Compressor York 104 Manual

Instruction Manual
SMC 104 SMC 106 SMC 108

TSMC 108
00.12
Specifications for
SMC 104-106-108 Mk3 and TSMC 108 Mk3, S-L-E
The SMC/TSMC-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 ex-
The variants featured on the unit are marked
pected 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
Analogue Control System
Thermopump
Water cooled top and side covers
Compressor
cooling Air cooled top and side covers
Oil cooling (water-cooled side covers)
Oil cooling OSSI/HE8S
Coupling
Drive type
V-belts
Explosion-proof electrical design
Pinion drive
Oil pump drive
Chain drive
Equipment for parallel operation
SABROE OVUR-type oil separator
0178-910-EN 1
Preface
The aim of this instruction manual is to this instruction manual to ensure a safe,
provide the operators with a thorough reliable and efficient operation of the product
knowledge of the compressor and the unit as YORK Refrigeration is unable to provide a
and at the same time provide information guarantee against damage of the product
about: occurring during the warranty period as a
result of incorrect operation.
S the function and maintenance of the
individual components;
Dismantling and assembly of compressors
S service schedules; and components should only be carried out
by authorized personnel to prevent
S procedure for dismantling and accidents.
reassembling of the compressor.
The contents of this instruction manual must
00.07
This instruction manual draws attention to
not be copied or passed on to any
typical errors which may occur during opera-
unauthorized person without YORK
tions. The manual states causes of error and
0171-500-EN
Refrigeration’s permission.
explains what should be done to rectify the
errors in question.
YORK Refrigeration’s General Conditions for
It is imperative that the operators familiarize the Supply of Components and Spare Parts
themselves thoroughly with the contents of will apply.
In the space below you can enter the name and address of your local YORK Refrigeration
Representative:
2 0178-910-EN
List of Contents
Specifications for SMC 104-106-108 Mk3 and TSMC 108 Mk3, S-L-E . . . . . . . . . . . . . . . 1
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
List of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
First Aid for accidents with Ammonia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
First Aid for accidents with HFC/HCFC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Protecting the environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Description of compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Handling of the compressor, areas of application, safety equipment etc. . . . . . . . . . . . . . 16
Sound data for reciprocating and screw sompressor units - all types of compressors. . 17
Vibration data for compressors - all types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Compressor data for reciprocating compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Operating limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
R717 - Operating limits single stage compressors CMO, SMC 100 S-L, SMC 180 . . 23
R717 - Operating limits single stage compressors SMC 100 E . . . . . . . . . . . . . . . . . . . 24
R717 - Operating limits two-stage compressors TCMO, TSMC 100 S-L-E, TSMC 180 . 25
R22- Operating limits single stage compressors CMO, SMC 100 S-L, SMC 180 . . . . 26
R22 - Operating limits two-stage compressors TCMO, TSMC 100 S-L, TSMC 180 . 27
R134a - Operating limits single stage compressors CMO, SMC 100 S-L . . . . . . . . . . 28
R134a - Operating limits two-stage compressors TCMO, TSMC 100 S-L . . . . . . . . . . 29
R404A - Operating limits single stage compressors CMO, SMC 100 S-L . . . . . . . . . . 30
R404A - Operating limits two-stage compressors, TCMO, TSMC 100 S-L . . . . . . . . . 31
R507 - Operating limits single stage compressors CMO, SMC 100 S-L . . . . . . . . . . . 32
R507 - Operating limits two-stage compressors TCMO, TSMC 100 S-L . . . . . . . . . . . 33
R407 - Operating limits one-stage compressors CMO & SMC . . . . . . . . . . . . . . . . . . . 34
General operating instructions for CMO/TCMO, SMC/TSMC piston compressors . . . . . 35
Starting up compressor and plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Stopping and starting-up compressor during a short period of standstill . . . . . . . . . . . 36
Stopping plant for brief periods (until 2-3 days) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Stopping plant for lengthy periods (more than 2-3 days) . . . . . . . . . . . . . . . . . . . . . . . . 37
Automatic plants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Pressure testing refrigeration plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Pumping down refrigeration plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Operating log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Servicing the piston compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Pressure drop test: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Removing refrigerant from compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Lubricating oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Lubricating oil requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
General rules for use of lubricating oil in refrigeration compressors . . . . . . . . . . . . . . . 46
Instructions for choosing lubricating oil for refrigeration compressors . . . . . . . . . . . . . 46
Charging refrigeration compressor with lubricating oil . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Changing oil in refrigeration compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Charging the compressor with oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
0178-910-EN 3
Assessing the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Visual assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Analytical evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
The analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Expected discharge gas temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Servicing the refrigeration plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Maintenance of reciprocating compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
1. If the compressor is operational . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
2. If the compressor is inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Top covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Mounting top and water covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Discharge valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Tightness testing of discharge valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Cylinder lining with suction valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Main bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Compressor lubricating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Chain-driven oil pump with inverse direction of rotation . . . . . . . . . . . . . . . . . . . . . . . . . 72
Oil pressure valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
By-pass valve pos. 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Suction filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Stop valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Unloaded start and capacity regulation on SMC and TSMC 100 and 180 compressors 81
Description of unloader mechanism and capacity regulation . . . . . . . . . . . . . . . . . . . . . 81
Pilot solenoid valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Schematic outlines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Standard unloaded start and capacity regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Schematic drawings 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Totally unloaded start and capacity regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Schematic drawings 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Relief cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Heating rods for heating the oil in reciprocating and screw compressors . . . . . . . . . . . . . 88
Stop valves pos. 23 and 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Monitoring cylinder lining insertion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
1. Checking clearance volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Adjustment is made as follows: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
2. Checking lifting reserve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Check lifting reserve: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Pressure gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Undersize Bearing Diameters for Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Sundry clearances and check dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
4 0178-910-EN
Torque moments for screws and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Refrigeration Plant Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Operational reliability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Pumping down the refrigeration plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Dismantling plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Tightness testing and pump-down of refrigeration plant . . . . . . . . . . . . . . . . . . . . . . . . . 100
Trouble-shooting on the Reciprocating Compressor Plant . . . . . . . . . . . . . . . . . . . . . . . . . 101
Remedying malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Selecting lubricating oil for SABROE compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Data sheet for listed Sabroe oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
List of major oil companies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Alignment of unit, AMR coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Fitting and alignment of AMR-type coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Boring of motor flange for AMR coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
V-belt drive for piston compressor types (T)CMO and (T)SMC . . . . . . . . . . . . . . . . . . . . . 150
Oil Separator OVUR for SMC/TSMC 100 HPC - SMC/TSMC 180 . . . . . . . . . . . . . . . . . . . 152
Connections on SMC 104-106-108 Mk3, HPC 104S-106S-108S . . . . . . . . . . . . . . . . . . . 156
Connections on TSMC 108 Mk3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Oil return in parallel operation for reciprocating compressors . . . . . . . . . . . . . . . . . . . . . . . 158
Reciprocating compressors used for air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Water-cooling of reciprocating compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Pressure loss in water cooling on SMC/TSMC/HPC compressors . . . . . . . . . . . . . . . . 165
Thermo pump cooling of R717 reciprocating compressors . . . . . . . . . . . . . . . . . . . . . . . . . 166
Principle drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Oil cooling with an OSSI or HE8S oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
HFC and HCFC compressors: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Cooling of the intermediate gas on TCMO and TSMC 100 and 180 . . . . . . . . . . . . . . . . . 176
Ordering Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Spare parts sets for compressors and units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1825
Compressor block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1825
Spare part set for Basic Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1825
List of parts for SMC/TSMC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0661-680
Tools for compressor SMC/TSMC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0661-684
Spare Parts drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0661-521/0661-522
Spare Parts drawings (in detail) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0661-520
Piping diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . order specific
Wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . order specific
Dimension sketch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . order specific
Cooling water diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . order specific
Foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . order specific
Positioning of vibration dampers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . order specific
0178-910-EN 5
First Aid for Accidents with Ammonia
(Chemical formula: NH3 - refrigerant no.: R717)
Inhalation
Warning! 1. Move affected personnel into fresh air
immediately and loosen clothing restricting
No plant can ever be said to be too safe -
breathing.
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. water, taking small mouthfuls.
5. If the patient is conscious and the mouth
Since ammonia is self-alarming, it serves as is not burnt, feed the patient with
its own warning agent so that no person sweetened tea or coffee (never feed an
96.01
remains voluntarily in concentrations which unconscious person).
are hazardous. Since ammonia is lighter than 6. Oxygen may be administered, but only
air, adequate ventilation is the best means of when authorised by a doctor.
0170-008-DA
preventing an accumulation. 7. If the patient’s breathing stops, apply
artificial respiration.
Experience has shown that ammonia is
extremely hard to ignite and under normal Eye injuries from liquid splashes or con-
conditions a very stable compound. At ex- centrated vapour
tremely high, though limited concentrations,
1. Force the eyelids open and rinse eyes
ammonia can form ignitable mixtures with air
immediately for at least 30 minutes with
and oxygen and should be treated with re- the salt water solution just mentioned.
spect.
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 (wetted with a sterile isotonic (0.9%) NaCl-
assisting should be duly protected to avoid solution (salt water) to affected areas until
further injuries. medical advice is available.
6 0178-910-EN
First Aid for Accidents with HFC/HCFC
Refrigerant no.: R134a - R505A - R507 - R22, etc.
Inhalation
Warning! 1. Move affected persons into fresh air
No plant can ever be said to be too safe - immediately. Keep the patients still and
safety is a way of life. warm and loosen clothing restricting
breathing.
General 2. If the patient is unconscious, call a doctor/
HFC/HCFC form colourless and invisible ambulance with oxygen equipment
gasses which are heavier than air and smell immediately.
faintly of chloroform at high concentrations.
They are non-toxic, non-inflammable, non- 3. Give artificial respiration until a doctor
explosive and non-corrosive under normal authorizes other treatment.
operating conditions. When heated to above
approx. 300°C, they break down into toxic, Eye Injuries
acid gas components, which are strongly 1. Force the eyelids open and rinse with a
irritating and aggressive to nose, eyes and sterile isotonic (0.9%) NaCl-solution (salt
skin and generally corrosive. Besides the water) or pure running water continuously
obvious risk of unnoticeable, heavy gases for 30 minutes.
displacing the atmospheric oxygen,
inhalation of larger concentrations may have 2. Contact a doctor or get the patient to a
an accumulating, anaesthetic effect which hospital immediately for medical advice.
may not be immediately apparent. 24 hours
medical observation is therefore recom- Skin Injuries - Freeze Burns
mended.
1. Wash immediately with large quantities of
lukewarm water to reheat the skin.
Basic Rules for First Aid
Continue for at least 15 minutes, removing
1. When moving affected persons from low- contaminated clothing carefully while
lying or poorly ventilated rooms where washing.
high gas concentrations are suspected,
the rescuer must be wearing a lifeline and 2. Treat exactly like heat burns and seek
be under continuous observation from an medical advice.
assistant outside the room.
3. Avoid direct contact with contaminated oil/
2. Adrenaline or similar heart stimuli must refrigerant mixtures from electrically
not be used. burnt-out hermetic compressors.
0178-910-EN 7
Protecting the Operator as well as the Environment
concentrations of refrigerant vapours are in-

