The filter should be cleaned in a cleansing
fluid with a suitable stiff brush, however, with-
out damaging the filter mesh.

Blow dry the filter strainer with compressed

air. Give the filter a regular cleaning in accor-
T0177142_0 V11
dance with the stated servicing dates.

The extra suction filter consists of an inde- Note:

pendent filter housing fitted on the compres- It is important to keep the suction filter
sor between end cover Pos. 7A and suction clean and in good order as a soiled or
stop valve Pos. 66A. clogged filter reduces the capacity of the
compressor.
Remove filter strainer Pos. 66F as described
below. On delivery of the compressor, the By total clogging there is also the risk that the
filter has a filter bag insert Pos. 66G, retain- filter may burst and severely contaminate the
ing very small dirt particles coming with the compressor.
suction gas from the refrigeration plant.
When refitting of the filter, O-rings Pos. 66J
The filter bag is kept in place by a supporting and 66C must be in place and in good order.
spring Pos. 66H and must be used for the Tighten screws Pos. 66K to the torque mo-
first 50 operating hours of the compressor. In ment prescribed in the table.

74 0171-370-EN
Stop valves

A Z AJ

AK

AC

AD S

E T

Y U

POS. 25

AG F C H D Q G N B J L P R M K
T0177142_0 V5

The suction and discharge stop valves Pos. S Mount threaded piece Pos. 25G in a
25 are used to isolate the compressor from soft-jawed vice and dismantle screw
the refrigeration plant. Pos. 25E.

They are closed completely by manual tight- Note:

ening and it is therefore advisable not to use The screw has a lefthand thread, and it
any tool to close the valve, as this will simply is therefore inadvisable to leave the
overload the valve parts. threaded piece in the valve holder while
dismantling the screw, as the guide pin
Dismantling of valve
Pos. 25N will be overloaded.
The valve seat is sealed with a teflon ring
Pos. 25H which, if necessary, can be re-
placed as follows: S The front and rear pieces Pos. 25C and
25D can now be separated and the teflon
S Once the pressure on the inlet and dis-
ring Pos. 25H removed.
charge sides of the valve has been equal-
The teflon ring will be flattened on one
ized to atmospheric, dismantle screws
outer edge, which is normally of no impor-
Pos. 25AJ. The valve throat Pos. 25B, and
tance to its sealing ability providing it is
with it the entire valve insert, can then be
free of scratches and marks. If required,
removed.
the teflon ring can be reversed when reas-
S Turn spindle clockwise until cone and sembling so that the other outer edge
threaded piece Pos. 25G can be removed seals towards the valve seat in the hous-
by hand. ing.

0171-370-EN 75
Reassembling of valve Pos. 25M to be serviced even when there
Reassembly is done in reverse order to that is excess pressure in the valve housing.
above. Note the following, however:

S Before mounting the complete valve in- Adopt the following procedure:
sert, the valve cone with threaded piece S Using handwheel, open valve completely
Pos. 25G must be screwed right into the to achieve a seal between valve cone and
valve neck Pos. 25B. valve throat. The gasket Pos. 25Q acts as
a sealing element.
S The O-ring Pos. 25J may have expanded
under the influence of the oil in the plant
S The packing screw joint Pos. 25M can
and will normally have to be replaced by a
now be unscrewed for inspection or re-
new one.
placement of O-rings Pos. 25R and 25P.
The stop valve has a so-called retroseal, Lubricate all parts thoroughly with oil be-
which enables the packing screw joint fore reassembling.

76 0171-370-EN
Compressor lubricating system

To oil pressure
regulating valve Pos. 22

To capacitiy
regulating system

11 9A

60

T0177131_0 V12

The oil system has two functions: The oil lu- Clockwise rotation increases the pressure;
bricates and cools all moving parts in the anticlockwise rotation lowers the pressure.
compressor and it works as a hydraulic sys-
Excess oil is returned to the crankcase.
tem for regulation of the compressor pump-
ing capacity. A description will follow later. From the shaft seal housing the oil is distrib-
uted as follows:
The oil pump pos. 11M sucks oil from the
crankcase through filter element Pos. 60 past S Through the hollow-bored crankshaft to
the magnetic filter located inside the lubricate one of the main bearings and the
filter element. The pump forces the oil connecting rod bearings.
through an internal pipe Pos. 9A and on to Lubrication of the piston pin bearings
the shaft seal housing. takes place through a bored channel in
the connecting rod.
The filter element Pos. 60 is a disposable S To the oil differential pressure cut-out and
filter which cannot be cleaned. See descrip- pressure gauge. The effective oil pressure
tion of Oil filter. can be read directly on the pressure
gauge (the suction pressure gauge of the
The shaft seal housing acts as a distribution
compressor). In case the compressor is
chamber for the oil. The oil pressure in the
fitted with UNISAB, the oil pressure is tak-
shaft seal housing is adjusted by means of
en through external pipe connections to
the oil pressure regulating valve Pos. 22,
the control box.
which is mounted on the one side cover.
S Through internal oil pipes the oil is taken
The regulation valve can be adjusted from to the regulating cylinders, Pos.12, for un-
the outside by means of a screwdriver. loaded start and capacity regulation.

0171-370-EN 77
Oil filter The filtered oil also passes a magnetic filter
Pos. 60J-K, where any small iron particles
All oil to the lubricating system of the com- are caught, before the oil flows to the oil
pressor is filtered through an oil filter, fitted in pump.
the crankcase.
Changing filter cartridge
The filtration element is a filter cartridge, pos. The filter cartridge should be replaced at reg-
60 A on Fig. 1, which cannot be cleaned and ular intervals. See the section entitled Servic-
therefore must be replaced by a new one ing compressors on this point. In particular, it
once the filter capacity is used up. should be remembered that the filter car-
tridge must often be replaced after a relative-
ly short operating time following initial start-
It is important therefore, to keep a spare
up.
filter cartridge in store at all times. It is
also recommendable to have gaskets, This is due to small particles of dirt originat-
pos. 59C and pos. 60B, available before ing from the plant during the initial operating
replacement of filter cartridge. period.

Fig. 1 59C 59A 59B

60B 60P 60N 60M 60J 60K 60A 60L 60H 60P-1

59D

The compressor must be discharged of oil Important

and the pressure adjusted to atmospheric Before the compressor is opened, make
pressure before the oil cartridge can be re- sure that it cannot operate. This is en-
moved from the compressor. Cf. The sec- sured by removing the motor main fuses.
tions Removing Refrigerant from Compressor In addition, make sure that the heating
and Changing Oil in Refrigeration Compres- cartridge is switched off.
sor for further information on this point.

78 0171-370-EN
The easiest method of dismantling the oil fil- Filter Cartridge, pos. 60A, cannot be
ter is via the left--hand side cover opening cleaned and must therefore be replaced
(the end of the compressor on which the ma- by a new unused one.
nometers/UNISAB are mounted). Dismantle
Mount the oil filter in the following order:
the oil filter by removing the screws, pos.
59B. Mind the gasket, pos. 59C. S Mount the gasket, pos. 60B

If a refrigerant--cooled oil cooler is mounted S Mount the filter cartridge, pos. 60A, the
in the compressor, this should be dismantled washer, pos. 60H and the self--locking nut,
together with the oil filter. Cf. the section Re- pos. 60P--1 as shown in fig. 1.
frigerant--cooled Oil Cooler for CMO Recipro- S Tighten the self--locking nut carefully with-
cating Compressor. out deforming the filter cartridge.

Replace the filter cartridge by dismantling the S Insert the complete oil filter together with
self--locking nut, pos. 60P--1 and the washer, the oil cooler (if mounted). Cf. Refriger-
pos. 60H. ant--cooled Oil Cooler

S Mount gasket, pos. 59C, and fasten oil fil-

Before mounting a new filter cartridge, clean
ter with the screws, pos. 59B.
the magnetic filter, pos. 60J--K, and the
centre shaft, pos. 60L, with a clean cloth S Mount the side cover. Fill up with new re-
without disassembling the parts any fur- frigerant machine oil and carry out start
ther. procedure as described in this manual.

0171-370-EN 79
Oil pump

• 11A
11F
•
• 11C

11J

• 11K

11L
•
•

11E
• T0177142_0 V13

• 11G
• 11D

The oil pump is a gearwheel pump directly If you wish to change the direction of rotation,
coupled onto the end of the crankshaft. turn pump as described, and mark and bore
Power is transferred via 2 retention pins Pos. off 4 new holes for tightening screws.
16J fitted at the end of crankshaft and one
pin 11M equipped with teflon bushings. Thread M8 and effective thread depth 13
mm. Depth of hole for core drill max. 16 mm.
On compressors with normal rotating direc-
tion (indicated by an arrow on end cover at A compressor ordered for reverse direction of
shaft seal end) the oil pump is mounted with rotation is mounted with the pump in the cor-
the driving gearwheel at the bottom, as rect position.
shown on the drawing.
Dismantling of oil pump
If, because of the driving motor, the compres- 1. Dismantle all outer pipes and end cover
sor must have a reverse direction of rotation, Pos. 4A by the pump.
the oil pump must be turned 180° to take the 2. Remove screws Pos. 11B, after which
driving gearwheel to top position. Before only the guide pins Pos. 11G keep the
mounting the oil pump in its new position, pump in place.
dismantle oil pump cover Pos. 11D from
Normally, the oil pump has a very long life,
pump house Pos. 11C and turn it 180°. In this
thus repairs on it do not pay, instead it should
way the in- and outlet gates of the oil pump
be replaced by a new one.
remain in front of their respective connec-
tions to bearing cover Pos. 5A. Holes for
guide pins to the oil pump in this new position Remounting of oil pump
have been bored whereas threaded holes for On remounting of oil pump, turn shaft until
clamping have not. Hereby, wrong mounting retaining pin Pos. 11L catches the groove in
on compressors with normal direction of rota- retaining pin Pos. 11M. Pay attention to gas-
tion is avoided. ket Pos. 11A.

80 0171-370-EN
Oil pressure valve Adjustment
The oil pressure valve Pos. 22 regulates the Oil pressure: 4.5 bar.
oil pressure in the compressor. Mounted in
The oil pressure can be read off the suction
the cover Pos. 87A, it connects directly with
gauge or on UNISAB II.
the oil pressure chamber in the shaft seal
housing. On more recent compressor models the
The oil pressure is regulated by a spring adjusting screw may be locked by means
loaded cone, the spring pressure being ad- of an M6 pointed screw, fig. 1, which must
justed by turning an adjusting screw at the be loosened before adjustment can take
valve end. Use a screwdriver for this pur- place.
pose.
Service
Turning to the right (clockwise) raises the oil
Since the oil pressure valve is not subject to
pressure; turning to the left (anticlockwise)
any appreciable wear or soiling, it should not
lowers the pressure.
be disassembled during routine services.

Fig. 1 In the event of a malfunction, the complete

locking screw valve should be replaced.
22A

22B

T0177083_0

0171-370-EN 81
Capacity regulation and unloaded start
The same type of regulating system is used Further, the regulating system must force the
in both CMO and TCMO compressors. It suction valves open at compressor standstill
should be pointed out, however, that on the or during its starting-up phase. In this way
CMO compressors all cylinders are con- the motor is started with as little resistance
nected to the regulating system whereas only from the compressor as possible as there is
part of the TCMO cylinders can be connected no compression of gas in the cylinder. Once
to this system. the motor has reached its maximum moment,
the regulating system starts loading the com-
pressor with capacity.
The regulating function
Fig. 1 illustrates how the regulating system is
The purpose of the regulating system is to connected to the lubricating system of the
adapt the compressor capacity to the need compressor. As shown in fig. 2 the unloading
for cooling of the refrigeration plant. This is cylinders are controlled by three 3-way sole-
achieved by unloading cylinders or by putting noid valves. Oil pressure regulating valve
them to work. This is achieved by guiding the pos. 22 is set to maintain a constant oil pres-
suction valve fitted on each cylinder. sure of 4.5 bar in the oil system.

Fig. 1

To oil pressure regulating valve pos. 22

To capacity regulating system

A

11 9A

60
T0177131_0 V12

82 0171-370-EN
Function

1
Fig. 2
2 Three-way solenoid
3 valves
4A 2A 1A 3A

1A
2A
3A Relief cylinders
4A
3

2 22 Oil pressure
22
regulating valve
1 B

A: Oil pressure from lubricating system

B: Oil return from crankcase
T0177142_0 V8

One way of achieving capacity unloading is Dismantling of unloading cylinder

to switch off the current to solenoid valve no. As the unloading cylinder is not exposed to
1. This shuts off the oil pressure to unloading any particular wear and tear, it will rarely
cylinder no. 1A and at the same time the have to be dismantled. It can be dismantled
3-way function of the solenoid valve opens, as one unit by removal of Allen screws Pos.
hereby connecting the unloading cylinder to 12A, but in order to get to the screws, cylin-
the crankcase. der linings, pistons, connecting rods must be
dismantled, and possibly the crankshaft must
be removed.
The springs in the unloading cylinder
squeezes the oil out of the unloading cylin- Once screws pos. 12A have been dismantled
der. The piston in the unloading cylinder on both unloading cylinders, lift them out of
moves upwards and forces the suction valve the recess and pull them apart in order that
open in order to prevent compression in the oil pipe pos. 62A and gaskets pos. 62H may
compressor cylinder. be released.

Disassembling of unloading cylinder

The TCMO compressor is not equipped with
Press bottom piece Pos. 12C slightly into cyl-
an unloading mechanism at the HP stage
inder Pos. 12E and pull out circlip Pos. 12J
and on 2 LP cylinders. Thus, the torque of
from its track by a rotating movement.
the electric motor must be sufficient before
the oil pressure in the compressor starts Once the circlip has been removed, the parts
loading compressor capacity. can be pulled apart.

0171-370-EN 83
Assembling of unloading cylinder Mounting of unloading cylinder in the
compressor
By assembling of unloading cylinder, the two
1. Lubricate O-ring pos. 62H with refrigerant
sealing rings must be positioned as shown
machine oil.
on spare parts drawing.
2. Turn the two unloading cylinders pos. 12
so that the oil inlet holes are facing each
During mounting of circlip pos. 12J it is a other and place them in the compressor
good idea to push bottom piece pos. 12C into block.
the cylinder pos. 12E in a vice with soft jaws.
3. Press the two unloading cylinders against
each other, guiding them to engage with
Note: oil pipe pos. 62A. Take care not to dam-
On assembling the unloading cylinder, age O-rings pos. 62H.
make sure that the two threaded holes in 4. Press the two unlading cylinders down
the bottom piece pos. 12C are on a level into the recess in the block and tighten
with the hole for oil supply to the cylinder with screws pos. 12A and washers pos.
pos. 12E. 12B.

84 0171-370-EN
Capacity stages and regulating sequence

Capacity stages The TCMO compressors have no unloading

The CMO compressors can be capacity cylinders on two HP and two LP cylinders,
regulated in 4 stages with the various per- and thus they can be capacity regulated as
centages of full capacity as shown in the shown in the following table.
table below.

Compressor Capacity in %

CMO 24 100 75 50 25 Compressor Capacity in %

CMO 26 100 67 50 33
TCMO 100 67 50 33
CMO 28 100 75 50 25
Solenoid 1 2 3
Solenoid valve no
1 2 3
valve no

Regulating sequence
Unloading takes place in numerical order The sequence of unloading of the cylinders
with rising figures, whereas loading takes is shown on the following principle diagram,
place in reverse order with falling figures. fig. 3.

Fig. 3

4 4 HP

4 4

2 2 1 2

1 1
Shaft end
1 1 3 4 1 1 LP

2 3

3 3 CMO 24 2 3
CMO 26

CMO 28 TCMO 28

T0177142_0 V10

0171-370-EN 85
Pilot solenoid valves
Fig. 4 shows the position of the solenoid
valves on the side cover.

Fig. 4
22

1 2 3

T0177142_0 V17

From the chamber under the oil discharge Fig. 5

valve Pos. 22 the oil flows through a bored
channel in the side cover to the valve block.
Here oil is distributed through channel A to
each single solenoid valve.
2
S Channel B connects the solenoid valve
with the relevant unloading cylinder. A
1
S Channel C takes the oil back to the crank- B
case from the unloading cylinders. C
At a dead coil the relevant compressor cy-
linder hereof is unloaded. The solenoid valve
closes between channels A and B and
opens between channels B and C. Hereby,
the oil pressure in the unloading cylinder is
50B
equalized to the pressure in the crank case.
80P
At an energized coil the relevant compres-
sor cylinder is working. The solenoid valve
opens between channels A and B and 80N
closes between channels B and C.
p9034_0.d23
Fig. 5 shows a cross-section of the solenoid
valve.

86 0171-370-EN
Dismantling and assembly of solenoid and each part in the tube be dismantled.
valves Nozzle no. 1 can be unscrewed by means of
When electricity has been switched off to the an Allen screw. However, take care that you
solenoid coil, hand screw pos. 80N can be do not lose the small steel ball pos. 2.
dismantled and coil pos. 50B pulled out At assembly tighten the nozzle and the arma-
across armature tube pos. 80P. ture tube with 10 and 50 Nm, respectively.
There is no gasket in connection with the
The armature tube can now be unscrewed nozzle.

0171-370-EN 87
The TCMO 28 compressor

The TCMO 28 compressor is available in 2 Further, the solenoid valve must be con-
versions: with or without built-in capacity trolled by the capacity regulating system of
regulating system. (Please refer to page 1 the compressor so that when the compressor
to see which compressor version you have). capacity is regulated down to 50% or lower,
The systems are illustrated in the following solenoid valve H will open.
schematic drawings, fig. 1 and 2. This prevents the intermediate pressure in
the IP chamber from getting too low.
TCMO with capacity regulation
Unloaded start system:
Unloaded start of the compressor is obtained At compressor start, the pressure in the HP
partly by lifting suction valve plates on the chamber is usually equalized to intermediate
four low pressure cylinders, partly through a or suction pressure as non-return valve G
by-pass line with solenoid valve H, connect- closes against the discharge side of the
ing the high pressure chamber with the inter- plant.
mediate pressure chamber.

The solenoid valve H must be connected to To be on the safe side open solenoid valve H
the star-delta starter of the motor in order to on starting the compressor, hereby equaliz-
energize the valve coil (open valve) when- ing any excess pressure in the HP chamber
ever pilot voltage is connected and the motor to the pressure in the IP chamber. At the
starter is in star position. same time the four cylinders on the LP side
Whenever the motor starter switches to its have been unloaded. All these factors put
delta position, the current to the solenoid together result in a proper start unloading of
valve H is disconnected and is closes. the compressor.
Fig. 1

IP LP

H
IP
A: LP suction gas inlet
B B: HP discharge gas outlet
A
G 26 D: Oil pressure connection
HP 58 E: Oil return to crankcase
25
100% 67% 50%

22 E
D
1 2 3

88 0171-370-EN
Capacity regulation
Capacity regulation takes place by lifting the Unloading takes place in numerical sequence
suction valve plates on four of the six LP cyl- with rising figures, whereas loading takes
inders. The stagewise unloading appears place with falling figures.
from fig.1 and from the sketch earlier on.

Solenoid valve no 1 unloads two cylinders, When the LP-cylinders are unloaded, a bal-
thus reducing capacity to 67%. ance no longer exists in the cylinder ratio be-
Solenoid valve no 2 further unloads one tween HP- and LP-cylinders. In order to keep
valve, thus reducing capacity to 50%. the intermediate pressure at a suitable value
Valve no 3 unloads one more cylinder, reduc- under these circumstances, solenoid valve
ing capacity to 33%, which is the lowest H must open together with unloading
capacity at which the compressor is able to stage 2 and remain open also during un-
work. loading stage 3.