Warning! haled, they will attack the human nervous
system.
No plant can ever be said to be 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 will decompose to produce poi-
vironment. It is therefore absolutely impera-
sonous chemicals, which have a very pun-
tive to protect nature against pollution.
gent odour, thus warning the personnel of
To this end, many countries have passed le- their presence.
gislation in an effort to reduce pollution and
At high concentrations R717 causes respira-
preserve the environment. This legislation
tory problems, and when ammonia vapour
applies to all fields of industry, including re-
and air mix 15 to 28 vol. %, the combination
01.02
frigeration, and must be complied with.
is explosive and can be ignited by an electric
Be especially careful with the following sub- spark or open flame.
0170-009-EN
stances:
Oil vapour in the ammonia vapour increases
S refrigerants this risk significantly as the point of ignition
S cooling media (brine, etc) falls below that of the mixture ratio stated.
S lubricating oils. Usually the strong smell of ammonia will
Refrigerants usually have a natural boiling warn the personnel before the concentra-
point considerably below 0°C. This means tions become dangerous.
that liquid refrigerants can be extremely
The following table shows the values for the
harmful if they come into contact with skin or
max. permissible refrigerant content in air
eyes.
measured in volume %. Certain countries
High concentrations of refrigerant vapours may, however, have an official limit which
are suffocating when they displace air. If high differs from those stated.
Halogenated refrigerants Ammonia
HFC HCFC
R134a R404A R407C R410A R507 R22 R717
Unit
TWA
Time weighted ave- vol.% 0.1 0.1 0.1 0.1 0.1 0.1 0.005
rage during a week
Warning smell vol.% 0.2 0.002
8 0178-910-EN
Furthermore, it can be said about If the refrigerant is not to be reused, return it
refrigerants: to the supplier or to an authorized incinera-
tion plant.
S If released to the atmosphere, haloge-
Halogenated refrigerants must never be
nated refrigerants of the type HCFC
mixed. Nor must R717 ever be mixed with
(e.g. R22) may cause a depletion of the
halogenated refrigerants.
ozone layer in the stratosphere. The
ozone layer protects the earth from the Purging a Refrigeration Plant
ultraviolet rays of the sun. Refrigerants of If it is necessary to purge air from a refrige-
the types HFC and HCFC are greenhouse ration plant, make sure to observe the follo-
gases with contribute to an intensification wing:
of the greenhouse effect. They must, S Refrigerants must not be released to the
therefore, never be released to the atmo- atmosphere.
sphere. Use a separate compressor to
draw the refrigerant into the plant con- S When purging an R717 plant, use an ap-
denser/receiver or into separate refriger- proved air purger. The purged air must
ant cylinders. pass through an open container of water
for any remaining R717 to be absorbed.
S Most halogenated refrigerants are mis- The water mixture must be sent to an au-
cible with oil. Oil drained from a refrigera- thorized incineration plant.
tion plant will often contain significant
S Halogenated refrigerants cannot be ab-
amounts of refrigerant. Therefore, reduce
sorbed by water. An approved air purger
the pressure in the vessel or compressor
must be fitted to the plant. This must be
as much as possible before draining the
checked regularly using a leak detector.
oil.
S Ammonia is easily absorbed by water: Cooling Media

At 15°C 1 litre of water can absorb approx. Salt solutions (brines) of calcium chloride
0.5 kg liquid ammonia (or approx. 700 (CaCl2) or sodium chloride (NaCl) are often
litres ammonia vapour). used.
In recent years alcohol, glycol and halogena-
S Even small amounts of ammonia in water ted compounds have been used in the brine
(2-5 mg per litre) are enough to wreak production.
havoc with marine life if allowed to pollute In general, all brines must be considered as
waterways and lakes. being harmful to nature and they must be
used with caution. Be very careful when
S As ammonia is alkaline, it will damage
charging or purging a refrigeration plant.
plant life if released to the atmosphere in
Never empty brines down a sewer or into
large quantities.
the environment.
Refrigerant evacuated from a refrigerant The brine must be collected in suitable con-
plant must be charged into refrigerant cylin- tainers clearly marked with the contents and
ders intended for this specific refrigerant. sent to an approved incineration plant.
0178-910-EN 9
Lubricating Oils -- Mineral oil
-- Semi-synthetic oil
Warning!
-- Alkyl benzene-based synthetic oil
When charging oil, avoid that your skin
comes into direct contact with the oil. Direct -- Polyalphaolefine-based synthetic oil
contact with oils may in the long run develop
-- Glycol-based synthetic oil.
allergy attacks. Use therefore always protec-
tive equipment - goggles and gloves - when -- Ester oil
charging oil.
When changing the oil in the compressor or
Refrigeration compressors are lubricated by draining oil from the vessels of the refrigera-
one of the following oil types depending on tion plant, always collect the used oil in con-
the refrigerant, plant type and operating containers marked “waste oil” and send them to
ditions. an approved incineration plant.
NOTE
This instruction only provides general information. The owner of the refrigeration plant is
responsible for ensuring that all codes, regulations and industry standards are complied
with.
10 0178-910-EN
Description of compressor
SMC 104-106-108 Mk &
TSMC 108 Mk 3, S-L-E
The SMC 100 and TSMC 100 compressors

have 100 mm diameter pistons, as indicated
SABROE
96.12
by the first digit in the type designation. The

number of cylinders in the compressor block AARHUS DENMARK
0171-481-EN
is indicated by the following two digits, Type Refrigerant

where, for example, SMC 108 is an 8-cylin- Shop no Year
der compressor. SMC 100 is a one-stage Max. speed r.p.m.
compressor which compresses the gas in a
Swept volume m3/h
Working pressure bar
single stage.
Test pressure bar
In the TSMC 100 two-stage compressors, the

T0177093_2
gas is compressed in two stages at a ratio of
1:3 between the number of high- and low-
Similarly, the name-plate indicates the com-
pressure cylinders. Thus, a TSMC 108 has 2
pressor’s serial number, which is also stamp-
high-pressure cylinders and 6 low-pressure
ed into the compressor housing near the suc-
cylinders. The SMC 100 and TSMC 100 are
tion chambers.
available in three versions: an S-type with 80
mm stroke, an L-type with 100 mm stroke, Whenever contacting SABROE about the
and an E-type with 120 mm stroke. compressor, its serial number should be
The compressor works on the refrigerants stated.
mentioned in the following chapter.
In the compressors the pistons operate in
The type can be determined by the name- cylinder linings, inserted in the compressor
plate, located on the end face of the com- block with two cylinders under each top cov-
pressor, facing away from the coupling/belt er. The suction valves, of the ring-plate type,
drive. The following illustration shows a are mounted at the top of the cylinder linings.
SABROE nameplate. The pressure valves form the top of the cylin-
0178-910-EN 11
der linings and are kept in position by a pow- At the axle end, the crankshaft is fitted with a
erful safety spring. The safety spring allows balanced slide-ringtype seal consisting of a
the discharge valve unit to rise, providing a cast iron ring with an O-ring which rotates
greater throughflow aperture in the event of with the crankshaft, and a stationary
liquid strokes in the cylinder. This prevents spring-loaded carbon ring.
any overloading of the connecting rod bear-
ings. All compressors can be capacity-regulated
by connecting or disconnecting the cylinders
The crankshaft is supported in slide bearings in pairs. The following diagram shows the
able to assimilate both radial and axial capacity stages at which the compressors
forces. The oil pressure for the bearings and can operate.
the capacity regulating system is supplied
from the gearwheel oil pump incorporated in Capacity regulation is controlled by means of
the compressor. solenoid valves mounted on the compressor.
25% 33% 50% 67% 75% 100%
SMC 104 x x
SMC 106 x x x
SMC 108 x x x x
TSMC 108 x x x
12 0178-910-EN
Handling of the compressor, areas of application,
safety equipment etc.
Direction of rotation clearly marked with red paint. The weight of