TCMO without capacity regulation

Fig. 2

IP LP A: LP suction gas inlet

H B: HP discharge gas outlet
IP
D: Oil pressure connection
B E: Oil return to crankcase
A
G 26
HP 58 25

22 E
D

Unloaded start system: in delta position, the valve coil must be de-
Unloaded start of the compressor takes place energized (closed valve).
partly by means of lifted suction valve plates
on four LP-cylinders, partly through a by- At start-up of compressor the HP-chamber
pass line with solenoid valve H, connecting must have been unloaded to intermediate
the HP chamber with the IP intermediate pressure. For this purpose a non-return valve
pressure chamber. G has been fitted in the discharge pipe in or-
der to prevent flashback of the condensing
The solenoid valve must be connected to the pressure into the HP-chamber.
star-delta starter so as to energize the valve
coil (open valve) at standstill and with the At start-up, the four LP cylinders are un-
starter in star position. With the motor starter loaded until the oil pressure has built up.

0171-370-EN 89
Cooling of intermediate discharge gas on the TCMO 28 compressor
The TCMO 28 compressor compresses the S Cooling of the intermediate pressure gas
refrigerant gas in two stages with 6 LP-cylin- by means of an intermediate cooler.
ders and 2 HP-cylinders, respectively. The gas is carried to a vessel with liquid
from the condenser. The superheated gas
Each stage has its own suction and pressure
from the LP stage is carried through the
chamber. The HP stage suction chamber and
refrigerant liquid and this reduces the su-
the LP stage pressure chamber is connected
perheat considerably.
by means of an external piping.
S Cooling of the intermediate gas by means
of liquid injection into the intermediate
IP HP pipe.
Liquid refrigerant is mixed with the inter-
mediate gas and reduces the superheat
IP IP when it evaporates.
LP LP IP IP
S The injection system can also incorporate
a plate heat exchanger in which the liquid
LP for injection into the intermediate pipe sub-
cools the liquid to the evaporating system.

When these systems are used the super-

heat must not fall below 10K.
In this piping, called the intermediate pipe,
the intermediate pressure gas is cooled by Please refer to the section Cooling of the in-
means of 1 of the following 3 systems: termediate gas for further information.

90 0171-370-EN
 Heating Rods, pos. 30, Element for Oil Heating
To keep the lubricating oil in the compressor As illustrated in the drawing Fig. 1.2 the hea-
warm during an idle period, the oil receiver is ting rod consists of an electric heating ele-
fitted with one or two built-in heating rods. ment incorporated in a pipe with a diameter
Before start-up, the heating rod must have of 30 mm. The entire heating cartridge is
been activated for six to eight hours to en- screwed on at the G 1 1/4” thread.
sure that the oil includes only a minimum of
refrigerant. When containing much refriger- Note:
ant, the oil will loose its lubricating property The heating rod must not be energized if
and the following operational interruptions the oil level in the receiver is below the
minimum mark in the sight glass, and it
may occur:
should generally be switched off during
In reciprocating compressors there is a compressor operation. For reciprocating
serious risk that the oil will foam during start- compressors, remember to turn off the
up due to the falling suction pressure. heating rod whenever the crankcase is
opened for inspection.
Screw compressors starting with much re-
01.06

frigerant dissolved in the oil may be stopped The following table shows which heating rods
by the flow switch. The reason for this is that are used for the various compressor types.
The spare parts lists for compressor and unit
0170-017-EN

the oil will foam due to the fall of pressure

through oil pipe and oil filter. include the current part numbers.
Fig. 1.2
Marking: Prod. no
NV 50 Watt
G 1 1/4”
Volt
Manu. date

Ø 30
30
50

L1
80 L2

Fig. 1.3
Heating rods
Power Voltage L1 L2 Used for:
Watt V mm mm
270 250
270 230 CMO - TCMO - SMC 100 - TSMC 100
270 115*
460 250 158 175 HPO-HPC-SMC180-TSMC180-
460 230 SAB81/83/85/87/89-SAB110-SAB128Mk3/4-
460 115* SAB163Mk3/4-SAB128HR-SAB163HR-
SAB202-SAB330-VMY536-SAB283L/E-SAB355L
* Can be delivered with a UL approval. All heating rods are executed in Degree of Protection IP54.

0171-370-EN 91
Stop valves pos. 23 and 42

23G

23A 23D 23F 23C 23B 23E

Fig. 1
Danv

42A 42H

Fig. 2

95.03
0171-463-EN
42G

42F 42E 42C

42D 42B
T0177156_0

The compressor is fitted with stop valves trating the valves whenever they are not
pos. 23 for charging of oil and pos. 42 for used.
draining of oil. They are service-free valves
and should as a rule not be dismantled. S If the valve is used as an oil charging
valve it is fitted with a nut pos. 23C and
The valves are safeguarded against inadver- threaded nipple pos. 23B as shown by
tent opening by means of a red cap. fig. 1.

The red cap can further be used for opening S If the valve is used as a purge valve it is
or closing the valve by unscrewing it and fitted with a screwed connection as illus-
turning it upside down. The square hole in trated by fig. 2.
the top of the cap fits the square in the valve
spindle. The purge valve is fitted either directly on
the top cover or by means of an intermedi-
The valves are equipped with a blank nut ate connection in the cast pressure chan-
pos. 23G/42H that prevents dirt from pene- nels in the frame.

92 0171-370-EN
 Sundry clearances and check dimensions

Bearing clearance All measurements stated are in mm

CMO 1 CMO 2 SMC 65 SMC 100 SMC 100 SMC180
CMP 1 TCMO 2 TSMC 65 TSMC 100 TSMC 100 TSMC 180
TCMO1 4--10 cyl. 12--16 cyl.
CMO4 HPO HPC Mk1 & Mk2

Main bearings manufactured 0.08 0.08 0.08 0.08 0.08 0.14

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 0.18 0.20 0.20 0.25

piston pin max. -- -- -- -- -- --
Piston
91.04

At 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
0171-901-EN

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

Crankshaft end-play
min. 0.30 0.30 0.30 0.40 0.75 0.95
max. 0.55 0.55 0.55 0.64 1.00 1.20
The end--play can be adjusted by means of the gasket under the bearing cover.
The gasket is available in the following thicknesses: 0.3, 0.5, 0.75 and 1.0 mm.

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 2.50
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 60 55 80 80 135
--0.09 --0.09 --0.09 --0.09 --0.09 --0.14
New

Connecting rod --0.025 --0.030 0 0 0 --0.015

50 55 55 80 80 135
bearing journals --0.040 --0.049 --0.02 --0.02 --0.02 --0.040
--0.010
Intermediate journals 80
--0.029
--0.06 --0.06 --0.06 --0.07 --0.07 --0.11
Main bearing journals 54.5 59.5 54.5 79.5 79.5 134
Ground down

--0.09 --0.09 --0.09 --0.09 --0.09 --0.14

Connecting rod --0.025 --0.025 0 0 0 --0.015
bearing journals 49.5 54.5 54.5 79.5 79.5 134
--0.040 --0.040 --0.02 --0.02 --0.02 --0.040
--0.010
.
Intermediate journals 79.5
--0.029

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

0171-370-EN 93
 Undersize Bearing Diameters for Crankshaft
Reciprocating Compressors with 4 to 8 Cylinders

B
A A

B C

R=2.5 R=2.5
R=d
a

96.05
45 °
c
T0177137_0

0171-904-EN
A B C a b c d
Main bearing Connecting rod bearing
Compressor First Super First Super
type grinding finish grinding finish
or or
Final Final
grinding grinding
mm mm mm mm mm mm mm mm mm
--0.060 --0.060 --0.030 --0.035 0.0 0.0
HPO 59.5 59.5 54.5 54.5 35 0.2 1.0 2.5 2.5
--0.070 --0.090 --0.049 --0.050 --0.1 --0.3
CMO 2
Ra=0,20 Ra=0,20

HPC, 0.0
40
SMC/TSMC --0.1
100 S
--0.070 --0.070 0.000 0.000
79.5 79.5 79.5 79.5 0.0
SMC/TSMC --0.080 --0.090 --0.010 --0.020 50 0.2 1 3 3.5
100 L Ra=0.35 Ra=0.35 --0.1

SMC/TSMC 0.0
60
100 E --0.1

--0.110 --0.110 0.000 --0.015 0.0

SMC/TSMC 134.0 134.0 134.0 134.0 70 0.16 1.15 5 6
180 --0.120 --0.140 --0.010 --0.040 --0.1
Ra=0,63 Ra=0,63

Undersize bearings: See SABROE spare parts list.

94 0171-370-EN
 Torque moments for screws and bolts

Metric thread (ISO 8.8)

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

Kpm 0.28 0.53 0.94 2.2 4.1 7.0 11 15 23 30 38 52 68

ft.lbf. 2.1 3.9 6.8 16 30 50 80 110 170 220 270 370 490

Nm 2.7 5.2 9.2 22 40 69 108 147 225 295 375 510 670
00.10

Metric thread (ISO 12.9)

M 4 5 6 8 10 12 14 16 18 20 22 24 27
0171-465-EN

Kpm 0.42 0.78 1.4 3.2 6.1 10 16 23 34 44 55 76 100

ft.lbf. 3.0 5.7 10 23 44 75 120 160 240 320 400 550 720

Nm 4.1 7.6 14 31 60 98 157 225 335 430 540 745 980

Connecting rods with UNF thread

HPO/CMO HPC/SMC 100 SMC 180

UNF 5/16” 3/8” 5/8”

Kpm 2.1 4.4 17
ft.lbf. 15 32 130
T0177082_0
Nm 20 43 167

Bolts for top, side and end covers

Compressor T/CMO HPO T/SMC 100 HPC T/SMC 180
Top/side End Top/side End Top/side and end Top/side and end Top/side and end
Location covers covers covers
covers covers covers 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.lbf. 63 100 95 147 100 147 310
Nm 85 135 130 200 135 200 420

0171-370-EN 95
 Bolt on discharge valve
HPO/CMO HPC/SMC 100 SMC 180

Kpm 3.2 10.2 35

ft.lbf. 23 75 255
Nm 32 101 344

AMR B Torque
Compressor Type Coupling Thread Kpm. ft.lbf. Nm
Type B D B D B D
D
HPO/CMO/TCMO AMR225 5/16” 3.5 13 25 96 34 130

104-108 AMR312S 7/16” 5.6 20 40 147 55 200

HPC/ 112-116 AMR350S 1/2” 13 20 95 147 128 200

SMC/
TSMC
186-188 AMR450S 11/16” 28 13 200 96 275 130

Coupling Torque (B)

Compressor Type Thread
Type Kpm. ft.lbf. Nm
128 225 5/16” 3.5 25 34
Serie 52

SAB 163 262 3/8” 4.2 30 41

Serie 52 B
202 312 7/16” 5.6 40 55

200 5/16” 3.5 25 34

225 5/16” 3.5 25 34

262 3/8” 4.2 30 41

Depends
VMY on the size 312 7/16” 5.6 40 55
Serie 52

of the motor

350 1/2” 13 95 128

375 9/16” 18 130 177

425 5/8” 25 175 245

450 11/16” 28 200 275

96 0171-370-EN
 Refrigeration Plant Maintenance

Operational Reliability refrigerant. Adjust any constant-pressure

valves to bring evaporating pressure down
The main reasons for operating malfunctions
to atmospheric pressure.
of the plant are:
3. Start up the compressor. Adjust regulating
1. Incorrect control of liquid supply to evapo-
system to lower suction pressure.
rator.
4. Watch the suction pressure gauge!
2. Moisture in plant.
When the suction pressure is equal to at-
3. Air in plant. mospheric pressure, stop the compressor
and shut off the discharge stop valve.
4. Anti-freezing liquid is missing. Shut off any stop valve in the oil return
line.
94.05

5. Congestion due to metal shavings and

dirt. If the receiver has an extra stop valve in
the feed line, this can be closed. Practical-
0171-464-EN

6. Congestion due to iron oxides.

ly the entire refrigerant charge will then be
7. Congestion due to copper oxides. collected in the receiver.

8. Inadequate refrigerant charge. Note:

The receiver must not be overfilled! There
In the following some information is given should be a minimum gas volume of 5%.
about how to keep contaminants out of the
refrigeration system and at the same time 5. A slight overpressure should normally re-
facilitating day-to-day supervision of the main in the piping system - this safe-
plant. guards the system against the penetration
of air and moisture.

Pumping down of Refrigeration 6. Before dismantling any parts, the opera-

Plant tor should put on a gas mask.

Before dismantling any parts of the refrigera-

tion plant for inspection or repair, the plant Dismantling of plant
must be pumped down. To prevent moisture from penetrating into the
refrigeration plant during repairs, it is advisa-
1. Open compressor suction and discharge
ble to follow the rules below:
stop valves.
1. No component should be opened un-
2. Close liquid stop valve after the condenser necessarily.
or receiver so that liquid refrigerant can be
collected in the receiver. Any solenoid 2. When dismantling the system, the pres-
valves in the liquid line must be opened by sure in the system should be a little higher
force, so that the liquid line is emptied of than atmospheric.

0171-370-EN 97
3. Note: Tightness Testing and Pumping
If the piping system is colder than the sur- down of Refrigeration Plant
roundings, there is a considerable risk of
Before charging refrigerant to the system part
damp precipitation (condensation) on cold
which has been opened, the part must be
plant parts. Plant components to be dis- pressure tested as described in the section
mantled must be warmer than the ambi- entitled Pressure testing.
ent temperature.
Pump down the refrigeration plant to elimin-
ate air and moisture. See the section Evacu-
4. No two points in the system should be ation. Otherwise, follow the instructions given
opened at the same time. in the separate instruction manual on plant
components.

5. Plug, close or at least cover opening with Note:

oiled paper or suchlike. If the oil in the oil separator of the screw
compressor has been in contact with at-
mospheric air for a rather long time, it
6. Be aware of the possibility of filters must be replaced with fresh oil of the
being very moist. same grade and make.

98 0171-370-EN
 Trouble-shooting on the Reciprocating Compressor
Plant

Operating condition lefthand column, the error being briefly de-

scribed in the next column. The third column
Experience shows that pressure and temper-
states code numbers for the possible causes
ature variations in a refrigeration circuit can
of the error.
provide information about the operating con-
dition of the refrigeration plant. The code numbers refer to the subsequent
chart.
In particular, suction and condenser pres-
sures as well as the temperatures of suction The section entitled Remedying malfunctions
and discharge gases may provide important states how to remedy the observed error.
information as to the operating conditions
See the following example for the correct
of the plant.
procedure.
91.05

It often takes only very slight modifications to

variable pressures and temperatures to pro- Example
duce considerable changes in operating con- Observed error: discharge pipe temperature
0170-335-EN

ditions. too low - error code 15.

Using the following troubleshooting chart, it is Cause codes:

possible to ascertain the cause of and reme- 26 (Liquid in suction line)
dy for any operating disturbance. 32 (Too much coolant/air to condenser)
39 (Expansion valve produces too little su-
Using the trouble-shooting chart perheating)

In the following chart, each individual error Any explanatory comments will be stated in
option is indicated by a code number in the the section that follows.

0171-370-EN 99
Error
code Observed error Cause code
1 Compressor fails to start 1, 2, 3, 4, 5, 6, 7, 9, 10, 12, 14.
2 Compressor starts and stops too often 9, 10, 11, 13, 21, 22, 23, 24, 32, 34, 35, 36, 37,
40, 41, 43, 44, 51, 52, 54, 56, 59.
3 Compressor starts but stops again immediately 3, 5, 6, 9, 10, 11, 12, 13, 14, 15, 17, 18, 41,
42, 49, 50, 55, 61.
4 Compressor operates continuously 8, 21, 22, 24, 41, 46, 52, 53, 56, 60.
5 Abnormal noise from compressor 16, 17, 18, 19, 26, 48, 49, 50, 51, 52, 53, 54, 56,
57, 58.
6 Insufficient capacity on compressor 13, 15, 17, 18, 20, 21, 22, 23, 24, 32, 34, 35, 36,
37, 40, 41, 44, 45, 46, 49, 50, 51, 52, 53, 56, 60.
7 Liquid stroke in compressor during start up 16, 18, 26, 37, 38, 39, 44, 56, 61.
8 Liquid stroke in compressor during operation 21, 23, 26, 37, 39.
9 Excessive condenser pressure 9, 25, 28, 29, 30, 31, 33.
10 Too low condenser pressure 22, 32, 51, 52, 54, 60.
11 Excessive suction pressure 13, 17, 26, 34, 39, 52, 53, 54, 5,. 60.
12 Too low suction pressure 11, 13, 20, 21, 22, 23, 32, 35, 36, 37, 40, 41, 42,
44, 45, 56, 59.
13 Too low oil pressure 12, 15, 17, 18, 26, 49, 50, 55.

14 Excessive discharge pipe temperature 11, 21, 22, 23, 28, 29, 30, 31, 33, 34, 35, 36, 37,
40, 41, 46, 52, 54.
15 Too low discharge pipe temperature 26, 32, 39.
16 Excessive oil temperature 33, 34, 35, 36, 37, 40, 50, 52.
17 Oil level in crankcase falling 16, 18, 20, 26, 51, 57, 58.
18 Oil foaming vigorously in crankcase 16, 26, 39, 61.
19 Crankcase sweating or frosting up 16, 18, 26, 37, 39.
20 Capacity regulating oscillating 13, 15, 16, 17, 18, 49, 55, 56.
21 Impossible to bleed plant 10, 43, 51, 52, 53, 54, 60.

100 0171-370-EN
 Code Case Code Case

1 No power - master switch not cut in 34 External pressure equalization on

2 Blown fuses - loose wiring or expansion valve closed
connections 35 Expansion valve partly clogged by
3 Electrical voltage too low ice, dirt, wax
4 No control current 36 Expansion valve has lost charge
5 Motor protection device activated 37 Expansion valve sensor misplaced
6 Control current circuit open 38 Expansion valve is leaky
7 Pump/fan not started 39 Expansion valve provides too little
8 Welded contracts in motor protection superheating
9 High-pressure cut-out has 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
42 Solenoid valve in liquid/suction line
small
closed
12 Oil pressure cut-out has cut
13 Capacity regulator incorrectly set 43 Solenoid valve leaky
14 Defrosting timer breaks current 44 Evaporator iced up or clogged
15 Oil charge insufficient 45 Cooling air being recirculated
16 Compressor capacity too high (short-circuited)
during start-up 46 Excessive load on plant
17 Oil pressure too low (adjust oil pres- 47 Refrigerant collecting in cold con-
sure regulating valve) denser (close off by-pass)
18 Oil foaming in crankcase 48 Coupling misaligned or loose bolts
19 Oil overcharge 49 Oil pump defective
20 Poor oil return - oil in evaporators 50 Bearings worn out or defective
51 Defective piston rings or worn
21 Restricted supply of refrigerant
cylinder
22 Refrigerant charge insufficient
52 Discharge valves defective or leaky
23 Refrigerant vapour in liquid line
53 Suction valves defective or leaky
24 Leaky refrigeration plant
25 Refrigerant overcharge 54 Compressor by-pass open - leaky
26 Liquid in suction line safety valve
27 At low temperature operation, de- 55 Compressor oil filter clogged
gree of charge in evaporators rises 56 Capacity regulator defective
28 Insufficient coolant/air to condenser 57 Solenoid valve in oil return clogged/
29 Temperature of coolant/air too high defective
30 Non-condensable gases in 58 Filter in oil return clogged
condenser 59 Compressor capacity too high
31 Condenser needs cleaning 60 Compressor capacity too low
32 Too much coolant/air to condenser 61 Heating element in crankcase
33 Water valve closed defective

0171-370-EN 101
Remedying malfunctions
1. Compressor fails to start

1.6 Control current circuit open owing Pinpoint open switch and
to activated: remedy cause of
pressure cut-outs interruption.
thermostats
motor protection device
defrosting timer
1.9 High-pressure cut-out has cut Reset pressure cut-out and investigate cause
of high condenser pressure.