In order to reduce the noise level from the the unit is stated on the package as well as in
electric motors these are often executed with the shipping documents.
specially shaped fan wings, thus determining During transportation and handling care
a particular direction of rotation. should be taken not to damage any of the
In case you yourself order a motor you components, pipe or wiring connections.
should take into consideration whether the Areas of application of the recipro-
motor is intended for direct coupling or for
cating compressors
belt drive of the compressor.
Compressor types:
The direction of rotation of the compressor BFO 3-4-5
for compressors CMO-TCMO and SMC- CMO-TCMO,
TSMC is indicated by an arrow cast into the
97.12
SMC 100-TSMC 100 Mk3, S, L, E

compressor cover, near the shaft seal. SMC 180-TSMC 180,
On the BFO compressors the direction of HPO-HPC
0170-119-EN
rotation is not indicated by an arrow but is In view of preventing an unintended applica-

standard as illustrated by the following tion of the compressor, which could cause
sketch: injuries to the operating staff or lead to tech-
nical damage, the compressors may only be
applied for the following purposes:
The compressor may ONLY be used:

S As a refrigeration compressor with a num-
ber of revolutions and with operating limits
Seen towards shaft end
as indicated in this manual or according to
a written agreement with SABROE.
Handling of compressor and unit
S With the following refrigerants:
For lifting of the compressor the large models
R717 -- R221 -- R134a1 -- R404A1 --
are equipped with a threaded hole for mount-
R410A1 -- R5071 -- R6001 -- R600A1 --
ing of the lifting eye. As to the weight of the
R2901 -- LPG1
compressor, see table on compressor data. 1) Exempted are the following compres-
Note: sors:
SMC-TSMC 100 E (only R717)
The compressor block alone may be lifted HPO and HPC (only R717 and R410A))
in the lifting eye. The same applies to the All other types of gas may only be
motor. used following a written approval from
SABROE.
The unit is lifted by catching the lifting eyes
welded onto the unit frame. These have been S As a heat pump:
0178-910-EN 13
-- BFO 3-4-5 manual handle, to which there is free ac-
cess.
CMO - TCMO and SMC - TSMC may
be used with a max. discharge pressure S It must be able to stop any dangerous si-
of 25 bar. tuation, which may occur, as quickly as
possible without this leading to any further
-- HPO -- HPC may be used with a max.
danger.
discharge pressure of 40 bar.
S In an explosion-prone environment, pro- Combustion motors
vided the compressor is fitted with ap- If combustion motors are installed in rooms
proved explosion-proof equipment. containing refrigeration machinery or rooms
The compressor must NOT be used: where there are pipes and components con-
S For evacuating the refrigeration plant of air taining refrigerant, you must make sure that
and moisture, the combustion air for the motor is derived
from an area in which there is no refrigerant
S For putting the refrigeration plant under air
gas, in case of leakage.
pressure in view of a pressure testing,
S As an air compressor. Failure to do so will involve a risk of the lubri-
Emergency device cating oil from the combustion motor mixing
with the refrigerant; at worst, this may give
The compressor control system must be
rise to corrosion and damage the motor.
equipped with an emergency device.
In case the compressor is delivered with a Explosion-proof electrical execution
SABROE-control system this emergency de-
If the compressor is delivered in an explo-
vice is found as an integrated part of the con-
sion-proof electrical execution, this is stated
trol.
in the table on page 1 of this instruction
The emergency device must be executed in manual.
a way to make it stay in its stopped position,
following a stop instruction, until it is deliber- Likewise, the compressor will, besides the
ately set back again. It must not be possible SABROE name plate, be equipped with an
to block the emergency stop without a stop Ex-name plate like the one illustrated below.
instruction being released.
It should only be possible to set back the
emergency device by a deliberate act, and
this set back must not cause the compressor
to start operating. It should only make it pos-
sible to restart it.
Other demands to the emergency device:

S It must be possible to operate it by means
T2516273_0
of an easily recognizable and visible
14 0178-910-EN
The temperature of tangible surfaces close to the warning signs during operation
When a compressor is working, the surfaces are so hot that your skin may be burnt from 1
that are in contact with the warm discharge second’s touch or longer.
gas also get warm. However, the temperatu-
re depends on which refrigerants and under
which operating conditions the compressor
is working. Often, it exceeds 70°C which for
metal surfaces may cause your skin to be
burnt even at a light touch.
Consequently, the compressors will be equip-

ped with yellow warning signs informing
you that pipes, vessels and machine parts
0178-910-EN 15
Sound data for reciprocating and screw
compressor units -- all types of compressors
In the following tables the noise data of the For screw compressors the average values
compressors is stated in: are indicated in the tables for the following
components.
-- A-weighted sound power level LW
S SAB 128, SAB 163, SAB 202, SV and
(Sound Power Level)
FV:
-- A-weighted sound pressure level LP Compressor block + IP23 special motor +
(Sound Pressure level) oil separator.
The values for LW constitute an average of a S SAB 110:

large number of measurings on various units. Compressor block + IP23 standard motor
The measurings have been carried out in ac- + oil separator
cordance with ISO 9614-2. Dimensional tolerances are:
99.02
The values are further stated as average ±3 dB for SAB, SV and FV screw com-
sound pressure in a free field above a re- pressors
0170-114--EN
flecting plane at a distance of 1 meter from ±5 dB for VMY screw compressors
a fictional frame around the unit. See fig. 1.
As to the reciprocating compressors the
values are stated for the compressor block
Normally, the immediate sound pressure
only.
lies between the LW and LP values and can
be calculated provided that the acoustic data The dimensional values are stated for 100%
of the machine room is known. capacity.
Fig. 1
Fictional frame
Dimensional plane
1 meter Reflecting plane