1.10 Low-pressure cut-out has cut Compressor cannot start before suction pres-
sure has risen above set point for pressure
cut-out restarting.

1.12 Oil-pressure cut-out has cut Compressor starts at reset.

Check oil level. If oil
foams in crankcase, see section 18.

2. Compressor starts and stops too often

2.9 High-pressure cut-out cuts at High condenser pressure - see section 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 suction pressure - see section 12.
low suction pressure.
If low-pressure cut-out is set too high, adjust
pressure cut-out.

2.11 Low-pressure cut-out differential is Increase differential pressure - see also special
too small between stopping and instructions.
starting
2.13 Compressor capacity too high Check operating conditions and, if need be,
reduce capacity.

2.41 Filter in suction line clogged Check suction filters on compressor.

2.43 Solenoid valve in liquid line does Check direction of flow.

not close tight.
Replace defective valve.

2.52 discharge valves on compressor At compressor stop, pressure equalizes rela-

are leaky. tively quickly between suction and discharge
side
Clean or change discharge valves.

102 0171-370-EN
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.

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
shortage.
3.18 Oil pressure failing owing to for- Reduce capacity. See sections 17 and 18.
mation of foam in oil.

4. Compressor operates continuously

4.10 Thermostat or low-pressure Adjust operating points.

cut-out does not cut at too low
temperature/pressure

4.21 Restricted supply of refrigerant to Remove dirt in filters and check function of ex-
evaporator. Compressor working pansion device as per special instructions.
at too low suction pressure.

4.22 Refrigerant charge unsufficient Top up with refrigerant of correct type.

0171-370-EN 103
5. Abnormal noise from compressor

5.16 Compressor capacity too high du- Reduce capacity.

ring start-up

5.17 Oil pressure too low See section 13.

5.26 Liquid refrigerant in suction line Liquid stroke. See points 7 and 8.
Adjust expansion or float valves.

5.48 Incorrect alignment of motor and Check alignment as per special instructions.
compressor
Loose bolts in coupling Tighten with torque wrench

5.50 Worn or defective bearings Overhaul or replace.

5.51 Too much oil circulating Check oil level.

5.53 through the plant, resulting in too
5.57 Solenoid valve, filter or jets in oil return system
low oil level in
5.58 compressor may be clogged. Leaky suction valve ring
plates, piston rings and worn-out cylinder may
also produce such oil consumption.

5.56 Capacity regulation oscillating Low oil pressure - see section 13.
owing to failing oil pressure

6. Too little capacity on compressor

6.15 Insufficient oil charge Top up with fresh oil of same type and make.

6.44 Iced-up evaporator Defrost evaporator; adjust defrosting time if

required.
6.49 Defective oil pump and hence fail- Repair or replace oil pump
ing oil pressure
6.56 Defective capacity regulating sys- Cause is most often failure in oil pressure or
tem refrigerant in oil; see section 4.5.

104 0171-370-EN
7. Liquid stroke in compressor during start-up

Liquid stroke in the compressor should not occur, as in the worst instance this can
cause rupture to the valve ring plates and damage to the inbuilt relief devices. Fur-
thermore, it can result in damage to the connecting rod bearings and cylinders if the
coolant degreases the faces and impairs the lubricating capacity of the oil.

7.18 Adsorption of (H)CFC refrigerant Reduce compressor capacity or start with

in oil throttled suction stop valve.
Sudden reduction in pressure Follow instructions in section 18.
across the oil sump (suction pres-
sure) produces foaming

7.26 Refrigerant has condensed in suc- Heating element in crankcase should be con-
tion line or crankcase nected for 6-8 hours before starting, so that
refrigerant dissolved in oil can be boiled out
before starting compressor up.
Suction line has free fall towards Start with throttled suction stop valve - stop
compressor when hammering is heard.
Liquid separator should be mounted in suction
pipe.

8. Liquid stroke in compressor during operation

8.23 Refrigerant gas in liquid line Expansion valve is oscillating.

8.39 Superheating of expansion valve Adjust superheating, which should normally be

is set too low 5-8°C.

0171-370-EN 105
9. Excessive condenser pressure

In the event of abnormally high pressures in the refrigeration system, there is a risk of
damage to the compressor. At very high pressures (see pressure testing), the risk of
the components in the refrigeration plant exploding can constitute a threat to life.
Abnormally high pressures can occur in the case of:
- extreme heating of plant parts (fire, solar radiation or other abnormal heating);
- volumetric expansion of fluids in sealed-off premises.

9.25 Overfilling with refrigerant Refrigerant fills condenser and reduces its ef-
fective area.
Draw off coolant.

9.28 Insufficient condenser cooling, Regulate water/air supply or reduce compres-

e.g. if cooling water fails, fan/ sor capacity, if called for. Check condenser as
coling water pump clogs, soiling, per instructions for same.
scaling or fouling of heat-transmit-
ting surfaces
9.30 Presence of non-condensable Blow air out at condenser. Follow instructions
gases (especially air) in conden- for condenser.
ser.

10. Too low condenser pressure

10.32 Excessive condenser cooling Regulate condenser cooling.

10.51 Defective piston rings or worn cy- Replace worn parts. See compressor instruc-
linders tions.

10.52 Discharge valves are defective or See compressor instructions. Check valve ring
leaky plates and piston rings.

10.54 Bypass between high-pressure Check compressor for internal leakage by per-
side and suction side of compres- forming pressure-drop test.
sor
See compressor instructions.

10.60 Compressor lacks capacity. Check whether compressor capacity corre-

sponds to load on plant. Reduce condenser
cooling.

106 0171-370-EN
11. Excessive suction pressure

11.26 Error in setting of liquid regulation Liquid refrigerant in suction line.

valve
Adjust, repair or 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 si- Check system for any by-pass detectable as a
de and high-pressure side of com- warm connection.
pressor. Safety valve leaky, or
opens prematurely. Adjust or repair leaky valves.

11.60 Compressor lacks capacity. Regulate compressor capacity.

Check whether all cylinders are operating.
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 abnor-
mally 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 Find and seal any leak.

12.35 Freezing-up of expansion valve Thaw out expansion valve with hot, wet cloths.
(HFC/HCFC plant)
Replace dessicant in drying filter.

12.36 Thermostatic expansion valve has Valve fails to open - change valve.
lost charge

12.40 Excessive superheating of suc- Regulate expansion valves to higher capacity.

tion gas

0171-370-EN 107
 12.41 Filter in liquid line clogged Check and clean filter in liquid line.

12.42 Solenoid valve in liquid line fails to Coil may have blown. Control signal lacking.
open

12.59 Compressor has excessive capa- Reduce compressor capacity.

city
Check capacity regulating system.

13. Oil temperature too low

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 point 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 Check refrigerant charge

result of reduced refrigerant sup-
ply to evaporator (extensive su-
perheating) owing to insufficient
refrigerant charge.

14.22 Excessive suction temperature as Check thermostatic expansion valves

result of reduced refrigerant sup-
ply to evaporator (extensive su-
perheating) owing to incorrectly
adjusted liquid regulating 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 Localize by-pass and remedy any leakages.
low-pressure side of compressor,
e.g. leaky safety valve

108 0171-370-EN
15. Too low discharge pipe temperature

15.26 Low suction temperature as result Adjust liquid regulating valve. Increase super-
of overflow of liquid refrigerant heating.
from evaporator

16. Excessive oil temperature

During operation, the heat of the compressor crankcase must be 40-70°C. When
working with R717 and R22, it may be necessary to supply the compressor with oil
cooling.
See point 14.

17. Oil level in crankcase falling

Where HFC/HCFC refrigerants are used, there will be some blending of refrigerant
and oil during the initial operating period. It may therefore prove necessary to top up
the oil after initial start-up of the plant.
Note:
The oil level must always be visible in the oil level sight glass on the compressor.

17.20 Filter in solenoid valve or jet in oil Oil return pipe must be warm during opera-
return line clogged tions. Clean filter.

17.26 Liquid in suction line and crank- Examine evaporator system and check super
case may cause foaming in oil heating of suction gas.
and thus increase oil consumption

17.51 Worn-out piston rings or cylinders Renew piston rings and, if need be, renew pis-
tons and cylinder linings.

17.57 Solenoid valve in oil return line de- Coil in solenoid valve defective.
fective - Replace coil.
- Electrical control signal lacking.

0171-370-EN 109
18. Heavy oil foaming in crankcase

18.26 Liquid in suction line See 17.26.

18.61 Too much refrigerant dissolved in - Before starting compressor, heating element
oil must have been on for at least 8 hours in
order to boil refrigerant out of oil. During
start-up phase, capacity should be con-
nected at a slow rate to prevent sudden drop
in pressure on suction side with resultant
foaming.
- Under normal operating conditions, com-
pressor should operate under as stable
pressure conditions as possible.

19. 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 val- Increase superheating on thermostatic expan-
ve producing too much liquid sion valve.

20. Capacity regulation oscillating

20.18 Oil foaming in crankcase See point 18.

21. Impossible to bleed plant

21.43 Solenoid valve leaky Pinpoint and seal leak, or change leaky com-
ponent.

21.51 Defective piston rings Check and replace any defective parts.

21.52 Defective discharge valves Check and replace any defective parts.

21.53 Defective suction valves Check and replace any defective parts.

110 0171-370-EN
 Selecting Lubricating Oil for SABROE Compressors

During the past few years Sabroe Lubricating oils with relatively high viscosities
Refrigeration has experienced a number of must be used to ensure satisfactory lubrica-
problems with mineral oils, particularly in tion of refrigeration compressors.
R717 plants. The problems can be divided
To obtain the best lubrication, the oil must:
into two groups:
S Provide the required fluidity at the lowest
a: The oil changes viscosity evaporating temperature encountered in
b: The oil decomposes (becomes very black) the plant and at the highest permissible
temperatures in the compressors.
The problems have been seen with several
S Provide acceptable fluidity at start-up.
mineral oil brands, often occuring within a
few operating hours and resulting in severe S Provide sufficient oxidation stability (the oil
consequences for both compressor and must be moisture-free when added to the
system).
plants.
S Provide sufficient chemical stability when
Following the careful investigation undertak- used together with the particular refriger-
en by Sabroe Refrigeration during the past ant.
00.06

few years, it has been decided to introduce a In addition, the extent to which different re-
range of synthetic oils which can fulfil the de- frigerants dissolve in the oil must be deter-
0170-151--EN

mands of modern refrigeration plants. mined, so that the oil return systems, etc. can
be designed to function properly.
Mineral oils may continue to be used in re-
frigeration plants, providing the lubricating Stratification
quality is carefully monitored. For modern, It should be noted that in certain plants, par-
high capacity refrigeration plants, where long ticularly with HFC and HCFC refrigerants, the
lifetime for both lubricants and moving parts oil may stratify into layers in the refrigerant
is expected, Sabroe Refrigeration recom- receivers and evaporators at certain operat-
mends the choice of synthetic lubricating oils. ing conditions and at particular oil concentra-
tions.
The application areas and specifications for
these synthetic oils can be found in the fol- The Oil recommendation diagrams for
lowing pages. Installers and/or users are at SABROE compressors for HFC and HCFC
liberty to choose either Sabroe Refrigera- will indicate the limits for Sabroe oils at which
tion’s own or alternative oil brands which fulfil this stratification occurs. The oil concentra-
the necessary specifications. tions stated in these diagrams must not be
exceeded. This will enable suitable oil rectifi-
General cation/return systems to be designed to bal-
This recommendation only deals with the lu- ance with the compressor oil ”carry-over” so
brication of the compressor. The perfor- that the maximum concentration is not ex-
mance of the lubricant in the plant (receiver, ceeded.
evaporator, etc.) must, however, also be tak- For area A in the diagrams, the max oil con-
en into consideration. centration in liquid phase must not exceed

0171-370-EN 111
2%. For the other area, the max. oil con- oil best suited to the operating conditions.
centration must not exceed 5%. For area B: With this code number, it is possible to se-
please contact Sabroe Refrigeration. lect the correct Sabroe oil for the application.
The marked area on each side of the sepa-
Plants with several different compressor rating line in the diagram shows the zone
types/makes where both oils are useable.
In plants comprising several different inter-
connected compressor types and makes, it is Oil types and oil companies
strongly recommended that all compressors As a result of the large number of oil compa-
should use the same type of oil. This is es- nies world-wide that deals in oil for refrigera-
sential where automatic oil return systems tion plants, it is impossible for Sabroe
are employed. Refrigeration to test the many different
If it is intended to change the oil from one brands of oil on the market. It is our experi-
type to another, please refer to the Oil chang- ence, however, that some oil brands during
ing on SABROE compressors later in this use can change character and thus no longer
publication. fit the specifications given by the companies
at delivery. We have thus experienced
Selecting the lubricating oil changes in the specifications as well as in
There are a number of operating diagrams the formula and performance without having
for the selection of lubricating oils for Sabroe had any information about this from the oil
compressors operating with various refriger- company. This makes it very difficult for Sa-
ants. Once the general conditions concern- broe Refrigeration to give a general approval
ing the lubrication of the compressor and oil of the various oil brands.
type in the plant have been considered, the
specific plant conditions must be taken For this reason Sabroe Refrigeration has, in
into consideration. cooperation with a large recognised oil com-
pany, developed a series of three oils which
Use the Oil recommendation diagrams to se-
cover most purposes. Sabroe Refrigeration
lect the appropriate oil code number.
has however, also listed a limited number of
The oil code number consists of letters des-
oils which can be supplied through Sabroe
ignating the oil type together with the Sabroe
Refrigeration. The typical data of these oils
viscosity grade number.
can be found in the Data Sheet for Sabroe
Code
Oil types
Oils. We suggest you to use these Sabroe
design oils, which are delivered in 20 litre pails and
M Mineral oil 208 litre drums and can be ordered using the
Synthetic oil based on parts no. listed in the List of Oils.
A
Alkylbenzene
Synthetic oils based on It is of course possible to use similar oils from
PAO
Polyalphaolefin other oil companies, and in this connection,
AP Mixture of A and PAO-oils the Data Sheet for Sabroe Oils may be help-
E Synthetic ester-based lubricants ful.

In the oil recommendation diagrams for each Please note, however, that Sabroe
refrigerant and compressor type, it is pos- Refrigeration has not tested any other oils
sible to determine the code number for the than our own brand, and hence we cannot

112 0171-370-EN
answer for the quality, the stability or the suit- Screw compressors:
ability of other oils for any purposes. The oil The oil temperature before injection in
company in question is thus solely responsi- the compressor, but after the oil cooler
ble for the quality and suitability of the oil de- Max. permitted oil temperature = set-
livered, and if any problems are experienced ting point for alarm
with these oils in the compressors or in the
Min. permitted oil temperature = set-
refrigeration plant, the oil supplier should be
ting point for alarm
contacted directly.
• Condensing pressure
• Evaporating pressure
When choosing oils from other oil compa-
nies, please pay particular attention to the S Oil viscosity in the compressor during
oil’s effectiveness in the compressor and the operation and under the influence of:
refrigeration plant as a whole. • Refrigerant type and solubility of refrig-
erant in the oil
Pay particular attention to the following as- • Operating temperatures
pects:
• Vapour pressure in the oil reservoir
Reciprocating compressor: Suction
S Oil type pressure and oil temperature in the
crankcase.
S Refrigerant type
Screw compressor: Discharge pressure
S Compressor type and gas temperature.

S Miscibility between refrigerant and oil S Compatibility with the neoprene O-rings:
the aniline point gives an indication of how
S Operating data for the compressor the O-ring material reacts to the oil.
At an aniline point less than approximately
• Discharge gas temperature
100°C the material tends to swell, and at
• Oil temperatures: an aniline point higher than approximately
120°C it tends to shrink.
Reciprocating compressors:

Normal oil temp. in the crankcase For this reason it is not recommended to
50-60 °C change oil type from M oil to PAO oil as a
leakage may occur if the O-rings are not
Max. permitted oil temperature = Set-
changed. Sabroe Refrigeration therefore
ting point for alarm
recommends using the Sabroe AP68 oil
Min. permitted oil temperatures = set- as it reduces the risk of leaks considerably
ting point for alarm - if fitted in this case.

0171-370-EN 113
Sabroe Refrigeration can supply a calculation Sabroe Refrigeration is aware, however, that
showing the operating data on request. several customers have been using mineral
oils for many years without problems. Those
Attention is drawn to the following viscosity customers who wish to continue using miner-
limits during operation: al oils in existing, as well as new, compres-
sors can do so, providing the compressor
S Optimum viscosity range
type and operating conditions are similar to
(to be designed for) = 20 to 50 cSt
the existing ones (excepting the HPC and
S Max. permissible viscosity =100 cSt HPO series compressors).
S Min. permissible viscosity =10 cSt
(only applicable to HCFC and HFC under Sabroe Refrigeration has therefore decided
cartain operating conditions: 7cSt)
to market a brand of mineral oil which has
S Max. permissible viscosity during the been tested and found to be suitable for most
starting of the compressor = 500 cSt general refrigerating purposes.
Maximum refrigerant concentration in the oil
at running condition: 25% - also if viscosity If another brand of mineral oil is chosen, the
requirements are met. specifications in the data sheet in this recom-
mendation should be followed as a guideline.
Use of mineral oil
Lately we have experienced a number of
Mineral oil can be used in refrigerating
problems with mineral oil, particularly in R717
plants, providing the lubricating quality is
plants. The problems can be divided into two
carefully monitored. For modern, high capac-
groups:
ity refrigeration plants, in which a long life-
a: The oil changes viscosity within a few time for both lubricant and moving parts is
operating hours. expected, Sabroe Refrigeration recommends
b: The oil decomposes (becomes very using synthetic lubricating oils.
black) within a few operating hours.
A benefit of using the synthetic lubricant oil is
The problems have been seen with several
a much lower oil carry-over to the plant and
oil brands and have resulted in severe con-
longer intervals between oil changes.
sequences for both compressors and plants.
A better fluidity at lower temperatures also
gives an easier drainage at the cold parts of
When using mineral oil, it is thus important
the plant.
that the plant is monitored very closely, that
oil samples are taken regularly (every
1-2,000 hours) and that the condition/colour
How to use the oil recommendation dia-
of the oil is checked on a weekly basis.
grams:
Sabroe Refrigeration therefore recom- To determine the code number, first refer to
mends only to use M oil at moderate oper- the Oil recommendation diagram for the re-
ating conditions - cf. the attached oil rec- frigerant and compressor type and then plot
ommendation diagrams. the proposed operating conditions.

114 0171-370-EN
 Example (recip. compressors): the example above, a oil code number E5
Refrigerant: R134a can be selected.
Condensing temp. TC +35°C
Evaporating temp. TE --3°C Code no Area no
1 2
Please observe !
E5 Y
Plants may operate at different conditions
from time to time, for example at different E9 Y
evaporating temperatures due to plant
In plants which incorporate both screw and
variations or at different condensing tem-
reciprocating compressors and where the
peratures due to seasonal changes.
recommendations indicate the use of differ-
By plotting TC and TE in the oil recom-
ent oil types, please contact Sabroe
mendation diagram, this example would
Refrigeration for advice.
require a No 1 oil. If, however, TE
changes at certain times, e.g. from --3 to Changing oil on Sabroe compressors
+7°C, a No 2 oil should be utilised. But, as
The oil should never be changed to another
+7°C is inside the marked area, the No 1
type without consulting the oil supplier. Nor is
oil can be utilised also at this TE.
it advisable to ”top up” compressors with an
R134a other oil than the one already used for the
TC
particular plant and compressor.
°F °C
158 70
Mixing different oils may result in operating
140 60 2
problems in the refrigerant plant and damage
122 50
to the compressors. Incompatibility between
Condensing temperature

104 40
• • the different oil types may degrade the lubri-
86 30
cating properties or may cause oil residues to
68 20 1
form in the compressor or oil separator or in
50 10
the plant. These oil residues can block filters
32 0
and damage the moving parts in the com-
14 -10
pressor.
-4 -20

-22 -30 Furthermore, changing the oil from one type

-60 -50 -40 -30 -20 -10 0 10 20 30 ° C
or make to another should only be undertak-
TE
-76 -58 -40 -22 -4 1432 50 68 86 ° F en in connection with a careful procedure in-
Evaporating temperature
volving the drainage and thorough evacua-
By referring to the Oil recommendation table tion of the refrigeration plant. Information on
placed at the bottom of each oil recommen- a suitable procedure can be obtained from
dation diagram, it is possible to select the Sabroe Refrigeration as well as from a num-
code number for the appropriate oil type. In ber of oil companies.

0171-370-EN 115
It is imperative that oil is only used from the Oil drums should, ideally, be ”racked” and
original container and that both the make and mounted with a proper barrel tap to ensure
type complies with the specification for the an effective airtight seal.
plant.
Oil changing intervals
Ensure that the original container is sealed A list of the recommended intervals for
during storage to prevent moisture from the changing the oil can be found in the com-
air being absorbed into the oil - many oils, pressor instruction manual. These are pro-
particulary the polyolester oils, are extremely vided for guidance only. The actual interval
hygroscopic. Consequently, it is recom- between oil changes will often be determined
mended that the oil is only purchased in con- by a variety of operating parameters within
tainers corresponding to the amount to be the plant.
used on each occasion.
It is strongly recommended to monitor the
If the oil is only partially used, make sure that quality of the oil by carrying out oil analyses
it is effectively re-sealed in the original con- with regular intervals. This will also give a
tainer and that it is stored in a warm, dry good indication of the condition of the plant.
place. Ideally with nitrogen blanking of the oil The service can be supplied by Sabroe
to keep the water content below 50 ppm. Refrigeration or the oil suppliers.

Oil recommendation diagram symbols:

Y : In case of a new plant. Very suitable.
l : In case you wish to change from mineral oil
A : Max oil concentration in liquid phase at: TE: 2% W
B : Max oil concentration in liquid phase: contact Sabroe Refrigeration
C : Min suction temperature --50°C: at TE< --50°C superheating must be introduced.
* : Dry expansion systems only. Flooded systems to be considered individually: contact Sabroe Refrigeration
SH : Suction gas superheat, K (Kelvin)
: Zone in which both oils are useable
: Calculation must be performed using COMP1

116 0171-370-EN
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 °C 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
PAO3 66 10.1 136 0.835 266 <--45 138 0.03
PAO5 94 13.7 147 0.838 255 <--45 144 0.03
PAO9 208 25 149 0.846 260 <--39 154 0.03
E3
Due to the big difference between polyolester-based lubricants from various suppliers,
suppliers it is
E5
p
not possible to p yp
present typical g another oil brand than the one
data for these oils. When using
E9 recommended by Sabroe Refrigeration, please contact the oil supplier to select the correct
oil type
type.
E11

The listed data are typical values and are intended as a guideline only when selecting a similar
oil from a different oil company. Data equivalence alone does not necessarily qualify the oil for
use in Sabroe Refrigeration’s Sabroe compressors.

0171-370-EN 117
List of part numbers for available Sabroe oils

Part no.
Oil brand Oil code no.
no
20 litre pail 208 litre pail
Mobil Gargoyle Arctic 300 M 1 (M68) 1231-264 1231-296
Sabroe Oil A100 A 3 (A100) 1231-263 1231-262
Sabroe Oil AP68 AP 1 (AP68) 1231-257 1231-260
Sabroe Oil PAO68 PAO 3 (P68) 1231-256 1231-259
Mobil Gargoyle Arctic SHC 228 PAO 5 (P100) 1231-282 1231-283
Mobil Gargoyle Arctic SHC 230 PAO 9 (P220) 1231-284 1231-285
Mobil EAL Arctic 68 E 3 (E68) 1231-272 1231-273
Mobil EAL Arctic 100 E 5 (E100) 1231-274 1231-275
Mobil EAL Arctic 220 E 9 (E220) 1231-279
Sabroe H oil E11 (E370) 3914 1512 954 1) 9415 0008 000
1) 18.9 litre pail (5 US gallons)

The oils recommended by the former Stal Refrigeration correspond to the following oils:

Stal Refrigeration oil type Sabroe oil

A Mobil Gargoyle Arctic 300 -- M1 (M68)

B Sabroe Oil PAO 68 -- PAO 3 (PAO 68)
C Mobil Gargoyle Arctic SHC 230 -- PAO 9 (PAO 220)
H Sabroe H oil -- E 11 (E 370)

118 0171-370-EN
R717 TC
one-stage
°F °C
reciprocating
122 50
compressors
104 40
Condensing temperature
86 30

68 20 1

50 10

32 0

Code no Area 14 -10

no
1
-4 -20
PAO 3 Y

-22 -30
AP 1 l/Y -60 -50 -40 -30 -20 -10 0 10 20 °C
TE
M1 Se e -76 -58 -40 -22 -4 14 32 50 68 °F
note 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.
Y : Very suitable in case of a new plant.
l : In case you wish to change from mineral oil.

0171-370-EN 119
R717 TC
two-stage
°F °C
reciprocating
122 50
compressors
104 40
Condensing temperature
86 30
1
68 20

50 10

32 0

Code no Area 14 -10

no
1
-4 -20
PAO 3 Y

-22 -30
AP 1 l/Y -60 -50 -40 -30 -20 -10 0 10 20 °C
TE
M1 See -76 -58 -40 -22 -4 14 32 50 68 °F
note 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.
Y : Very suitable in case of a new plant.
l : In case you wish to change from mineral oil.

120 0171-370-EN
R717 TC
HPO og HPC
°F °C
reciprocating
176 80
compressors
158 70

Condensing temperature
140 60
1
122 50

104 40

86 30

68 20

50 10
Code no Area
no
1 32 0
PAO 5 Y -30 -20 -10 0 10 20 30 40 50 °C
TE
-22 -4 14 32 50 68 86 104 122 °F
Evaporating temperature

Please observe: PAO 5 oil is the only oil which can be used in the HPO and HPC compressors

Y : Very suitable in case of a new plant.

0171-370-EN 121
R22 TC
Contact Sabroe Refrigeration

one-stage
°F °C
reciprocating 2
122 50
compressors
104 40
Condensing temperature
86 30
1
68 20

50 10

32 0

14 -10 A
Code no Area -4 -20
no
1
-22 -30
A3 Y
-60 -50 -40 -30 -20 -10 0 10 20 °C
TE
-76 -58 -40 -22 -4 14 32 50 68 ° F
C Evaporating temperature

Y : Very suitable In case of a new plant.

A : Max oil concentration in liquid phase at TE: 2% W.
C : Min suction temperature -50 °C. At TE<-50°C superheating must be introduced.

122 0171-370-EN
R22 TC
two-stage
°F °C
reciprocating
122 50
compressors
104 40
Condensing temperature
86 30 1
A
68 20

50 10

32 0

14 -10

Code no Area -4 -20

no
1
-22 -30
A3 Y -60 -50 -40 -30 -20 -10 0 10 20 °C
TE
-76 -58 -40 -22 -4 14 32 50 68 °F
C Evaporating temperature

Y : Very suitable in case of a new plant.

A : Max oil concentration in liquid phase at TE: 2% W.
C : Min suction temperature -50 °C. At TE<-50°C superheating must be introduced.

0171-370-EN 123
 TC
R134a
°F °C
one-stage
158 70
reciprocating
140 60 2
compressors
122 50

Condensing temperature 104 40

86 30

68 20 1
50 10

32 0

14 -10
Code no Area
no -4 -20
1 2
-22 -30
E5 Y
E9 Y
-60 -50 -40 -30 -20 -10 0 10 20 30 ° C
TE
-76 -58 -40 -22 -4 14 32 50 68 86 ° F
Evaporating temperature

Y : Very suitable in case of a new plant.

: Zone in which both oils are applicable.

124 0171-370-EN
R134a TC

two-stage °F °C
reciprocating 158 70
compressors 140 60

122 50
1
Condensing temperature 104 40

86 30

68 20

50 10

32 0

14 -10

-4 -20
Code no Område
no -22 -30
1
-40 -40
E5 Y
-70 -60 -50 -40 -30 -20 -10 0 10 20 30 °C
TE
-94 -76 -58 -40 -22 -4 14 32 50 68 86 ° F
Evaporating temperature

Y : Very suitable in case of a new plant.

0171-370-EN 125
R407C TC
one-stage
°F °C
reciprocating
122 50
compressors
104 40
Condensing temperature
86 30

68 20

1
50 10

32 0

14 -10
B
Code no Area -4 -20
no
1
-22 -30
E3 Y -60 -50 -40 -30 -20 -10 0 10 20 °C
TE
-76 -58 -40 -22 -4 14 32 50 68 °F
C Evaporating temperature

Y: Very suitable in case of a new plant.

B: Max oil concentration in liquid phase: contact Sabroe Refrigeration
C: Min suction temperature -50 °C. At TE<-50°C superheating must be introduced.

126 0171-370-EN
R407C TC
two-stage
°F °C
reciprocating
122 50
compressors
104 40
Condensing temperature
86 30 1
68 20 B

50 10

32 0

14 -10

Code no Area -4 -20

no
1
-22 -30
E3 Y -60 -50 -40 -30 -20 -10 0 10 20 °C
TE
-76 -58 -40 -22 -4 14 32 50 68 °F
C Evaporating temperature

Y: Very suitable in case of a new plant.

B: Max oil concentration in liquid phase: contact Sabroe Refrigeration
C: Min suction temperature -50 °C. At TE<-50°C superheating must be introduced.

0171-370-EN 127
R404A TC
one-stage
°F °C
reciprocating
122 50
compressors
104 40 2
Condensing temperature

86 30

68 20

50 10 1

32 0

Code no Area 14 -10

no
1 2
-4 -20
E3 Y
-22 -30
E5 Y -60 -50 -40 -30 -20 -10 0 10 20 °C
TE
-76 -58 -40 -22 -4 14 32 50 68 °F
C Evaporating temperature

Y: Very suitable in case of a new plant.

C: Min suction temperature -50 °C. At TE<-50°C superheating must be introduced.
: Zone in which both oils are applicable.

128 0171-370-EN
R404A TC
two-stage
°F °C
reciprocating
122 50
compressors
104 40
Condensing temperature
86 30
1
68 20

50 10

32 0

14 -10

Code no Area -4 -20

no
1
-22 -30
E3 Y -60 -50 -40 -30 -20 -10 0 10 20 °C
TE
-76 -58 -40 -22 -4 14 32 50 68 °F
C Evaporating temperature

Y: Very suitable in case of a new plant.

C: Min suction temperature -50 °C. At TE<-50°C superheating must be introduced.

0171-370-EN 129
R410A TC
HPO and HPC
°F °C
reciprocating
122 60
compressors
50
104
40
Condensing temperature

86
30
68 20

10 1
50

0
32
A
-10
14
-20
Code no Area -4
no -30
1
-22 -40
E5 Y

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

TE
-76 -58 -40 -22 -4 14 32 50 68 °F
Evaporating temperature

Y: Very suitable in case of a new plant.

A: Max oil concentration in liquid phase at: TE: 2%W

130 0171-370-EN
R507 TC
one-stage
°F °C
reciprocating
122 50
compressors
104 40
Condensing temperature
86 30

68 20
1
50 10

32 0

14 -10

Code no Area -4 -20

no
1
-22 -30
E5 Y -60 -50 -40 -30 -20 -10 0 10 20 °C
TE
-76 -58 -40 -22 -4 14 32 50 68 °F
C Evaporating temperature

Y: Very suitable in case of a new plant.

C: Min suction temperature -50 °C. At TE<-50°C superheating must be introduced.

0171-370-EN 131
R507 TC
two-stage
°F °C
reciprocating
122 50
compressors
104 40
Condensing temperature
86 30
1
68 20

50 10

32 0

14 -10

Code no Area -4 -20

no
1
-22 -30
E5 Y -60 -50 -40 -30 -20 -10 0 10 20 °C
TE
-76 -58 -40 -22 -4 14 32 50 68 °F
C Evaporating temperature

Y: Very suitable in case of a new plant.

C: Min suction temperature -50 °C. At TE<-50°C superheating must be introduced.

132 0171-370-EN
R717 TC

screw compressors °F °C

122 50

104 40

Condensing temperature
86 30

68 20 1

50 10

32 0

14 -10
Code no Area
no
1 -4 -20
PAO 3 Y
-22 -30
AP 1 l/Y 20 °C
-60 -50 -40 -30 -20 -10 0 10
TE
M1 See -76 -58 -40 -22 -4 14 32 50 68 °F
note
C 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.
HLI: Calculation must be performed using COMP1.

Y : Very suitable in case of a new plant.

l : In case you wish to change from mineral oil.
C : Min suction temperature -50 °C. At TE<-50°C superheating must be introduced.
: Calculation must be performed using COMP1.

0171-370-EN 133
R22 TC
SH10 SH20 SH25 SH5 SH10
screw compressors °F °C
with journal 122 50
bearings or roller
2
bearings Condensing temperature 104 40

86 30 SH5

68 20
1
50 10

32 0 A

Code no Area 14 -10

no
1 2* SH20
-4 -20
A3 Y
-22 -30
PAO 5 Y -60 -50 -40 -30 -20 -10 0 10 20 °C
TE
-76 -58 -40 -22 -4 14 32 50 68 °F
C Evaporating temperature

By using the calculation programme COMP1 it is possible to optimize the requirement for suction superheat values
(SH) as stated in the diagram. See Oil types and oil companies in this section. Due to the ongoing development of
lubrication oils, please contact Sabroe Refrigeration for an update on the requirement for superheat.

HLI: Calculation must be performed using COMP1.

Y : Very suitable in case of a new plant.

A : Max oil concentration in liquid phase at TE: 2%W.
C : Min suction temperature -50 °C. At TE<-50°C superheating must be introduced.
* : Dry expansion systems only. Flooded systems to be considered individually: contact Sabroe
Refrigeration.
SH : Suction gas superheat, K (Kelvin).
: Calculation must be performed using COMP1.

134 0171-370-EN
R22 TC

screw compressors °F °C
with roller bearings 122 50
only
104 40
Condensing temperature
86 30

68 20
1
50 10

32 0 A

14 -10
Code no Area no
1 SH20
-4 -20
A3 Y
-22 -30
-60 -50 -40 -30 -20 -10 0 10 20 °C
TE
-76 -58 -40 -22 -4 14 32 50 68 °F
C Evaporating temperature

By using the calculation programme COMP1 it is possible to optimize the requirement for suction superheat values
(SH) as stated in the diagram. See Oil types and oil companies in this section. Due to the ongoing development of
lubrication oils, please contact Sabroe Refrigeration for an update on the requirement for superheat.

HLI: Calculation must be performed using COMP1.

Y : In case of a new plant. Very suitable.

A : Max oil concentration in liquid phase at: TE: 2% W
C : Min suction temperature --50°C: at TE< --50°C superheating must be introduced.
* : Dry expansion systems only. Flooded systems to be considered individually: contact Sabroe Refrigeration
SH : Suction gas superheat, K (Kelvin)
: Calculation must be performed using COMP1

0171-370-EN 135
R134a TC

screw compressors °F °C SH30

158 70

140 60 SH20

122 50
Condensing temperature 2 SH10
104 40

86 30
SH5
68 20

50 10 1

32 0
Code no Area no
(See note) 14 -10
1 2 SH20
E5 Y -4 -20
E9 Y -50 -40 -30 -20 -10 0 10 20 30 °C
TE
-58 -40 -22 -4 14 32 50 68 86 ° F
Evaporating temperature

Note: For the compressors type ”S”, ”Rotatune”, ”SAB 81”, ”SAB 83”, and ”SAB 85” only Sabroe oil H is approved.
By using the calculation programme COMP1 it is possible to optimize the requirement for suction superheat values
(SH) as stated in the diagram. See Oil types and oil companies in this section. Due to the ongoing development of
lubrication oils, please contact Sabroe Refrigeration for an update on the requirement for superheat.
HLI: Calculation must be performed using COMP1.
Y : In case of a new plant. Very suitable.
SH : Suction gas superheat, K (Kelvin)
: Zone in which both oils are useable
: Calculation must be performed using COMP1

136 0171-370-EN
R404A TC

screw compressors
°F °C
SH15
104 40

86 30

Condensing temperature
3 SH10
68 20 2 (3)

50 10
(2)
32 0
1
14 -10
B
Code no Area no
(See note) -4 -20
1 2 3 SH15

E3 Y -22 -30
E5 Y -70 -60 -50 -40 -30 -20 -10 0 10 °C
E9 Y TE
-94 -76 -58 -40 -22 -4 14 32 50 °F
C Evaporating temperature
Note: For the compressors type ”S”, ”Rotatune”, ”SAB 81”, ”SAB 83”, and ”SAB 85” only Sabroe oil H is approved.
By using the calculation programme COMP1 it is possible to optimize the requirement for suction superheat values
(SH) as stated in the diagram. See Oil types and oil companies in this section. Due to the ongoing development of
lubrication oils, please contact Sabroe Refrigeration for an update on the requirement for superheat.
HLI: Calculation must be performed using COMP1.

Y : In case of a new plant. Very suitable.