1 meter
16 0178-910-EN
Note the following, however: S the acoustics is another factor that can
change the sound level in a room. Please
S at part load or if the compressor works
note that the sound conditions of the site
with a wrongly set Vi the sound level can
have not been included in the stated
sometimes be a little higher than the one
dimensional values.
indicated in the tables.
S additional equipment such as heat ex- S by contacting SABROE you can have
changers, pipes, valves etc. as well as the sound data calculated for other operating
choice of a different motor type can in- conditions.
crease the noise level in the machine
room.
The tables have been divided into reciprocat-
S as already mentioned, the stated sound ing and screw compressors, respectively.
pressures are only average values above The reciprocating compressors are further
a fictional frame around the noise source. divided into one- and two-stage compressors
Thus, it is sometimes possible to measure as well as in a heat pump. In each table the
higher values in local areas than the ones operating conditions of the compressor dur-
stated -- for inst. near the compressor and ing noise measuring have been stated, just
motor. as the refrigerant used has been mentioned.
0178-910-EN 17
RECIPROCATING COMPRESSORS Two-stage
One-stage Evaporating temperature = --35°C
Evaporating temperature = --15°C Condensing temperature = +35°C
Condensing temperature =+35°C Refrigerant = R22/R717
Refrigerant = R22/R717 Number of revolutions =1450 rpm.
Number of revolutions =1450 rpm.
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
SMC 108 S 97 81 TSMC 116 E 98 82
SMC 112 S 99 82
SMC 116 S 100 83
Evaporating temperature = --35°C
Condensing temperature = +35°C
SMC 104 L 96 80
Refrigerant = R22/R717
SMC 106 L 97 81
Number of revolutions = 900 rpm.
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
Number of revolutions =1450 rpm.
Condensing temperature = +35°C
Number of revolutions = 900 rpm. 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
18 0178-910-EN
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 rpm. Number of revolutions = 2950 rpm.
*Number of revolutions = 6000 rpm.
Compressor unit 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 128 HM Mk2 102 84
SAB 128 HF Mk2 106 88
Condensing temperature =+35°C
SAB 128 HM Mk3 101 84 Refrigerant = R22/R717
SAB 128 HF Mk3 104 86 Number of revolutions = 2950 rpm.
SAB 163 HM Mk2 105 86
SAB 163 HF Mk2 109 90
SAB 163 HM Mk3 103 86 Compressor block LW LP
SAB 163 HF Mk3 106 87
VMY 347 H 97 82
SAB 202 SM 104 85
SAB 202 SF 105 86 VMY 447 H 100 85
SAB 202 LM 104 85 VMY 536 H 104 88
SAB 202 LF 105 86
SV 17 100 83
Evaporating temperature = 0°C
SV 19 101 84
Condensing temperature =+35°C
FV 19* 101 86
SV 24 103 85
Number of revolutions = 2950 rpm.
FV 24* 104 86
SV 26 103 85
FV 26* 107 85
SAB 81 101 86
SAB 83 102 85 VMY 347 M 99 84
SAB 85 103 86
VMY 447 M 101 86
SV 87 105 86
SV 89 108 85 VMY 536 M 105 89
0178-910-EN 19
Vibration Data for Compressors - All Compressor Types
Vibration data for YORK Refrigeration’s Vibration for YORK 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. Class III, C, which fixes max. permissible
permissible operating vibrations at 17.8 operating vibrations at 11.2 mm/s.
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. -- For screw compressors, if the compres-
sor runs at a wrong Vi-ratio.
S When placing the unit on the vibration
-- The pipe connections have been
dampers delivered by YORK 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 delivered
cur if: together with the order.
20 0178-910-EN
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)
0178-910-EN 21
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
22 0178-910-EN
TC
°F °C
60
R717
140
Operating Limits
122 50
Single--Stage
104 40
2 Compressor Type
86 30
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
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
0178-910-EN 23
R717
TC
°F °C
158 70
140 60
Operating limits
122 50
two-stage
compressors
104 40 1
TCMO
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
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.
24 0178-910-EN
TC
°F °C
158 70 R22
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
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 thermostatic
expansion valve
2) Not applicable
0178-910-EN 25
TC
°F °C
140 60
R22
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
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)
26 0178-910-EN
°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
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
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
1 1000 no
2 1200 no
SMC 100 S 700
1200 no
3
1 Not applicable
2 1000 no
SMC 100 L
1000 700 no
3
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.
0178-910-EN 27
TC
°F °C
158 70
R134a
1
Operating limits
140 60
2 two-stage
122 50 compressors
104 40 3 TCMO
TSMC 100 S-L
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

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.
28 0178-910-EN
TC
°F °C R404A
122 50 single stage
1
compressors
104 40
CMO
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

max min required 1)
1200 no
1
CMO 20 900
1500 no
2
1 1000 no
SMC 100 S 1200 700 no
2
1 1000 no
SMC 100 L 700
2 1200 no

0178-910-EN 29
°F
TC
°C R404A
two-stage
122 50
compressors
TCMO
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

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

Only air-cooled.
30 0178-910-EN
°F
TC
°C R507
122 50 single stage
1
104 40
compressors
CMO
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

max min required 1)
1200 no
1
CMO 20 900
1500 no
2
1200 no
1
SMC 100 S 1200 700 no
1 1000 no
SMC 100 L 700
2 1200 no

0178-910-EN 31
R507
TC
°F °C
140 60
Operating limits
two-stage
122 50
compressors
TCMO
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
32 °F
274263.4 Rev. 0
--94 --76 --58 --40 --22 --4 14
Area rpm Oil-cooling Note

Type 1)
max min required
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

Only air-cooled.
32 0178-910-EN
TC
R407C
°F °C Operating Limits
140 60
one-Stage
122 50
Compressor type
104 40 1 CMO & SMC
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
T245411_0 view 2