B : Max oil concentration in liquid phase: contact Sabroe Refrigeration
C : Min suction temperature --50°C: at TE< --50°C superheating must be introduced.
SH : Suction gas superheat, K (Kelvin)
: Zone in which both oils are useable
: Calculation must be performed using COMP1

0171-370-EN 137
R407C TC

screw compressors
°F °C
122 50
SH10
104 40
Condensing temperature SH5
86 30 2

68 20

50 10

32 0 1
B
14 -10

Code no Area no -4 -20

(See note) SH5
1 2
-22 -30
E3 Y -70 -60 -50 -40 -30 -20 -10 0 10 20 °C
E9 Y TE
-94 -76 -58 -40 -22 -4 14 32 50 68 ° F
C Evaporating temperature

Note: For the compressors type ”S”, ”Rotatune”, ”SAB 81”, ”SAB 83”, and ”SAB 85” only Sabroe oil H is approved.
By using the calculation programme COMP1 it is possible to optimize the requirement for suction superheat values
(SH) as stated in the diagram. See Oil types and oil companies in this section. Due to the ongoing development of
lubrication oils, please contact Sabroe Refrigeration for an update on the requirement for superheat.
HLI: Calculation must be performed using COMP1.
Y : In case of a new plant. Very suitable.
B : Max oil concentration in liquid phase: contact Sabroe Refrigeration
C : Min suction temperature --50°C: at TE< --50°C superheating must be introduced.
SH : Suction gas superheat, K (Kelvin)
: Zone in which both oils are useable
: Calculation must be performed using COMP1

138 0171-370-EN
R507 TC

screw compressors
°F °C

104 40
2
86 30 SH5

Condensing temperature 68 20

50 10 1 SH5

32 0
SH15
14 -10

Code no Area no -4 -20

(See note) SH30
1 2
-22 -30
E5 Y -70 -60 -50 -40 -30 -20 -10 0 10 °C
E9 Y TE
-94 -76 -58 -40 -22 -4 14 32 50 °F
C Evaporating temperature

Note: For the compressors type ”S”, ”Rotatune”, ”SAB 81”, ”SAB 83”, and ”SAB 85” only Sabroe oil H is approved.
By using the calculation programme COMP1 it is possible to optimize the requirement for suction superheat values
(SH) as stated in the diagram. See Oil types and oil companies in this section. Due to the ongoing development of
lubrication oils, please contact Sabroe Refrigeration for an update on the requirement for superheat.
HLI: Calculation must be performed using COMP1.

Y : In case of a new plant. Very suitable.

C : Min suction temperature --50°C: at TE< --50°C superheating must be introduced.
SH : Suction gas superheat, K (Kelvin)
: Zone in which both oils are useable
: Calculation must be performed using COMP1

0171-370-EN 139
List of Major Oil Companies
The oil from the companies listed below are NOT tested by Sabroe Refrigeration and are there-
fore NOT approved by Sabroe Refrigeration either. The following list reflects the information
provided by the companies themselves. The assessment of durability and suitability of specific
oils for specific purposes are entirely at the companies’ own discretion. Oils tested and ap-
proved by Sabroe Refrigeration can be found in the ”List of part numbers for available Sabroe
oils”.

Oil Oil Types

Company M A PAO AP E
Aral
• •
Avia
•
BP
• • • •
Castrol
• • • •
Chevron (UK: Gulf Oil)
• • •
CPI Engineering Services
• • •
DEA
• • • •
Elf / Lub Marine 1
• • •
Esso/Exxon
• • •
Fina
• • •
Fuchs
• • • •
Hydro-Texaco
• • • •
ICI
•
Kuwait Petroleum (Q8)
• •
Mobil
• • • • •
Petro-Canada
•
Shell
• • • •
Statoil
• •
Sun Oil
• •

140 0171-370-EN
 Alignment of unit, AMR coupling

Where the compressor and motor are directly manufacturer prior to delivery. The following
interlinked, an AMR coupling is used; this is a sections will deal with the individual points
torsionally rigid coupling with enough radial concerning the fitter.
and axial flexibility to assimilate small move-
ments between the two machines. Alignment of unit with foundation
Whenever installing a unit directly onto the
In order to ensure compressor and motor a
foundation or machine floor, it should stand
long life as well as noise- and vibration-free
free of stresses and press down evenly on all
operation, compressor unit and coupling
supports.
need to be aligned with care. Misalignment of
the compressor unit or coupling may The unit can be installed in the following
produce stresses and vibrations which can ways:
be transmitted to the compressor and motor
S on vibration dampers
bearings and thus cause major damage.
S straight onto a foundation, using founda-
Vibrations may be caused by the following:
01.04

tion bolts.
S Distortion between compressor unit and Whichever method is used, the unit must be
foundation. aligned before hooking the connection pipes
0171-460-EN

S Distortion between compressor and base up to the installation.

frame. Vibration dampers are supplied as shown at
S Distortion between motor and base frame. the top or bottom of drawing T0177040, de-
pending whether the compressor unit is in-
S Strains from pipe connections between
tended for use on land or at sea.
compressor and plant.
The purpose of the vibration dampers is to
S Misalignment of coupling linking compres-
diminish the vibrations from the compressor
sor and motor.
unit to the foundation. In addition, the marine
S Untruth in compressor or motor shafts. vibration dampers serve to cushion vibrations
S Untruth in coupling. from the foundation to the compressor unit,
at the same time securing the unit to the
S Imperfect balancing of coupling. foundation.
S Imbalance in compressor or motor.
It is imperative that the vibration dampers be
The points up to and including coupling align- placed correctly, as shown in the completed
ment are the responsibility of the fitter setting drawing forwarded to customer or distributor.
up the unit. The other points must be This drawing is valid only for the unit in
checked by the compressor or motor question .

0171-370-EN 141
Installation on vibration dampers

1
A1
A2
H Hmax

A1
A2

T0177040_0

The vibration dampers supplied are marked Industrial Marine-

with a code, for instance LM6-60. LM6 indi- type 1 type 2
cates the size; 60 indicates the rubber hard-
Flexion min 1,0 min 3,0
ness and is therefore an expression of bear- max 2,0 max 5,0
A1-A2
ing and damping ability.
Height adjustment H = H+12 with disks
max
supplied as shown
When using vibration dampers, the machine
room floor is assumed to have the necessary
The flexion of a damper is adjusted by in-
bearing stregth and to be level enough to en-
creasing or decreasing the load in relation to
able adjustment of the vibration dampers to
the other supports. The foot can be raised by
be made within the adjusting measurements
screwing the adjusting rod down or inserting
stated on the drawing submitted.
more disks between damper and foot (marine
design), thereby increasing load and hence
In order for the individual vibration damper to also the flexion.
cushion properly, a sufficient load must be
imposed. Measure A1 and H in an unloaded Once the installation has cooled down, check
and A2 in a loaded set-up, as shown in draw- during operation that the flexion of the damp-
ing T0177040. ers is still correct!

142 0171-370-EN
Installing directly on foundation Perform this check with the bolts loosened. If
slip occurs at one or more resting surfaces,
When installing a unit directly on a concrete
shim up before tightening. If unaligned, there
foundation, the foundation should be cast in
is a risk of stresses occurring in the compres-
accordance with the foundation drawings dis-
sor frame, which will damage the bearings.
patched.

When the foundation has been cast - with the Alignment of motor with base frame
holes shown for foundation bolts - and has Check the contact faces of the motor against
set, place the unit in position, allowing it to the base frame in the same way as for the
rest on beams levelled at a suitable height so compressor.
that the foundation plates are recessed
slightly into the foundation. Stresses from piping connections
In order to prevent stress being transmitted
Check that the foundation plates are right
from piping connections between unit and
next to the base frame. This can be achieved
plant, pipes must be laid so as not to gener-
by binding them to the resting surfaces of the
ate compressive stresses or tensile strains in
base frame with steel flex.
the event of expansions or contractions due
The concrete cast down around the founda- to temperature changes. Steel piping ex-
tion bolts should contain only a small amount pands approx. 1 mm per metre per 100°C.
of water, so that it can be well tamped around We recommend that piping be laid as shown
the bolts. Low water content produces no in example 2 of the sketch. Example 1 dem-
contraction of the setting concrete. onstrates too rigid pipe laying.

10-14 days should be allowed to elapse be-

fore removing the beams and tightening the
nuts for the foundation bolts. > 1.5 m

Before that, however, remove the steel flex

and check that there is no space between the
base frame and the foundation plates. If
there is, place shims between the plates be- 1 2
fore tightening.

Alignment of compressor with base

frame T0177057_0

Check that the entire footing of the compres- Final alignment of compressor and motor can
sor makes full contact against the milled-off be performed once all piping has been con-
faces of the base frame. nected to the unit.

0171-370-EN 143
Fitting and alignment of AMR-type coupling
Installation and alignment Important
In principle, alignment involves manoeuvring Before any work on the coupling, ensure
that the compressor motor cannot be
the motor so as to make the shaft form an
started inadvertenly.
extension of the crankshaft.

Fig. 1
1
Compressor Motor
Z
2

X
a

A
B
C
T0177120_0/V2

Distance Max. variation measured with a feeler

C Torque moment gauge at a 180° turning of the coupling
AMR nominal* Pos. 1 Pos. 2
Compressor type of
coupling Horisontal Vertical
A B D Max.
mm max. min./max.
Nm Nm Nm mm
mm mm
HPO/CMO 2 225 76,0 34 130 0,1 0,1/0,2 0,1
HPC/SMC
312 S 103,5 147 55 200 0,2 0,1/0,3 0,2
104-108
SMC 112-116 350 S 114,5 147 128 200 0,2 0,1/0,3 0,2
SMC 180 450 S 149,0 295 275 130 0,3 0,1/0,4 0,3

* See Final mounting, pt. 4

144 0171-370-EN
Preliminary installation Alignment
S Check tightening of coupling flange on Check that the motor with loose bolts stands
compressor. with all four feet on the base frame. Insert
any liner plates needed where there is an air
S Tighten 8 coupling bolts securing lamellar gap beneath the feet. Tauten the bolts slight-
segments to intermediate piece to pre- ly.
scribed moment stated in table. It is worth-
while doing this before placing the inter- Achieving parallel shafts in
mediate piece in position.
horizontal plane
S Mount retaining plate from coupling S Turn coupling so that alignment gauge is
screen onto compressor and insert sup- in upper position. See fig. 1.
port ring for coupling screen over motor S Guide measuring pin (Pos. 2) towards
flange. coupling flange, using a 1.0 mm feeler
gauge, and fix pin. Remove feeler gauge.
S Insert coupling intermediate piece. Create
space between flanges either by shifting S Rotate coupling 180° and measure
entire motor or just motor coupling flange. change in distance from measuring pin to
The intermediate piece should only be flange, using feeler gauges. This change
secured to the compressor flange. Do is called ”x”.
not insert the last four bolts in the mo- S Insert shims of thickness ”y” either under
tor flange until the coupling has been both front feet or both rear feet, thereby
aligned. tilting motor in direction required. Shim
As the compressor shaft rotates during the thickness ”y” is calculated using the fol-
alignment procedure, the motor must turn lowing formula (see drawings):
with it, as the bolts in the intermediate
b
piece engage in the free holes in the mo- y = X •
2xa
tor coupling flange.

S Line up motor so that free holes in motor

feet are right over threaded holes in base
frame.

S Shift motor coupling flange to make up

distance ”C” in table. See fig. 1.
y
S Tighten two bolts in coupling hub.
On CMO units, the motor flange must be b
correctly positioned before putting the mo-
tor into place.
S After tightening motor bolts, repeat meas-
S Tighten measuring pin on coupling flange urement and compare result with values in
of compressor, as shown in drawing. table under Pos. 2.

0171-370-EN 145
Achieving correct centre height S Turn coupling 180° and, using feeler
gauges, measure deviations from one mil-
S Turn coupling so that alignment gauge
limetre at both pins.
faces vertically down.
S Guide measuring pin (pos. 1) towards S Moving and turning motor and repeating
coupling flange, using a 1.0 mm feeler this measurement, align motor in accord-
gauge, and fix pin. Remove feeler gauge. ance with pos. 1 horizontal and pos. 2 in
S Rotate coupling 180° and measure in- table. Remember that the motor must be
crease in distance ”z” from one millimetre firmly secured during any measurements.
using feeler gauges.
Final installation
S Then lift motor by placing shims of thick-
ness equal to half value of ”z” under all S Tighten foundation bolts on motor (see
four feet. torque table).

S After securing motor, repeat measurement S Fit four bolts into motor coupling flange so
and compare result with table values in that thin shims are placed between flange
pos. 1 vertical. Remember that the centre- and lamellae, with rounded side facing la-
line of the motor shaft must be at least mella. There are no thin shims on cou-
0.05 mm higher than the centreline of the plings for CMO and HPO.
compressor, corresponding to a minimum
S Tighten bolts to torque specified in table.
of 0.1 mm distance less at the top position
of the alignment gauge. S Readjust flange distance ”C” so that la-
mellae are aligned, by moving motor
Achieving parallel shafts in vertical flange on shaft and fastening motor
plane flange.
S The motor is now positioned at its correct S Check alignment of coupling in horizontal
height. What now remains is to push and and vertical planes for pos. 1 and pos. 2.
turn the motor at the level on which it is
already lined up. S Dismantle measuring pin and tighten
screw to prescribed torque.
S Turn coupling so that alignment gauge
faces out to one side horizontally. S Fit coupling guard.

S Guide both measuring pins towards coup- S Once normal operating temperature has
ling with a 1.0 mm feeler gauge in be- been achieved, double-check coupling
tween. alignment.

146 0171-370-EN
 Boring of motor flange for AMR coupling

A MAX. 0.02 mm

MAX. 0.02 mm
T0177131_0 V12
01.04

Unless the necessary data for the motor are S The bore should then be made to the rele-
known prior to dispatch, the motor flange for vant dimensions and to the following toler-
the AMR coupling will not be supplied in ances:
0170-502-EN

ready bored form.

H8 for AMR 312, 350 and 450,
In such case, the motor flange is supplied H7 for AMR 225.
prebored and balanced.
S Cut keyways.
Finish-boring is done as follows:
For reasons of balance, coupling AMR
S Secure flange in lathe or jig-boring ma- 312, 350 and 450 must be executed with
chine. Observe following tolerances for the two keyways shown.
alignment purposes:
S Make the width of the keyway to a toler-
Max. axial eccentricity ance of H7.
measured at point A 0.02 mm
S The keyway must be deep enough to al-
Max. axial eccentricity 0.02 mm low a clearance between parallel keys
measured at point B
and hub of 0.2-0.3 mm.
Max. boring diameter:

Compressor CMO - TCMO - HPO SMC - TSMC 100 - HPC SMC - TSMC 180

Coupling size AMR 225 AMR 312 - 350 AMR 450

Max. bore 65 mm 100 mm 110 mm

Boring tolerance H7 H8 H8

Note:Special flange for max. bore Ø75 mm is available for AMR 225.

0171-370-EN 147
V-Belt Drive for CMO/TCMO
Reciprocating Compressors

00.12
By letting the electromotor drive the com- mediately, which means that it is not neces-
pressor by means of a V-belt drive, the speed sary to check beforehand whether the belts
of the compressor can be selected so that its match.

0171-594-EN
max. capacity corresponds to the capacity
However, it is not recommended to fit a new
requirements of the plant.
V-belt together with used and worn belts.
The V-belts are referred to as SPB Red Instead it is recommended to mount a new
Power. Their cross-sectional dimensions are set of V-belts.
shown in fig. 1.
Fig. 2 S = C plus SPB 2650
Fig. 1
16.3

13

The V-belts are of an excellent quality. Under

normal operating conditions they do not
require any service and are moreover shape-
permanent, which means that they can be
characterised as S = C plus, which is
stamped on the outside of the belts, see fig. A V-belt drive which has been mounted and
2. Furthermore, the V-belts are made with so adjusted correctly will usually have a service
narrow tolerances that they can be fitted im- life of approx. 20,000 operating hours.

148 0171-370-EN
Transmission Ratio
Table 1 shows the pulley diameters used for length of the V-belts which must be used for
CMO/TCMO units. With these diameters the the different combinations of belt pulley dia-
compressor speeds mentioned in columns 3 meters. The length of the V-belts is stamped
and 4 can be achieved. Column 5 shows the on the outside of the belts as shown in fig. 2.

Table 1 - Standard Programme for V-Belts and Pulleys for CMO/TCMO

Standard V-Belt Pulley Compressor Speed

Diameter mm Compared to Motor Speed

Length of
50 Hz 60 Hz V-belts
Compressor Motor 1460 rpm 1760 rpm
rpm rpm

132 929 2120

140 985 2120
876
150 1056 2120
934
160 1126 2120
992
170 1197 2120
1051
250 180 1267 2120
1168
200 1408 2120
1308
224 1576 2120
1460
250 1760 2120
1548
265 2240
1635
280 2240
1752
300 2240

Power Transmission S The compressor pulleys, however, are

A correctly dimensioned V-belt drive must be only delivered with four grooves. Thus it
able to transmit the max. power of the motor, may occur that there are more grooves on
which corresponds to the nominal capacity the compressor pulley than on the motor
of the motor, which is stamped on the name pulley.
plate. The number of V-belts for which the
belt drive is dimensioned must, therefore, al-
ways be mounted. This can be checked by Servicing and Alignment of the
means of the following rules:
V-Belt Drive
S The motor pulleys are always delivered
with the number of grooves corresponding A V-belt drive which has been aligned cor-
to the number of V-belts which must be rectly will have a service life of approx.
used to transmit the max. power of the 20,000 operating hours. After the first
motor to the V-belt drive in question, thus adjustment, it is only necessary to check the
indicating how many V-belts must be belt drive according to the Service Checks as
mounted. stated in the Instruction Manual.

0171-370-EN 149
Dismantling of the Belt Drive • Loosen the adjusting screw pos. A on
the washer placed at the foot of the
Before removing the safety guard, make sure motor nearest the compressor. See fig.
that the motor cannot start unintentionally, 3.
e.g. due to an error in the regulating system. • Loosen the washer at the screw pos. B
and push it towards the compressor.
The best safety is achieved by dismount- • Loosen the screws securing the
ing the electric main fuses to the motor! motor to the base frame. Now push the
motor towards the compressor.
The belt drive is dismantled first by moving • It is now possible to dismount the
the motor towards the compressor, which is V-belts manually without damaging
done in the following way: them.

Fig. 3

D
2

A
B

The compressor pulley is dismounted by Fig. 4

means of the remover 3183-059 from the
general compressor tool set. The remover is
used as shown in fig. 4.

150 0171-370-EN
By tightening the screws one after the other, S By tightening the screw/s one after the
the belt pulley can be removed from the cone other, the belt pulley will be pushed over
of the shaft seal and lifted out manually. the conical bushing. At the same time the
bushing will loosen its grip on the motor
The motor pulley is mounted on the motor shaft.
shaft by means of a bushing, pos. 1, as
shown in fig. 5. On the outside the bushing is S The belt pulley and the bushing can now
shaped like a cone and fits the boring in the be removed manually.
belt pulley.
Control of V-Belts and Belt Pulleys
Fig. 5
On a V-belt in good condition, the outside
fabric must not be worn through. The belts
1
must not be frayed and there must be no vis-
2 ible cracks in the surface. It is not recom-
mended to replace a few of the V-belts with
new belts in a belt drive. Instead all of the
V-belts should be replaced. In case of abnor-
mal wear on the belts, it should be checked
whether the grooves in the belts are
damaged.
Inside the bushing is machined so that it fits
the dimensions of the motor shaft. The bush- In time the belt pulleys will wear on the two
ing can be placed on the motor shaft conical surfaces in the belt grooves and
manually. Never beat the bushing onto the should, therefore, be checked every time the
motor shaft as the impact may damage belts are replaced. This is done by means of
the bearings in the motor. a measuring gauge, which is placed in the
The bushing is tightened to the motor shaft belt grooves, several places in each groove.
by tightening the screws pos. 2, fig. 5, as de- When holding a flashlight behind the
scribed later in this section. measuring gauge, it is easy to see if a belt
pulley is worn as shown in fig. 6. It is
Dismount the motor pulley in the following
recommended to replace the belt pulley
way:
when the two surfaces of the measuring
S Unscrew the two or three screws (depen- gauge make full contact with the outer
ding on the size of the belt pulley), pos. 2. diameter of the belt pulley (marked with an A
in fig. 6) and when a light can be seen be-
S Mount one or two of the screws (depen- tween the measuring gauge and the conical
ding on the size of the belt pulley) in the surfaces of the groove. If the grooves are
hole/s where there is a thread only in the damaged in any other way, it should be
side of the holes facing the bushing. considered to replace the belt pulleys.

0171-370-EN 151
Fig. 6 - Wear on Belt Grooves Fig. 7

Pos. 1

Pos. 2

wear

The Motor Pulley

The measuring gauge is available from our
S First place the motor pulley on the motor
After-Market Service Department and has the
shaft. Then turn the bushing so that the
following Part no. 1622.001.
key on the shaft enters the key groove of
the bushing.
It must be possible to fit the bushing ma-
Mounting and Adjusting of the nually. It is not recommended to beat at
V-Belt Drive the bushing as this procedure may dama-
ge the bearings of the motor.
Modern V-belt drives are very sturdy and ef-
fective, but require on the other hand S Turn the belt pulley so that all the
a correct installation and adjustment. threaded holes in the pulley face the
smooth holes in the bushing as is shown
in fig. 8.
Before mounting the V-belt drive, it is neces-
sary to clean and degrease all machined sur-
Fig. 8
faces of the belt pulleys, shafts and bushing.
Bush no. Bush no.
Then proceed as follows: TB 1008-3030 TB 3525-5050

The Compressor Pulley

S Place the compressor pulley on the coni-

cal shaft and turn it so that the key on the
shaft faces the key groove.

S Oil the two or three socket cap screws, fig.

S Mount the washer, pos. 1, and the screw, 8, and mount them in the above-mentio-
pos. 2, as shown in fig. 7 and tighten them ned holes. Tighten the screws exactly
to a torque of 130 Nm. so much that it is still possible to move

152 0171-370-EN
 the belt pulley and the bushing on the drawn across the conical bushing and is
shaft. thus no longer flush with the compressor
pulley. It is, therefore, recommended to
Mounting of V-Belts place the motor pulley a little within the
S Mount the V-belts corresponding to the alignment with the straight-edge and to
number of grooves on the motor pulley. check the alignment after the screws have
Move the motor away from the compres- been tightened. If the compressor pulley is
sor by means of its slide rails and align it wider than the motor pulley, the straight-
so that the motor and compressor shafts edge can be placed on the side of the belt
are parallel. pulleys facing the motor/compressor.
If there are more grooves on the compres-
Fig. 9
sor pulley than on the motor pulley, the
free groove must be furthest from the
compressor. Never force the belts over
the belt pulleys as this can easily dama-
ge the belts.

S Tighten the screws securing the motor to

the base frame exactly so much that it is
still possible to move the motor on the
slide rails. Mount the washer shown in fig. To achieve a correct centering of the belt
3 and tighten the screw, pos. 1. pulley, the tightening must be carried out with
a torque wrench. All the screws must be
S Align the motor pulley by means of a tightened first to 1/3 torque, then 2/3 and fi-
straight-edge as shown in fig. 9 so that it nally full torque as stated in table 2. It is not
is flush with the compressor pulley. recommended to tighten the screws to a
Tighten the socket cap screws on the larger torque than stated in the table.
motor pulley fig. 8. Please note that when The number of the bushing is stamped into
tightening the screws, the belt pulley is its large end surface.
Tabel 2

Hexagon
Bushing No. of Max. Torque
Key Size
No. Screws Nm
mm
1008, 1108 3 2 5,7
1210, 1215, 1310, 1610, 1615 5 2 20,0
2012 6 2 31,0
2517 6 2 49,0
3020, 3030 8 2 92,0
3525, 3535 10 3 115,0
4040 12 3 172,0
4545 14 3 195,0
5050 14 3 275,0

0171-370-EN 153
Mounting of the V-Belt Drive
The two washers must be mounted as shown
in fig. 10.

Fig. 10

D
2

A
B

S By tightening the adjustment screw A and Fig. 11

loosening the adjustment screw C the mo-
tor is moved away from the compressor,
but still kept parallel with the compres-
sor, which can be checked by means of
the straight-edge.
S As the belt drive is tightened, the belt ten-
sion is measured by means of a tension
tester as shown in fig. 11.

154 0171-370-EN
S Press the indicator on the tension tester operation. The two belt pulleys will thus
down into the scale shown between the align and become parallel. Max. deviation
belt pulleys. must be:

S Press the tension tester with only one Belt Pulley Max. Deviation
finger slowly down towards the V-belt until Diameter mm mm
hearing or feeling a click. Do not press 112 0.5
after the click. 224 1.0
450 2.0
S Read the belt tension in the intersection
between the scale and the indicator as Fig. 13
shown in fig. 12.

Fig. 12

S When the belt drive has been tightened,

the screws securing the motor to the slide
S By further tightening of the belt tightener
rails must be tightened.
and repeated measurements, the belt
drive is tightened to the prescribed belt S Finally, the belt guard and the electric
tension as stated in tables 3 and 4. fuses to the motor must be mounted.
It is important to rotate the belt drive
two or three times before measuring Note:
the tension so that the belt tension is Never start the compressor unit until the
distributed on the full length of the belt guard has been mounted.
belts.
Tables 3 and 4
S After the first start-up, let the belt drive run
Besides being divided into min. and max.
for 15 to 30 minutes whereupon the ten-
values, the belt tension N (Newton) in
sion is checked and if necessary tightened
tables 3 and 4 consists of two columns,
to the value stated in the column
which are used as follows:
New V-Belts.
In connection with subsequent control and New Belts
adjustment, use the belt tension values in This tension is used the first time a new
the column Remounting. set of belts is mounted.

S When tightening the belt drive, it may be Remounting

advantageous to make the belt drive point This tension is used in connection with
a little as shown in fig. 13 as the belt ten- used V-belts or for the control of the belt
sion will decrease a little after a few hours’ tension after an operating period.

0171-370-EN 155
 Table 3 CMO/TCMO, 4-pole 50 Hz Motor

Belt Tension
Motor Pulley N
Di
Diameter
t New V-Belts Remounting
mm
Min. Max. Min. Max.
150 500 550 350 400
160 500 550 350 400
170 600 700 400 450
180 600 700 400 450
200 700 800 500 550
224 700 800 500 550
250 700 800 500 550
265 800 900 550 600
280 700 800 500 550
300 700 800 500 550

Table 4 CMO/TCMO, 4-pole 60 Hz Motor

Belt Tension
Motor Pulley N
Di
Diameter
t New V-Belts Remounting
mm
Min. Max. Min. Max.
132 500 550 350 400
140 500 550 350 400
150 550 600 400 450
160 500 550 350 400
170 600 700 400 450
180 600 700 400 450
200 700 800 500 550
224 700 800 500 550
250 700 800 500 550

156 0171-370-EN
 Thermo pump cooling of R717
reciprocating compressors
types SMC 104-106-108-112-116 / TSMC 108-116 /
CMO 24-26-28, TCMO 28

The thermo pump is a compressor cooling The pumping cycle of the thermo pump, i.e.
system for R717 reciprocating compressors. a filling and an evacuation period, lasts be-
Its purpose is to cool the oil in the crankcase tween 4 and 8 minutes depending on the
as well as the compressor discharge gas in number of cylinders of the compressor, its
order to lower the temperature in the entire capacity, the oil temperature in the crank-
compressor. case, and the operating pressure and tem-
peratures of the plant. The filling period itself
The thermo pump is mounted as a side cover
lasts 45 sec.
on the compressor and works by pressing
refrigerant under the top covers and into an During a pumping cycle the discharge gas
oil cooler which - depending on the operating temperature varies as no cooling of the dis-
conditions - has been built into the crank- charge gas takes place during the filling
case. period.
98.10

On TSMC compressors only the high pres-

Usually, the variation will be +/--10K of the
sure covers are cooled, and there is no oil
estimated discharge gas temperature
0171-361-EN

cooler in the crankcase.

stated in the table of this instruction manual.
The thermo pump works under the influence See table of contents.
of the heat coming from the oil in the crank-
case, thus regulating its own pump capacity. However, please notice that under normal
This means that the thermo pump works at a operating conditions the discharge gas tem-
slow pace whenever the compressor oil is perature must not be below the table value
cold, e.g. after start-up of the compressor, less the variation of approx. 10K .
but as the oil temperature increases so does
The important advantage of the thermo pump
pump capacity.
is that the refrigerant pumped by the thermo
However, the thermo pump will not start until pump is led directly into the compressor dis-
the discharge gas temperature of the com- charge gas and as a consequence has no
pressor is above 80°C. influence on the compressor capacity.

0171-370-EN 157
Principle drawings

SMC 104 SMC 106

98U 98U

98M 98M 98M 98M 98M

98Z
98Z
HP HP
98G 3 98G
2 1 A 2 A
LP 1 LP

98T 98B 98T 98B

98 98 98M
98M

98H 98H
C B C
B

98K 98K 98K 98K

80 98V 80
98V
98Y 98Y
D D

3185184_1 3185185_1

SMC 108 TSMC 108

98U

98M 98M 98M 98M

98M
98Z 98Z

4 1 HP 98G 1 S 98G
A HP IP A
LP
2 3 S 2

98T 98B 98B

98M 98
98

98H 98H
B C B C

98K 98K 98K 98K

80 98V 80 98V
98Y 98Y
D D

3185186_1 3185187_2

158 0171-370-EN
 SMC 112 SMC 116
98M 98M 98M 98M 98M
98M 98M

98Z 98Z
4
6 A 4 6
2 LP A
LP X
98G X 2 8 98G

98B 98B

98 98
98H 98H
98K B 98K
B
98K 98K 98V
98V
98Y
80 98Y 80
D
D
98M 98M
98M 98M
98M 98M 98M

HP 98Z
7
HP 98Z 3
5 LP A
1 3 A 1 98 5 98G
LP
98 98G
98T 98B
98T 98B
98M
98H
98M
98K
98H
98K B C
98K
98V
B C 98Y
98K 98V 80

80 98Y D

D
3185168_2 3185169_1

TSMC 116

98M 98M

S 4
HP A
IP
3 S 98G

98B

98
98H
B C

98K 98V 98K

80 98Y 98U
D

2 S

1 5

98T 98M

3185188_0

0171-370-EN 159
 CMO 24 CMO 26

98U
98U
98M 98M
98M 98M 98M

98Z
1
98Z

3+4 1+2 98G

2+3 4
LP A 98G LP A
98B
98B
98
98

98H
98H
B 98K C 98K
B C
98K
98K 98V
98V
80
98Y 80
98Y

D D

3185195_1
3185196_1

CMO 28 TCMO 28

98M 98M 98M 98M 98U 98M

98Z

98Z
1 IP 98G
2

3 4 HP
LP 98G
98B
98B
98
98

98H 98H
B B 98K C
98K C
98K
98K 98V 98V
80 98Y 80 98Y

D D
3185197_1 3185198_1

160 0171-370-EN
Structure of the thermo pump control the solenoid valves, pos. 98G and
Together with the cooling cover, pos. 98Q, pos. 98H, so that they are open and shut si-
the side cover, pos. 98A, forms a pump ves- multaneously. The thermo pump is safe-
sel, pos. 98, which is supplied with heat from guarded by the following systems:
the oil bath in the crankcase. The cooling (See principle drawing)
cover is equipped with cooling fins in order to a: A thermostat built into the control box pos.
provide a satisfactory thermal contact with 98B with sensors pos. 98X fitted on the
the oil. compressor discharge pipe.
As illustrated in the principle drawings, the
Fasten the sensor to the discharge pipe
pump vessel has the following three pipe
right next to the discharge stop valve by
connections:
means of two clips. Ensure a proper
S Connection pos. A which is linked to the thermal contact.
compressor suction side and which can be
blocked by means of solenoid valve pos. The thermostat is factory set to start up
98G. Used to lower the pressure in pump the thermo pump once the discharge gas
vessel pos. 98. Part of the pumping cycle. temperature is above 80°C.
S Connection pos. B emerges from the re- b: An evacuation system emptying the pump
ceiver or the priority tank and goes right to vessel through solenoid valve pos. 98V
the valve block pos. 80 which is of the sa- whenever the thermo pump stops.
me type as the one described in the sec-
Please, notice that the pipe connection
tion on: Solenoid valve controlled oil
pos. D to the plant evaporating side must
return in this instruction manual. be made at a spot where there is no risk
Please, note that the size of orifice
of the liquid flowing back to the compres-
pos. 80I must be 3.3 mm.
sor. Connection should, f.inst., be made to
S Connection pos. C is connected to the top the liquid separator or the evaporator.
covers and the oil cooler pos. 98T through c: A safety circuit with a non-return valve
a number of nozzles pos. 98M. pos. 98Z that opens for the flow at a pres-
Filling and evacuation of the pump vessel is sure 3 bar higher in the pump vessel than
controlled by two level sensors, pos. 98C, the one in the compressor discharge gas
which by means of the control box, pos. 98B, line.
98G 80 B 98B 98A

98Q
A
98C
98D 98E
98F
98L
C

98H 98X

T3185085_5

0171-370-EN 161
Description of pumping cycle Capacity regulation of thermo pump
On reducing the compressor capacity it be-
Filling of pump vessel comes necessary also to reduce the cooling
As soon as the liquid leaves the bottom level effect of the thermo pump. This is done as
sensor, the control box will activate the sole- follows:
noid valves pos. 98H in valve block pos. 80
SMC 104-106-108, TSMC 116
and pos. 98G.
CMO 24-26-28

Hereby, solenoid valve pos. 98G opens in the The pipe connection from the pump vessel to
pipe connection to the compressor suction the top covers is on its way divided into two
side and the pressure in the pump vessel de- pipe lines. In one of these pipe lines a sole-
creases slightly. At the same time solenoid noid valve, pos. 98U, is fitted.
valve pos. 98H opens and refrigerant liquid This solenoid valve is connected to the the
starts flowing to the pump vessel through capacity regulating system of the compressor
pipe connection B. and closes when the compressor capacity
has been reduced, as indicated in the follow-
Evacuation of pump vessel ing table:

When the top sensor has registered that the

liquid has reached the top level both solenoid Compressor Solenoid valve pos.98U
valves will be closed by the control box. capacity open closed

The pressure in the pump vessel now rises SMC 104 100% 50%
as a consequence of the heat impact from
the compressor oil and - when exceeding the SMC 106 100-67% 33%
pressure on the compressor discharge side -
will make the refrigerant flow through the SMC 108 100-75% 50-25%
pipe connections to the top covers and the oil
TSMC 116 100-83-67% 50-33%
cooler.
CMO 24 100-75% 50-25%
At the top covers the refrigerant expands
through the nozzles pos. 98M directly into the CMO 26 100-67% 50-33%
hot discharge gas, with immediate cooling of
the discharge gas. CMO 28 100-75% 50-25%

The oil cooler (not always required) is a

heat exchanger in which the expanding re- SMC 112-116
frigerant - after cooling of the oil - is taken to
On the SMC 112-116 two thermo pumps
the compressor discharge side.
have been mounted as shown on the prin-
ciple drawings.
Once the liquid in the pump vessel has re-
turned its lowest level, it is registered by the The total capacity of the thermo pumps is
bottom sensor and the control box opens the adapted to the compressor capacity by a
two solenoid valves for a new pumping cycle. power disconnection of the thermo pump

162 0171-370-EN
positioned at the compressor shaft end and Similarly, the other green diode for the bot-
marked X on the principle drawing. tom sensor will only be switched off from the
moment the bottom level has been registered
The disconnection is achieved through the
and until the liquid rises once more on filling
connection of the thermo pump via terminals
of the vessel.
5 and 6/7 or 8 to the capacity regulating sys-
tem of the compressor. The supply voltage to At the bottom level a time lag of a few se-
the thermo pump must be switched off once conds has been built in order to prevent the
the compressor capacity has been reduced solenoid valves from clattering in the event of
to the values indicated in the table below. any lapping in the vessel.

One of the red diodes, LD3, lights up once

Compr. Thermo pump at compr. the temperature of the discharge gas rises
shaft end above 80°C. The other red diode LD4 lights
capacity working not working up when the relay to the solenoid valves has
closed.
SMC 112 100-83-67% 50-33%
Functional testing
SMC 116 100-87-75-63% 50-37-25%
When stop valve in valve block pos. 80 is
closed the functioning of the pump may be
The pipe connections are shown on the prin-
tested as follows:
ciple drawings on the previous pages.
S Roll off the rubber cap on the external part
When the compressor is stopped the current of the level sensors so that the part with-
to the thermo pump is cut off, closing the so- out insulation can be touched with a fin-
lenoid valves pos. 98H and pos. 98G. ger.
At the same time solenoid valve pos. 98V
opens and drains the liquid in the thermo Note
pump back to the evaporating side of the It is quite safe to touch the level sensors
plant. See the previously mentioned point b. at this point as the voltage is extremely
weak.
Checking the pumping cycle
S Touching the sensor alters its capacity as
On dismantling the cover plate on the control
if the sensor were surrounded by liquid in
box four light diodes are made visible
the pump vessel.
(2 green and 2 red ones).
One of the green diodes that is connected to By touching the sensors in the order in
the top level sensor is switched on for a rela- which they are usually surrounded by
tively short period, i.e. from the moment the liquid at increasing liquid level it is pos-
sensor has registered the upper liquid level sible to check whether the solenoid valves
and until evacuation of the vessel has low- receive any voltage and open when the
ered the level below the sensor. sensors are released.

0171-370-EN 163
Possible sources of error Both diodes are constantly lit
In case the above tests should reveal that If one or both diodes are constantly lit, even
one or both of the diodes do not light up with no liquid on the sensor, this may be due
when touched, this may be due to: to a conductive connection between the inner
and the outer part of the level sensor rod.
1. No voltage to the control box.
Outside the side cover the level sensor rod is
2. Loose power connection. protected by O-rings and a protective cap
preventing water and moisture from making
3. Defective control box. contact.
(To be replaced by a new one)
An oil drop may have slipped inside the side
In case both diodes switch on and off correct- cover. In this case it is recommended to strip
ly but the built-in relay is not working, replace down the sensor rod and clean the parts. On
the control box. mounting make sure that the sensor rod cen-
ters in the sensor tube.
If the diodes light up and the relay is working,
the error may be found in the solenoid If, after remounting, the error persists, the
valves: control box must be replaced.
1. Loose connections to the solenoid valves.
Ensuring liquid to the thermo pump
2. Burnt coils in the solenoid valves. The thermo pump must always be ensured
liquid from the plant, no matter whether the
3. Some other malfunction in the solenoid plant lacks liquid or some other factor pre-
valves. vails.

If the above-mentioned sources of error are Thus, the thermo pump must also be en-
not present and the thermo pump still fails, sured liquid during a possible pump down by
the reason may be: means of the compressor.
1. Closed stop valve in the liquid line. In other words: During operation the com-
pressor must never be short of cooling.
2. Clogged filter in the liquid line.
This safety is achieved by either taking the
3. Dirt in the solenoid valves. liquid directly from the receiver, pipe connec-
tion B or by building a priority tank into the
4. Flash-gas in the liquid supply pipe or liquid liquid line of the plant (see drawing).
shortage. The liquid volume A of the priority vessel
must be minimum 10 litres per thermo pump.
5. A very low differential temperature be-
tween oil and condensing temperature. The liquid tube from the priority vessel to the
thermo pump must be dimensioned to pre-
6. Clogged nozzles pos. 98M. vent the formation of flash gas along the way.