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

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.
0178-910-EN 33
General operating instructions
for CMO/TCMO, SMC/TSMC piston 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.
34 0178-910-EN
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.
0178-910-EN 35
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,
36 0178-910-EN
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
0178-910-EN 37
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.
38 0178-910-EN
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
Oil pressure · Compressor pressure gauge
bar
Oil temperature · UNISAB II Control °C
Suction gas temp. · Thermometer in suction pipe
immediately °C
before compressor
Discharge gas temp. · Thermometer in discharge pipe
immediately after compressor but
°C
before oil separator
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.
0178-910-EN 39
Servicing the piston compressor
In order to ensure problem-free operation, it S Immediately after stopping compressor,

is advisable to carry out regular servicing to read off pressure on discharge and suc-
the refrigeration plant. In this section, tion side of compressor.
SABROE indicates some periodic services
S Close discharge stop valve quickly and,
fixed on the basis of the number of operating
from moment of closure, time how long it
hours from the first start-up or after over
takes for pressure to drop on high pres-
hand of the compressor.
sure side of compressor. Normally, the
pressure drop should not be more than 3
The servicing schedules also depend on the bar over a period of 5 minutes or so.
speed of the compressor. If the compressor
is running at less than 1200 rpm, SABROE If the pressure falls more quickly, this is
permits extended service intervals. However, due to internal leakage, which may occur:
the compressor must always operate within S where pressure valve ring plates are in
the speed recommended by SABROE. See bad contact with their seats (Pos. 20C
Description of compressor. Providing the against Pos. 20A and 19H);
99.03
compressor operates within the specified
pressures and temperatures and the pre- S with defective seal Pos. 19T; ( not CMO)
scribed periodic services are performed, the S with defective seal Pos. 19K;
0171-462-EN
compressor will have a long and efficient ser-
vice life. S because cylinder lining and top cover
have been tightened without long mount-
ing stopper having been fitted. Cylinder
S The following must therefore be checked
lining is thus resting on rocker arms, Pos.
daily:
15A; (not CMO).
Operating pressure,
Operating temperatures, S on safety valve, because valve cone does
Oil level and pressure, not fit tightly against seat, or outer O-ring
Abnormal noise and vibrations. Pos. 24B or inner O-ring Pos. 24C is de-
fective. (See Safety valve section.)
The actual operating conditions should be
During pressure drop testing, pay attention to
entered in an operating log daily. See the Op-
any piping connections to the discharge side
erating log section.
of the compressor, which may have an influ-
ence on the test result.
Pressure drop test: Removing refrigerant from

Using the pressure drop test, it is possible to compressor
check the internal tightness of the compres- Before the compressor can be dismantled,
sor from discharge to suction side. The pres- the refrigerant must be removed from the
sure drop test is performed with the compres- compressor, which can be done in the follow-
sor at standstill, as described below: ing ways:
40 0178-910-EN
1. Run compressor at lowest capacity stage
and throttle suction stop valve slowly until
completely closed.
42
2. The compressor will then stop on the low

Water
pressure cut-out. This can be adjusted to
stop compressor at a pressure lower than
R717
normal.
Connect the purge valve Pos. 42 to a sealed,
empty vessel which in turn is connected to an
3. Close discharge stop valve and other pip-
open tank containing water.
ing connections to compressor.
The water will absorb the refrigerant, which
can then be dispatched for proper destruc-
4. On HFC and HCFC compressors, remove tion. The moment the pressure is equalized,
remaining refrigerant gas using a pump- the valve must be reclosed in order to pre-
down compressor connected to purge val- vent water being sucked back into the com-
ve Pos. 42. pressor.
Note:
The following instructions apply to the
compressor only. Servicing of the refrig-
42 eration plant is described in a separate
section. Service the compressor motor ac-
cording to your own instructions. For the
various scheduled services, SABROE can
Evacuating pump supply ready-made spare-part sets, which
it would be an advantage to have before
R22
carrying out the scheduled service.
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.
0178-910-EN 41
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.
3.3 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.
42 0178-910-EN
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.
4.3 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
Piston and oil scraper rings
Unloading mechanism
Seal for tightness
4.4 Change:
Suction and discharge valve ring plates
V-belts
5.1 Check V-belt drive

5.2 For heat pump operation, inspect:
Valve seats
5 22500 15000 Cylinder linings
Piston and oil scraper rings.
Change:
Suction and discharge valve ring plates.
0178-910-EN 43
Operating Operating
No. Hours Hours Activity
< 1200 rpm > 1200 rpm
6.1 Change compressor oil,

Change oil filter cartridge,
Clean crankcase.
6.3 Check following:
Solenoid valves
Oil cooling system
Water cooling system for any deposits and clogging
Thermopump
6 30000 20000 Safety automatics
Heating rod
V-belt drive
Coupling and alignment
Valve seats
Cylinder linings
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)
7 37500 25000 As for service no. 5

10 60000 40000 Major overhaul; contact SABROE Refrigeration
Then repeat scheduled services from no. 3 inclusive.
44 0178-910-EN
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
0178-910-EN 45
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.
46 0178-910-EN
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.
0178-910-EN 47
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 diagram
5 5
illustrates, how many litres of oil a drop in
24 14 the oil level of 10 mm is approximately
CMO 26 16 equal 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

type size difference in
amount which must always be present in the 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 / 186
The following determinants decide the total
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.
48 0178-910-EN
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, in cooperation with Mobil Oil, which is
able to analyse all oil makes. This will mean
An oil sample must be drawn off while the
a uniform reporting of the results.
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-
ted. Refrigerant in the oil may produce ex-
bottle. Screw the lid loosely on and let the
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.
0178-910-EN 49
The analysis Wear particles expressed im ppm, are mea-
sured for:
The following section states some average
values that can be applied in practice. How- Lead max. 10
ever, you should be on the alert whenever Copper max. 10
the results of the analyses approach these Silicon max. 25
values. In some cases the water content of Iron max. 100
Chrome max. 5
100 ppm in HCFC plants may be too much
Nickel max. 5
and thus lead to Cu--plating in the shaft seal. Aluminium max. 10
Similarly, a rise in the oil viscosity of max. Tin max. 10
65% normally does not cause any operating
A report is drawn up for every sample re-
problems as the refrigerant reduces the oil
ceived. This report indicates:
viscosity in the plant.
S Whether the oil can still be used -- without
S Kinematic viscocity at +40°C.
taking any further action.
Max. indication from the specified value
at +40°C stated in the tables of Selecting S Whether the oil can be used after it has
lubricating oil for SABROE compressors been filtered through a very fine filter.
--15% specified value +65%
If this is necessary, the oil must be
S Acid number (TAN). max.0.1
pumped directly from the compressor unit
S Oxidation. max.7 through a 3 micron filter and back to the
unit. The system must be completely
S Water content (ppm). max.100 (HCFC)
closed, to prevent the oil being affected by
S Water content (ppm). max.600 (R717) moisture in the air.
S pH value. min.4 (HCFC) S Whether the oil is no longer fit for use.
S pH value. min.5 (R717) The report will always be sent to the address
stated on the sample label included in the
S Strong acids (SAN). max.0
form set. A copy will be sent to SABROE Re-
S The oil is filtered through two filters frigeration, so that we are in a position to ad-
(1,2 micron and 5 micron). vise you, if required.
50 0178-910-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
Set so that the compressor stops at

High and intermediate KP 5
Safety equipment
cut-out x x x x x a pressure 2 bar lower than the

(KP15) safety valve setting.
Low-pressure KP 1 Set to a pressure with saturation temp.

96.04
cut-out (KP15) x x x x x 5° C lower than the lowest evaporating

temperature.
1)
Oil pressure cut-out MP 55 x x x x x 3,5 bar
0170-012-EN
Discharge pipe x x x x * 120 ° C

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 -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
0178-910-EN 51
52
Expected discharge gas temperatures

HFC - HCFC
Suction gas superheat ° C
Condensing pressure bar


Condensing temp. ° C 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°
+10 0 -10 -20 -30 +10 0 -10 -20 -30 0 -10 -20 -30 -40 +10 0 -10 -20 -30
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 --
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 --
0178-910-EN
40 10.1 77 79 83 89 14.5 92 101 111 123 135 18.2 79

99 14 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
0170-105-EN 96.02
Servicing the refrigeration plant
During both 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 otherwise works as it is sup-
intact and the evaporator must function under posed to.
load - that is to say:
The service instructions outline some general
S the desired temperatures are observed,
guidelines for servicing the refrigeration
S the oil pressure and discharge pipe plant, with some references to the instruction
temperature on the compressor are manual. The service instructions should
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 condenser pressure im-
Daily
plies a risk of restricting the refri-
gerant supply to the evaporator.
Discharge pipe temperature Normal discharge pipe tempera-

ture acc. to instructions.
Filter in Accumulated dirt causes reduced

-- liquid line refrigerant supply to the evapora-
-- thermostatic valve Clean when tor.
Filters -- suction line needed 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 col-
Dehumidi- our switches from green to yellow,
fier When
there is moisture in the refrige-
needed
rant.
Change the drying filter regularly.
0178-910-EN 53
Check Interval Activity
Refrigerant change 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 regu-

Leak detection
larly for leaks. Flanges and joints
settle during the plant’s initial op-
eration period. They must there-
fore 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 temper-
atures lower than -25°C, use spe-
cial 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, if any, or re-
place by 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 Problem-free operation is condi-

When tional on the evaporator being
Evaporator needed 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
54 0178-910-EN
Maintenance of reciprocating compressor
SMC 104-106-108 Mk3, TSMC 108 Mk3 - S, L and E
SMC 112-116 and TSMC 116 Mk3 - S, L and E
General the oil time to escape without the oil foaming.

This is of great importance in compressors
When the compressor requires maintenance,
running on HFC/HCFC. An ammonia com-
it is important to follow the instructions given
pressor can stand having the pressure re-
below. In order to make sure that the com-
duced somewhat more quickly without the oil
pressor is working correctly, the gauge mea-
foaming.
surements and screw torques must be strictly
adhered to. Before opening the compressor, Once the pressure is down to approx. 0.1
it is expedient to ensure that you have spares bar, stop the compressor and perform the
of those seals and gaskets to be stripped following steps in the order specified:
down or dismantled. An O-ring which has
S Close suction stop valve.
been exposed to oil and heat for any length
of time may have expanded so much as to S Cut off power to compressor motor.
prevent it being refitted. S Close discharge stop valve.
00.01
All seals and gaskets used are resistant to

S Draw off last remains of refrigerant gas
oil, HFC/HCFC and ammonia. All O-rings are
through purge valve Pos. 42.
made of neoprene rubber.
0171-468--EN
S Having ensured that power to compressor

Pump-down motor cannot be inadvertently connected,
Before opening up the compressor for in- the compressor is ready for opening.
spection, the pressure inside must be low- S Remove all fuses, if any.
ered to slightly above atmospheric. This can
be done in the following way, depending on
2. If the compressor is inoperative
whether the compressor is operational or de-
fective. S Leave heating rod in crankcase connected
for a couple of hours before compressor
is due to be opened in order to heat up oil.
1. If the compressor is operational Warm oil does not contain as much refrig-
Run the compressor at minimum capacity at erant.
normal operating temperature.
S Suction stop valve must be open while
Adjust the low-pressure cut-out so that the heating rod is connected.
compressor stops at a suction pressure of
approx. 0.1 bar. S Keep discharge stop valve closed.
Throttle the suction stop valve very slowly. S Close suction stop valve and disconnect
Keep an eye on the suction pressure gauge. heating rod.
The suction pressure must be lowered slowly S Equalize pressure in compressor through
enough to give the refrigerant dissolved in purge valve Pos. 42.
0178-910-EN 55
S Once pressure has been equalized to at- de from a soft hammer while keeping the
mospheric, compressor is ready for two screws fitted. This must be done be-
opening. Remember to make sure that cause of the powerful spring pressure bene-
power cannot be inadvertently connected, ath the top cover. After dismantling the
thereby starting the motor. two bolts - unscrewing them alternately - the
top cover can be removed.
S Remove all fuses, if any.
Fitting top cover
Dismantling and assembly
Before fitting the top cover, the long plug
The following sections describe the individual must be fitted into the relief cylinder. Check,
components. When dismantling and assem- in addition, that the gasket Pos. 2C is intact
bling, parts should generally be fitted in the and, if necessary, check that the clearance
same position from which they were taken, volume and lifting reserve have been ad-
and should therefore be marked as they are justed as described later on in these instruc-
removed. Further they should be thoroughly tions.
cleaned, checked and lubricated prior to be-
ing reassembled. If the gasket Pos. 2C needs to be replaced at
all, the graphitized side must face the com-
Top covers pressor frame. After placing the top cover
loosely on top of the springs Pos. 21, it is
Dismantling top cover recommended that all screws be mounted by
Before dismantling the top cover, the relief hand, as they will jointly guide the top cover
mechanism must be deactivated; this is into position. Now tighten the top cover firmly
done by dismantling the short plug Pos. 12D with the two screws mentioned above, then
and mounting the long plug from the tool kit with the remaining ones.
instead. This moves the piston Pos. 12B to
the opposite end of the relief cylinder. Finally, cross-tighten all the screws to the
prescribed torque in the following sequence:
Loosen and remove screws Pos. 2E, except
for the two screws shown on the drawing.
7 1 3 5 9
11
15 13
16 14
12 10
8 4 2 6
These screws should be loosened approx. 1 Once the top cover has been fitted, remove
mm, then checking that the cover lifts off the the long plug and insert the short plug. The
gasket. If, to the contrary, it remains fastened top covers must be mounted as shown on
to the gasket, loosen it with a blow on the si- the following chart.
56 0178-910-EN
Mounting top and water covers
SMC 112 SMC 116 TSMC 116
SABROE SABROE SABROE SABROE
SABROE SABROE SABROE SABROE SABROE SABROE
Shaft end
Shaft end
Shaft end
Control end
SMC 104 SMC 106 SMC 108 TSMC 108
Shaft end
SABROE SABROE
Water covers
Right top covers
Shaft end
SABROE SABROE SABROE