164 0171-370-EN
 1 1

3
Receiver
Priority tank

3
B
B
2

1: Refrigerant liquid from condenser/receiver

2: Refrigerant liquid to evaporator
3: Refrigerant liquid reserve for oil cooling
B: Refrigerant liquid for oil cooling T0177101_0/4

Stopping a compressor equipped Power connection

with a thermo pump The control box is geared for 3 different
voltages: 110V - 50/60Hz
When the compressor is stopped there must 220V - 50/60Hz
still be a pilot current on the unit so that the 240V - 50HZ
solenoid valve pos. 98V is kept open until the
The control box contains a terminal strip as
pump vessel has been emptied of liquid.
shown in the sketch below.
K4
At the same time, stop valve pos. 98Y is kept
open.

Opening of compressor for repair K3 K1

Terminal 2 PT100 sensor Terminal 1
M1
Pump down of the compressor must take
N
place with the thermo pump system set out of Terminal 1 GND

function and after the pump vessel has been Terminal 4 GND
M2
N
emptied as described above.
Upper level sensor
L
GND
During pump down close stop valve in valve N Terminal 2
Terminal 1
block pos. 80 and pos. 98Y. Lower level sensor
K2

Cleaning of filter in the liquid Main voltage selector VS1

supply line 230

115

Pump down the compressor before opening

the filter in the liquid supply line for cleaning.

0171-370-EN 165
Oil return in parallel operation for
reciprocating compressors

On halocarbonic piston compressors operat- Each compressor is fitted, via an intermedi-

ing in parallel on the same plant, it is impor- ate piece, with a mechanical float which re-
tant to regulate the oil return flow to the gulates the oil level in the crankcase.
crankcases of the compressors so that they
This intermediate piece is mounted between
have the same oil level.
the compressor frame and the oil level glass,
This is achieved by using an oil distribution as shown in the drawing. This allows visual
system as described in this instruction. inspection of the oil level in the crankcase.

Float valve housing

with float valve Pipe connection Vent valve

Oil level glass

95.06
on compressor

0171-474-EN

T0177089_0/2

166 0171-370-EN
Schematic diagram

Standard
Oil separator with
solenoid valve controlled oil return
Parallel system,
fitted on unit Alternative
Oil separator with
float valve controlled oil return
Compressor 1 Compressor 2
5 5
1 1
5

2 2
3 7 3 7 8 12
4 6 4 6 11 13
9
10
Oil charging
Heating cartridge 9 Liquid level glass
Oil receiver

1. Compressor 8. Float valve for oil separator

2. Float valve for parallel operation (1374-005) 9. Oil receiver
3. Filter 10. Non return valve, 1 bar
4. Stop valve 11. Solenoid valve for driving pressure line
5. Oil separator 12. Nozzle dia. 0.4mm for driving pressure line
6. Solenoid valve for oil separator 13. Filter for driving pressure line
7. Nozzle for oil separator

Function From the oil tank, an oil pipe is drawn directly

to the mechanical float pos. 2 controlling the
The piping diagram is based on each com-
oil level in the crankcase.
pressor pos. 1 being equipped with an oil
separator pos. 5, from which the oil via
From the top of the oil tank pos. 9, a pipe is
solenoid valve pos. 6 and nozzle pos. 7, or
routed to the suction side of the plant.
through float valve pos. 8, is conveyed to
an oil tank pos. 9. A non-return valve pos. 10 is inserted in the
pipe, opening at a differential pressure of 1
The nozzle size for pos. 7 is stated in the
bar. Note the flow direction. A pressure 1 bar
section on Oil Separator.
higher than the suction pressure in the plant
The oil tank pos. 9 must have a volume equal is thus obtained in the oil tank. This is suffi-
to approx. 50% of the total oil volume to be cient to pump the oil through the float valve
contained in the compressors. without generating any foaming in the float
However, it should never be filled more than valve housings.
halfway with oil, corresponding to approx.
25% of the total oil quantity. Note:
After the initial starting up of the float sy-
There should be an oil level glass on the oil stem, the float housing must be ventilated
tank and a heating element to ensure warm, in the following way. See drawing of float
and hence refrigerant free, oil. housing.

0171-370-EN 167
Unscrew the cap on the vent valve and acti- connected to the discharge side of the plant,
vate the spring-loaded valve in the branch by as shown in the schematic diagram.
pressing it down with a screwdriver or similar.
In the pipe connection to the discharge side,
mount a 0.4 mm diameter nozzle Pos. 12
If the float-valve controlled oil return Pos. and a solenoid valve Pos. 11, which must be
8 is used, the oil tank must - in order to main- open also when only one compressor is op-
tain the driving pressure at 1 bar - also be erating.

168 0171-370-EN
 Refrigerant cooled oil cooler for
CMO reciprocating compressor

Under certain operating conditions -- as indi- Fig. 1

cated on the diagram on operating limits in
this instruction manual -- cooling of the com- Pos. 5
Screwed
pressor oil is required. connection
1349-053
On page 1 is stated whether the actual com- Gasket
2356-139
pressor has a built-in refrigerant cooled oil 5A
Nipple socket
cooler. 2312-022
Plug
As shown in fig. 1 the oil cooling system con- 2314-025
sists of a spiral of smooth steel pipes placed Gasket
5B 2356-130
round the oil filter.
Oilfilter with bracket
Via the cutting ring joints pos. 5, the spiral is
Oil cooler
connected to the external pipings, as illus- 4242-080
97.03

trated in fig. 2A an 2B. 4242-087

Connection, pos. B, pipe dimension OD 10

0171-356-EN

mm, emerges from receiver or priority vessel

and is conveyed to valve block pos. 80 which
is the same type as the one described in sec-
tion entitled: Solenoid controlled oil return of
this instruction manual.
Please, note that nozzle size pos. 80I must
be 3.3 mm.

Oil cooling system R22

Fig. 2A

0171-370-EN 169
Oil cooling system R717

Fig. 2B

Connect oil cooling system to the liquid sys- arrangement also contains a filter that can be
tem of the refrigeration plant where a point at taken apart and cleaned as described earlier.
liquid refrigerant is always present, and carry
The liquid will pass the solenoid valve which
out pipe connection so that no gas bubbles
is electrically coupled to thermostat KP77.
will occur in the liquid before the expansion
This opens the solenoid valve whenever the
valve.
oil temperature is above 55°C. (See table :
Pressure and temperature settings)
Pipe dimension is shown on fig. 3 and 4. A
priority vessel may possibly be used as de- Adjustment of liquid flow to the oil cooler
scribed under Ensuring liquid supply to Ther- takes place through the expansion valve
mopump in section Thermopump system for which for R22 compressors is a thermostattic
cooling. expansion valve with thermo sensor placed
on the discharge pipe of the oil cooler as
Function shown in fig. 3.

The valve arrangement Pos. 1 has a built--in For R717 it is a thermostatic injection valve
stop valve with which the cooling system can with thermo sensor placed at the compressor
be cut off from the refrigeration plant. The discharge branch as shown in fig. 4.

170 0171-370-EN
CMO 2 compressors for R22 Adjustment
Fig. 3 Adjustment of the thermostatic expansion
HP valve for R22 appears from table: Pressure
Thermo filter and temperature settings.
LP

Valve arrangement Pos. 1 The thermostatic injection valve for R717 is

OD10
Oil cooler factory set to begin opening at +75°C dis-
charge gas temperature and to be completely
80 Thermostatic
expansion valve Pos. 4 open at +95°C.
Solenoid valve Pos. 1C
To evaporator Dismantling oil cooler

From receiver
In order to facilitate the replacement of oil
filter cartridge, see section on Oil Filter, it is
DN 15 recommended to dismantle oil cooling spiral
3185-133 as described in the following:

CMO 2 compressors for R717 Dismantling:

After evacuation of the compressor as de-
Fig. 4 scribed previously, dismantle the two
union nuts Pos. 5A, after which the cool-
T
ing spiral can be pulled out from the
IP screwed connections together with the
LP
oil filter. See fig. 1.
OIL P

Mounting:
OD10 On remounting cooling spiral, counter
Oil cooler

Injection valve pressure must be exerted on the outside

80
on Pos. 5B when tightening union nut Pos.
Valve arrangement pos. 1
5A. See fig. 1.
DN 15

4849-063

0171-370-EN 171
Oil Separator and Oil Return
on CMO 24-26-28 and TCMO 28

Application creased oil consumption. Further, oils with a

low flame point can lead to an increased oil
The purpose of the oil separator is, under all
consumption in the R717 compressors.
operating conditions, to separate the oil con-
veyed out of the compressor with the dis-
For HCFC compressors the oil consumption
charge gas in order that it may be returned to
is of minor importance as the oil normally re-
the compressor crankcase.
turns to the compressor from the plant.
However, with the hot discharge gas some oil
is going to leave the oil separator - the so- Your compressor may be delivered with a
called oil consumption. normal standard oil separator, of which the
various types are shown in fig. 1, 2 and 3, or
With a normal standard oil separator the oil a fine filter oil separator as shown in fig. 4.

97.03
consumption will be approx. 35 to 45 ppm
(parts per million) for R717 compressors. With due regard to the normal discharge
gas temperature and a high flame point the

0171-336-EN
The oil consumption is, however, dependent fine filter oil separator separates the oil from
on the discharge gas temperature which at the discharge gas down to approx. 10 ppm in
rising temperatures often results in an in- R717 refrigeration plants.

Fig. 1

R22 CMO
Solenoid valve controlled Float valve controlled
execution execution

Discharge Discharge
gas out gas out

2 2

To compressor
housing via
valve block L 1
pos. 80 To compressor housing L 1
Discharge
gas in
Discharge gas in

T0177142_0 V14

172 0171-370-EN
 Fig. 2 R22-R717 TCMO

Solenoid valve controlled Float valve controlled

execution execution
2 Discharge gas out 2 Discharge gas out

1 1
Discharge
gas in Discharge gas in

To compressor
housing via L
valve block L
pos. 80 To compressor housing

T0177142_0 V14

Fig. 3 Fig. 4

R717 CMO R717 CMO

Normal standard oil separator Fine filter oil separator

1 • D

2
M

To compressor
housing via L To compressor
valve block
pos. 80 housing via
valve block
pos. 80

0171-370-EN 173
Function Fig. 5

The discharge gas from the compressor

G D
flows through the oil separator from pos.
F E
1 to 2 and passes through filters in which the
•
oil is separated from the discharge gas. In
• •
the oil separators fig. 1, 2 and 3 the oil is
separated in a number of rustproof wire-
mesh filters which normally need no cleaning 2
and consequently cannot be removed from K
the oil separator.
•
In the oil separator fig. 4 the oil is sepa-
rated, partly in above rustproof wire-mesh
filters, partly in a fine filter pos. K, posi- H
tioned in the upper part of the oil separator.
This fine filter may, as shown in fig. 5, be
•
taken out of the oil separator through the
flanged joint pos. D. On mounting of the fine
1
filter the nuts pos. E must be tightened even-
ly against the plate pos. F and secured with
counter nuts pos. G.

Also make sure that the fine filter is fitted cor- t4241347_1
rectly against the intermediate plate pos. H.

174 0171-370-EN
Oil return to the compressor a: Solenoid valve controlled
The separated oil leaves the oil separator oil return
through the connecting branches pos. L As illustrated in fig. 6 the oil is conveyed from
and in case of the fine filter oil separator
the oil separator through the screwed con-
fig. 4 also through branch pos. M. This
nections pos. 80A and 80B. Fig. 6 pos. also
means that two oil return systems are used
shows that pos. 80A is of such a length that it
for the fine filter oil separator.
pierces the base plate by approx. 10mm.
The oil flow from the connecting branches
pos. L and M can be regulated by the fol-
lowing systems: In this way any dirt particles may be collected
S Solenoid valve controlled oil return on the bottom of the oil separator instead of
S Float valve controlled oil return being returned with the oil to the compressor.

Fig. 6 80 m Compressor
Oil separator

Solenoid valve

80 m 80 c

Stop valve 80 m
L/M Filter
80 A

dia. 8/6
80 B

Valve block pos. 80C, shown in fig. 7, con- 80E, which can be removed by dismounting
sists of a stop valve pos. 80D, which is cover pos. 80F. The filter can be cleaned in a
closed and opened by turning of the spindle. cleansing fluid and blown clean with com-
This valve may be dismantled by unscrewing pressed air.
the big union nut from the valve block. On remounting tighten the cover with a
On refitting the nut, tighten it with 60 Nm. torque of 60 Nm. Remember gasket pos.
From the stop valve the oil passes filter pos. 80G.

0171-370-EN 175
Fig. 7 During start-up of the compressor, the sole-
1,4 Nm
80N noid valve can be kept closed for 20 to 30
80K mins. by means of a time relay, available as
80H
an additional equipment. This prevents any
80J
A
refrigerant from entering the compressor.
80M

80P
The seat of the solenoid valve pos. 80I also
60 Nm 80L
50 Nm
10 Nm
acts as a nozzle that regulates the oil flow
80Q back to the compressor.
80I
Select the nozzle size on the basis of table 8.
80
80D
We recommend not to use a bigger nozzle
size than prescribed. In order to replace the
nozzle the compressor must first be depres-
surized. Next, dismantle coil pos. 80J and
B
80E
armature tube pos. 80P.
80G The nozzle is screwed into the valve block
60 Nm 80F
and, on remounting, use gasket pos. 80Q
for the nozzle and gasket pos. 80L for the
armature tube. Tighten with the prescribed
moments of 10 and 50 Nm -- see fig. 7.
After the oil has been cleaned, it flows to the On mounting the coil keep it in place by
solenoid valve pos. 80H, which is always using hand screw pos. 80N and O-ring pos.
closed at compressor standstill. 80K and 80M.

Fig. 8
Two stage compressor
R717 One stage compr. Booster compr. TCMO TSMC TSMC
Mk 2 100 180
CMO SMC SMC CMO SMC SMC
Mk 2 100 180 Mk 2 100 180 LP HP LP HP LP HP
Number of cylinders

4 0.6 0.6 0.6 0.6 0.6 0.8

6 0.6 0.6 0.6 0.6 0.6 0.8
8 0.6 0.6 0.6 0.6 0.6 0.8 0.6 0.8 0.6 1.0 0.6
12 0.6 0.8
16 0.6 0.8 0.8 0.6

Two stage compressor

HFC/ One stage compr. Booster ompr. TCMO TSMC TSMC
HCFC Mk 2 100 180
CMO SMC SMC CMO SMC SMC
Mk 2 100 180 Mk 2 100 180 LP HP LP HP LP HP
Number of cylinders

4 0.6 0.6 0.8 0.6 0.8 1.0

6 0.6 0.6 0.8 0.6 0.8 1.0
8 0.6 0.6 0.8 0.6 0.8 1.0 0.6 0.6 0.8
12 0.8 1.0
16 0.8 1.0 0.6

176 0171-370-EN
b: Float valve controlled oil return

Fig. 9

To the compressor
A D

For the oil separators shown in fig. 1 and 2 the float valve will open and lead the oil back
the float valve is built into the oil separator. to the compressor crankcase.
After the oil separator has been depressu-
rized, this valve can be removed by disman-
The filter pos. D and the float valve can be
tling of the bottom cover.
cleaned by dismantling the threaded nipple
As to the oil separator types as shown in fig. on the stop valve housing and removing the
3, drain the separated oil from the float valve cover on the float housing after the valves
pos. C, as outlined in fig. 9, once the valves pos. A and B are closed and the pressure in
pos. A and B are open. At a rising oil level the compressor equalized to atmospheric.

0171-370-EN 177
 Connections on CMO/HPO 24-26-28

H N G L 1 2 K K K K,P

A B M R F S E O D C J
T0177142_0 V6

(OPT) KP15

93.11
MP55

0171-339-EN
C G H L O only for CMO

Thread Pressure Pressure Air-cooled/ Air-cooled Booster Thermo-

Pos. RG frame/ connect. water- with built-in with pump Normal appilication
(INCH) cover max. cooled oil-cooler oil-cooler

A 11/4 Suction Suction + + + + Heating rod

B 3/ Suction Suction + + + + Oil charging valve
4
C 1/ Suction Suction Plugged Plugged Plugged Plugged Applicable for thermostat KP 98 oil temp.
2
D 1/ Suction Suction Plugged + + Plugged Thermostat KP 77
2
E 3/ 3/ Suction H-pressure Plugged + + Plugged Inlet to built in oil cooler
4- 8
F 3/ 3/ Suction H-pressure Plugged + + Plugged Outlet from built in oil cooler
4- 8
G 1/ H-pressure H-pressure Plugged Plugged Plugged Plugged Applicable for KP 98
2
H 1/ H-pressure H-pressure + + + + Equalizing pressure for pressure gauge
4
and pressure switch
J 3/ Suction H-pressure Plugged + Plugged + Return from oil cooler/equalizing from
8
Thermopump
K 1/ H-pressure H-pressure - - - + Injection from Thermopump
4
L 1/ Suction Suction + + + + Suction pressure to pressure gauge and
4
pressure switch
M 3/ Suction - Plugged Plugged Plugged - Available
8
N 1/ Suction - + + + + Oil return from oil separator
4
O 1/ Oil Oil + + + + Oil pressure to pressure gauge and
4
pressure switch
P 1/ L-pressure H-pressure - - + + Return from oil cooler (Booster)
4
R 1/ H-pressure H-pressure - - - + Liquid supply to Thermopump
4
S 1/ H-pressure H-pressure - - - + Equalizing to suction side from Thermo-
4
pump

1 LP-suction stop valve + Is present on compressor block unit and used for
2 LP-discharge stop valve - Not present on compressor block

178 0171-370-EN
 Connections on TCMO 28
X H N L T V 3 1 U 2 P K

T0177142_0 V6
A B M R F S E G O D C J

(OPT) KP15

MP55

C G T H L O

Thread Pressure Pressure Air-cooled/ Air-cooled Thermo-

Pos. RG in frame/ connect. water- with built-in pump Normal application
(INCH) cover max. cooled oil cooler

A 11/4 Suction Suction + + + Heating rod

B 3/ Suction Suction + + + Oil charging valve
4
C 1/ Suction Suction Plugged Plugged Plugged Applicable for thermostat KP 98 oil temp.
2
D 1/ Suction Suction Plugged + Plugged Thermostat KP 77
2
E 3/ 3/ Suction H-pressure Plugged + Plugged Inlet to built-in oil cooler
4- 8
F 3/ 3/ Suction H-pressure Plugged + Plugged Outlet from built-in oil cooler
4- 8
G 1/ H-pressure H-pressure Plugged Plugged Plugged Applicable for thermostat KP 98
2
H 1/ H-pressure H-pressure + + + Equilizing pressure for pressure gauge
4
and pressure switch
J 3/ Suction - Available
8
K 1/ H-pressure H-pressure - - + Injection from Thermopump
4
L 1/ Suction Suction + + + Suction pressure to pressure gauge and
4
pressure control switch
M 3/ Suction - Plugged Plugged - Available
8
N 1/ Suction - + + + Oil return from oil separator
4
O 1/ Oil Oil + + + Oil pressure to pressure gauge and
4
pressure switch
P 1/ I-pressure H-pressure - + + Return from oil cooler/equalizing from Thermopump
4
R 1/ H-pressure H-pressure - - + Liquid supply toThermopump
4
S 1/ H-pressure H-pressure - - + Pressure equalizing from Thermopump
4
T 1/ I-pressure I-pressure + + + Intermediate pressure to pressure gauge
4
U 3/ H-pressure H-pressure + + + By-pass outlet
8
V 3/ I-pressure H-pressure + + + By-pass inlet
8
X 1/ H-pressure H-pressure + + + TEAT injection valve
2

1 LP-suction stop valve + Is present on compressor block unit and used for
2 LP-discharge stop valve - Not present on compressor block
3 I-pressure stop valve

0171-370-EN 179
Water cooling of the reciprocating compressor
CMO 24 - 26 - 28 and TCMO 28
HPO 24 - 26 - 28

The piston compressor can be cooled with cooling fins on the interior of the side cover
water on the top and side covers, the cooling Pos. 3A provide excellent cooling of the oil in
requirement being dependent on the operat- the crankcase.
ing conditions and the refrigerant on which
the compressor operates. When dismantling top or side covers with wa-
ter covers, it is a good idea first to dismantle
See page 1 for details. the topmost covers on the compressor. In
addition, you should ensure that the two cov-
Water cooling is obtained by mounting an ex- ers are kept tight against the intervening gas-
tra cover (water cover) Pos. 2K/3K on the ket. This will prevent water flowing into the
outside of top and side covers with the inter- compressor block.
vening gaskets Pos. 2L and 3L and 2P/3P in
Fitting cooling water hoses

01.05
between.
When supplied, the compressor is not fitted
Tighten top and water covers with the bolts with cooling water hoses or appurtenant as-

0171-333-EN
Pos. 2C, which are longer than the bolts for sembling parts. These are provided loose.
the air-cooled version. This avoids damage to the parts in transit. Fit
See the Spare-parts list at the end of this in- the cooling water hoses as shown in the fol-
struction manual for details. lowing drawing, corresponding to the specifi-
cation enclosed with the delivery.
For water cooling of the side covers, only a
special finned side cover Pos. 3A is used to- Please note:
gether with a water cover Pos. 3K and a gas-
S The direction of water throughflow is
kets Pos. 3L and 3P. These are also listed in
shown by arrows on the drawing.
the spare-parts list.
S The hose length is indicated opposite the
The water cover, together with the cover on respective Pos. nos. on the drawing.
which it is mounted, forms a ducting system
in which the water is channelled back and S The hoses must not be in contact with the
forth and effectively cools the top or side cov- frame, covers, discharge pipe or similar
er. By virtue of their large surface area, the components.

In the supply pipe to the water system a solenoid valve must be fitted which shuts off the water flow in
the refrigeration system at compressor standstill.
However, we do recommend to continue the water cooling for approx. 10 mins after the compressor has
been stopped as this protects the cooling water hoses against excessive temperatures

180 0171-370-EN
Cooling of Top and Side Covers
CMO 24-26-28 and TCMO 28

4
5 CMO 24 3185--226
Pos. no. Hose Type L (mm)
2
3
1 C 485
2 E 460
3 E 300
4 C 465
5 A 535
1

6
5
CMO 26 3185--227
4
Pos. no. Hose Type L (mm)
1 C 590
2 C 450
3 3 E 210
2
4 C 255
5 E 260
1 6 A 860

5
6 CMO 28 - TCMO 28 3185--228
4 4
Pos. no. Hose Type L (mm)
1 C 590
2 C 510
3
3 C 255
2
4 E 165
5 C 175
1 6 A 670

No. of Fittings

Fittings Strips

Part No. 1349.264 1349.261 1349.262 1349.263 1349.259 1349.265 1554.062

24 1 1 1 5 1 2 4

26 1 1 1 7 1 2 6

28 1 1 1 9 1 2 6

0171-370-EN 181
 Cooling of Top and Side Covers
HPO 24-26-28
HPO 24 3185--237
3
Pos. no. Hose Type L (mm)
1 C 590
4
2
2 E 300

3 E 465

4 C 510
1

3
HPO 26 3185--238
3
Pos. no. Hose Type L (mm)
1 C 590
2 2 E 210
4
3 E 260

1 4 C 450

HPO 28 3185--239
5 Pos. no. Hose Type L (mm)
2
4 4 1 C 590
2 C 710

3 3 C 270
6
4 E 165

1 5 C 530
6 A 375

No. of Fittings

Fittings Strips

Part No. 1349.264 1349.261 1349.262 1349.263 1349.259 1349.265 1554.062

24 1 0 0 6 0 2 4
26 1 0 0 8 0 2 6

28 1 1 1 9 1 2 6

182 0171-370-EN
 Cooling of Side Cover only
CMO 24-26-28 and TCMO 28

3185--229
CMO 24-26-28 and TCMO 28
Pos. no. Hose Type L (mm)
1 C 660

1
2 C 680
2

No. of Fittings

Fittings Strips

Part No. 1349.264 1349.261 1349.262 1349.263 1349.259 1349.265 1554.062

24 0 0 0 2 0 2 4
26 0 0 0 2 0 2 4
28 0 0 0 2 0 2 4

Mounting of hoses for cooling Max. permissible outlet temperature:

water +55°C
The flow direction of the water is indicated by Max. permissible temperature rise from
arrows on the sketch. The length of the hose inlet to outlet on the compressor:
is indicated by A-measures in the table. The 15°C
hoses must not touch frame, discharge pipes
or similar. Max. permissible cooling water pressure:
8 bar.
Max. permissible inlet temperature:
+40 °C Minimum water consumption is 5.5 litres per
kW motor power.
Min. permissible inlet temperature:
+10 °C

0171-370-EN 183
Pressure loss in water cooling system
on CMO/TCMO & HPO compressors

Pressure loss
p (mVS) CMO/
11 TCMO 28
HPO 28
10 CMO 26
HPO 26
9 CMO 24
HPO 24
8

0
0 200 400 600 800 1000 1200 1400 1600

Volumetric flow
V(l/hour)

184 0171-370-EN
 Reciprocating compressors used for air conditioning
CMO 24-26-28 and SMC 104-106-108

When the CMO or SMC compressor is used connected to any of the above pressure
for air conditioning, you can choose to control cut-outs.
the compressor capacity by means of one or
Pressure cut-out A must be set to a close at
two KP1 pressure cut-outs.
a pressure approx. 0.5 bar higher than the
CMO compressors are all controlled by three setpoint for cut-out B.
solenoid valves. When these are to be con-
A third cut-out, the low-pressure cut-out,
trolled with pressure cut-outs, cut-out A must
must be set to break at a pressure equal to
be connected in parallel with solenoid valves
the lowest evaporator temperature that can
nos. 1 and 2. Cut-out B must be connected
occur, however, never lower than started in
with solenoid valve no. 3.
section Pressure and temperature settings.
The SMC 108 must be connected in the At this temperature, the compressor must
same way as CMO. stop. This control form provides the following
91.06

capacity stages:
The SMC 106 is controlled by two solenoid
valves, where pressure cut-out A must be
0171-348-EN

connected to solenoid valve no. 1 and cut-out

B to solenoid valve no. 2. Capacity in %
Capacity stage 1 2 3
The SMC 104 is controlled by a solenoid val-
ve to be connected to pressure cut-out A. CMO 24 100 50 25
Only one cut-out is to be used for the SMC CMO 26 100 50 35
104. CMO 28 100 50 25
SMC 104 100 50 --
If the compressor features a solenoid valve SMC 106 100 66 33
for totally unloaded start, this must not be SMC 108 100 50 25

SMC 104 SMC 106 SMC 108 CMO

3 4 1
2 1 1 2 3
2
1
A A 1 A 2
1 2 3
1 B 2 B 3

A B

0171-370-EN 185
Cooling of intermediate gas on
TCMO and TSMC 100 and 180

At two-stage operation it is necessary to cool Fig. 1

CMO, SMC 100/180 compressor
the discharge gas from the LP stage before it
enters into the HP stage. This intermediate Oil separator
CT
cooling is done with the systems described Oil separator •
Equalizing pipe
below, depending on the type of refrigerant •
• MT HT

used. Suction
LP filter
MT
HP
Common for these intermediate cooling sys- LP •
tems is the fact that they must cool the inter- Float valve
mediate pressure gas sufficiently and, at the
Intermediate Liquid subcooling
same time, ensure that no liquid is admitted cooler • spiral
Oil drain off
into the HP stage, as liquid can produce li-

97.03
quid stroke in the HP cylinders and result in
Fig. 2
wear to the moving parts. It is important, TCMO, TSMC 100/180 compressor
therefore, to check the systems as indicated

0171-359-EN
Oil separator Oil separator
below.
CT
LP IP HP
LPIP
Intermediate cooling system with Suction filter
intermediate cooler type DVEA,
R717 Equalizing pipe

The two-stage R717 plant may consist of two Intermediate

Float valve
cooler
compressors, one low pressure compressor Liquid subcooling
(LP) and one high pressure compressor (HP) spiral

as illustrated in fig. 1. The plant may also Oil drain off

consist of two-stage compressors as shown
in fig. 2. In the intermediate cooler, the liquid level of
R717 is regulated by the float valve and the
In both cases the compressors are con- discharge gas from the LP stage is cooled by
nected to an intermediate cooler in which the bubbling up through the refrigerant from the
warm gas from the LP-stage is cooled down distributor at the bottom of the intermediate
before it flows on to the HP-stage. cooler.

186 0171-370-EN
In the liquid subcooling spiral, the refrigerant liquid refrigerant into the intermediate pipe.
flowing from the receiver to the evaporator This is achieved with the following systems 1
side of the refrigeration plant is cooled. The and 2:
intermediate cooler is dimensioned so that
1: Intermediate cooling with thermostatic
the cooled gas is free of liquid refrigerant be-
expansion valve type:
fore leaving the top of the intermediate cool-
TEA (R717) or TEX (R22)
er. It is important to check that the float valve
TCMO and TSMC 100/180
is functioning correctly and keeping the liquid
level constant. Frosting of the liquid level Fig. 3
pipe on the intermediate cooler indicates the TCMO and TSMC
liquid level. Oil separator

• CT
In order to avoid violent foaming of the liquid
in the intermediate cooler, the compressor IP HP Suction filter (opt.)
LP •
should run for a few minutes after start-up at LP IP

the lowest capacity stage to stabilize plant LP

pressures. Capacity can then be increased Opt. Mixing chamber

•
stage by stage at suitable time intervals. B
•

Make sure that the equalizing pipe on the in- TEA or TEX 80

termediate cooler has been connected. The

equalizing pipe safeguards against backflow
In the system in fig. 3 the liquid refrigerant
of liquid from the intermediate cooler to the
conveyed to the intermediate pipe is regu-
LP stage of the compressor, when the com-
lated by a thermostatic expansion valve
pressor is not working.
type TEA (R717) or TEX (R22) with a sen-
At regular intervals, the intermediate cooler sor placed on the intermediate pipe close to
must be drained of oil through the oil drain the HP stage.
valve.
A valve block pos. 80 is built into the liquid
Intermediate cooling system with system.
liquid injection into the intermedi- Connection, pos. B, pipe dimension OD 10
ate discharge gas, R22 and R717 mm, emerges from receiver or priority vessel
Two-stage compressors can be equipped and is conveyed to valve block pos. 80 which
with a pipe connection from the LP stage out- is the same type as the one described in sec-
let branch to the HP stage suction branch as tion entitled: Solenoid controlled oil return of
shown in fig. 3. this instruction manual.

In the pipe connection the hot discharge gas Please note:

from the LP stage is cooled by injection of that nozzle size pos. 80I must be 3.3 mm.

0171-370-EN 187
It is essential to make sure that the inter- before the HP-stage suction filter. The sensor
mediate cooling system functions correctly in must be fitted on the side of the pipe and in-
order to prevent too much liquid refrigerant sulated as shown in fig. 5
from being injected into the IP gas.

Too much liquid refrigerant may impede the Fig. 5

evaporation of the liquid before the IP gas is
sucked into the HP stage of the compressor.
This may result in liquid hammer and wear 12
and tear on moveable parts.
3
The expansion valve must be adjusted to su-
perheat the intermediate gas at a temper-
Sensor
ature not below 10 K.
Insulation
This is done by measuring the pressure and
the temperature of the intermediate gas be-
fore it enters the compressor to the HP
Note:
stage. (For this purpose SABROE has
S The necessary superheat of 10 K is in-
mounted an empty sensor pocket. To ensure
cluded in the curve, fig. 4.
an exact measurement the pocket can be
filled with oil before the thermometer is S An exact measurement of the temperature
introduced). cannot be read until after a stabilisation
Compare the measured values with the period which is not under 5 minutes for
curves in fig. 4. For any given intermediate R22 and not under 15 minutes for R717.
pressure the temperature must be close to S Before the initial adjustment of the valve it
the curve, but never below. must be adjusted to its highest level to
Fig. 4 make sure that the superheat is above 10
° C temperature HP suction side
K. Do this by turning the spindle 20 turns
35 clockwise for R717 and 2.5 turns for R22.
30
25
X The superheat can now be regulated on
X
20
X the basis of measurements and the curves
15
10
X in fig. 4.
X
5
0 X S The valve for R717 changes the super-
-5
X heat 0.5 K per rotation of the adjusting
-10
-15 X X R717 screw. The valve for R22 changes the su-
-20
X • • R22 perheat 4 K per rotation.
-25
-30 By turning the adjusting screw clockwise
-35 the superheat is increased. By turning the
-40
1 2 3 4 5 6 7 8 screw anti-clockwise the superheat is
Intermediate pressure (bar) reduced.

Position the sensor of the expansion valve on S SABROE has adjusted the valve to 10 K
the intermediate pressure pipe immediately superheat.

188 0171-370-EN
2: Intermediate cooling with thermostatic Fig. 7
injection valve type:
TEAT (R22) 83A
TCMO and TSMC 100/180

Different systems are applied for TCMO

and TSMC 100/180 as described below in
•
sections A and B.

A: TCMO For sub-cooling of liquid to the evaporators

the injected liquid first passes a liquid
Fig. 6 sub-cooler, mounted on the compressor.
KP 77
The liquid injection is controlled by a TEAT
T valve.
Suction filter Oil separator

B: TSMC 100/180
HP

LP
IP Fig. 8
KP 77
80
T
Oil separator

Liquid subcooler CT
TEAT To evaporator LP IP HP
LP IP Mixing chamber

LP
From receiver Liquid tank 4L
A

TEAT
Liquid supply
From receiver To evaporator
HESI

As illustrated in fig. 6 the intermediate gas is On TSMC 100 and 180 plants, the intermedi-
cooled by injecting refrigerant into the low ate cooling system can be designed as illus-
pressure stage pressure chamber in the trated in fig. 8, in which the intermediate cool-
compressor. The liquid is thoroughly mixed ing is carried out by a thermostatic injection
with the hot discharge gas by means of the valve of the TEAT type, and in which the sub-
distributor pos. 83A as may be seen from cooling takes place in a HESI heat exchang-
fig. 7. er.

0171-370-EN 189
Adjusting the TEAT valve: Adjustments are made by rotating the regu-
For both systems, A and B, the following lating spindle clockwise, 5 turns for every
applies: 10K of temperature increase.
The sensor of the TEAT valve is placed in a
Example:
sensor pocket at the discharge branch of the
compressor, and a proper thermal contact is Refrigerant R22
obtained by means of the heat conducting Regulating temperature
compound. factory setting 75°C
The solenoid valve is opened by the KP77 Estimated discharge
thermostat whenever the temperature of the gas temperature
pressure pipe is above 55°C. IT = --10°C
CT = 35°C 96°C
It is important to make sure that the interme- Superheat = 20°C
diate cooling system functions correctly and
thus prevent too much refrigerant from being Adjustment
injected into the intermediate pressure gas. 5
96 -- 75 x 10= 10.5 revolutions
Excess refrigerant may lead to the liquid be-
ing unable to evaporate before the intermedi-
ate pressure gas is sucked into the HP stage Under all circumstances, the regulating tem-
of the compressor and may thus cause liquid perature of the valve must be raised at least
strokes and wear to the moving parts. 10K, corresponding to 5 revolutions (clock-
wise).
When supplied, the TEAT valve is factory
set to the following regulating temperatures: When the plant has stabilized and the com-
pressor is working at 100% capacity, the val-
Refrigerant Regulating temp. ve must be readjusted to the same value as
the discharge temperature with the Antici-
R22 75 ° C pated discharge gas temperature in the table,
R717 75 ° C within -5K to +10K. (In the example, 91°C <
96°C < 106°C)

Before using the valve, the regulating tem- At reduced compressor capacity, the dis-
perature must be changed to the same value charge gas temperature may rise somewhat;
as the discharge gas temperature indicated under these circumstances it should be
in the table Anticipated discharge gas tem- checked that the discharge gas temperature
peratures in this instruction manual. does not exceed the Set point for the KP98.

190 0171-370-EN
 Ordering Spare Parts

When placing an order for spare parts, 3. Forwarding instructions

please state the following:
When ordering spare parts, please state the
forwarding address, and the address to
1. Compressor No which the invoice is to be sent. If appropriate,
All compressors are fitted with an identifica- please state the name of your local bank,
tion plate, which states the type and com- method of transport and required delivery
pressor no of the compressor and indicates date.
the type of refrigerant be used.

2. Part No 4. Classification certificate

Spare parts drawings and parts lists in the
If requiring a certificate from a classification
Service Manual contain the following spare
authority, please state this on the order as
94.05

part indentification:
the inspection and issuing procedures take
a) Spare part no -- a reference number, extra time and incur extra expenses.
0171-466-EN

which makes it easier to find a part in the

drawing and the parts list.
b) Designation of the part. 5. Quotation No
c) Part no -- a 7-digit number.
If a quotation no has been stated during earli-
When ordering spare parts, please state the er correspondence, please refer to this when
designation and part number. If in any doubt, placing your order -- it will help us to identify
state the spare part no too. and execute your order quickly.

0171-370-EN 191
Spare parts sets for compressors and units
CMO/TCMO - SMC/TSMC 100 - SMC/TSMC 180

On servicing compressor and unit it is always S Certificate spare part set

an advantage if you, as our customer, have Further to the parts from the extended
some of the most commonly used spare spare part set this set contains a major
parts at your disposal. This enables you or a number of components and wearing parts
summoned SABROE service engineer to selected by the classification societies.
carry out the necessary service work without
having to spend extra time on procuring the S Special spare part set
spare parts needed. This is a more compehensive set than the
extended spare part set as almost all
Spare parts are obtainable in sets as men-
O-rings and gaskets are included and for
tioned in the following.
the most wearing parts the number of
By contacting SABROE’s local representa-
parts has been extended.
tive it is possible to receive a list of the spare

97.03
part sets recommended by SABROE.

Spare part set for Basic Unit

Compressor block

0171-941-EN
S Standard spare part set
S Standard spare part set
This is a set consisting mainly of O-rings
Contains a suitable selection of O-rings
and gaskets for some of the components
as well as valve ring plates and valve
included in the unit.
springs.

S Extended spare part set S Certificate spare part set

Further to the parts included in the stan- Further to the parts from the standard
dard spare part set this set contains a spare part set this set contains other com-
cylinder lining and discharge valve as well ponents selected in accordance with the
as an extended number and types of gas- requirements of the classification soci-
kets and fittings. eties.

192 0171-370-EN