Shaft end
SABROE
Left top covers

SABROE
Side covers
T0177092_0
0178-910-EN 57
Discharge valve
21
20E
20F
20D
Pos. 20
20B 20A 20C 20G
As shown on the above drawing, the function Discharge valve types:

of the discharge valve Pos. 20 is partly to al-
Depending on the refrigerant and operating
low the compressed gas to pass from the
conditions under which the compressor oper-
compression chamber of the cylinder to the
ates, various discharge valves need to be
discharge chamber beneath the top covers
used to achieve an optimal function. The dis-
and partly to create a seal from the discharge
charge valves are selected as shown in the
chamber to the cylinder.
diagram below on the basis of the conden-
sating or intermediate pressure temperature.
Furthermore, the discharge valve acts as a
safety device in the event of liquid refrigerant Refri- Conditions Valve
passing the valve together with the discharge gerant type
gas, also called liquid stroke. Such stroke TC < 15°C LP
R717
should normally not occur, as liquid cannot TC ≥ 15°C HP
pass the valve as quickly as the compressed
TC < 15°C LP
gas. This produces a violent increase in pres-
sure in the compression chamber. 45°C R404A-R507
HFC/ 15°C ≤ TC < 50°C R22 HP
HCFC 70°C R134a
45°C R404A-R507
In order to avoid pressure of such intensity TC ≥ 50°C R22 VHP
that it may damage the bearings in the com- 70°C R134a
pressor, the discharge valve is retained in
position by the safety spring Pos. 21, which Marking
allows it to lift a little under the strain of in-
creased pressure. All pressure valves supplied from SABROE
today are marked as described below and
shown on the sketch.
Liquid strokes are heard as a distinct
hammering in the compressor; the cause Refrigerant R717 :
must be found immediately and the mal- All discharge valves are marked with one
function rectified. groove.
58 0178-910-EN
Refrigerants HFC/HCFC : S Tighten bottom nut Pos. 20E to torque of
All discharge valves are marked with two 10.2 Kpm @ 100 Nm. If need be, exert
grooves. counterpressure with 5 mm Allen key on
bolt head.
S Fit spring guide Pos. 20F and tighten top

Marked with
LP-HP or VHP nut to same torque: 10.2 Kpm @ 100 Nm.
Tightness testing of discharge

valve
This is done by means of the pressure drop
test as described elsewhere in this instruction
Marked with
manual.
one groove for R717
two grooves for HFC/HCFC Service life of discharge and
suction valves
Dismantling In order to ensure that the compressor al-
S When top cover has been removed, spring ways works perfectly, it is advisable - at suit-
Pos. 21 and discharge valve Pos. 20 can able intervals - to replace the suction and dis-
be lifted out by hand. See dismantling of charge valve ring plates.
top cover. It is difficult to give altogether precise times
for such replacements, as the durability of
S Tighten discharge valve in a soft-jawed
the valve ring plates depends on the follow-
vice, then dismantle two nuts Pos. 20E
ing factors:
together with spring guide Pos. 20F.
S If the compressor is exposed to liquid
S Screw Pos. 20D, discharge valve seat
stroke or moist refrigerant gas, the service
Pos. 20A and ring plate Pos. 20C can now
life is reduced.
be disassembled by hand.
S Speed of the compressor:
S Remove valve springs Pos. 20G by hand. At 900 rpm, the service life of the valve
ring plates is considerably longer than at
Assembly
1500 rpm.
Before assembling the discharge valve, you
must make sure that the valve springs Pos. S The compressor ratio at which the com-
20G are in good order and fixed firmly in their pressor operates:
apertures. At high compression ratios, the load on
valve ring plates and springs is appreci-
Assemble the discharge valve in reverse se- ably larger than at low compression ratios.
quence to that described above. Note the fol- When the valve ring plates are changed,
lowing, however: the valve springs should also be replaced.
0178-910-EN 59
Cylinder lining with suction valve Dismantling suction valve
Marking of suction valve stop: Dismantling the screws Pos. 19N makes it
possible for the guide ring Pos. 19J, suction
valve stop Pos. 19H and ring plate Pos. 19F
to be removed from the cylinder lining. The
Marking of
suction valve paper gasket Pos. 19T can be expected to
disintegrate during dismantling and require
replacement.
Mounting suction valve

one groove for R717 Before reassembling the suction valve, you
two grooves for must ensure that the valve springs Pos. 19G
HFC/HCFC
are in good order and fixed firmly in their
apertures.
T0177131_0 v3
Perform the assembly in reverse sequence to
that described above. Note the following,
The cylinder lining and suction valve form an however:
integral unit which can be dismantled by re-
S Change paper gasket.
moving the screws 19N.
S Before tightening screws 19N, ensure suc-
In order to gain access to the cylinder lining tion valve plate can be moved freely in its
or suction valve, the top cover, spring Pos. guide. Tighten screws Pos. 19N to torque
21, and discharge valve Pos. 20 need to be of 1.4 Kpm @ 14 Nm.
disassembled.
Inserting cylinder lining
Extracting cylinder lining S Rotate crankshaft to position piston at top
dead centre.
S Rotate crankshaft to position relevant pis-
ton at top dead centre. S Check that long plug from tool kit is
screwed into relief cylinder; see Top cov-
S Fit the two T-shape extractors no. 3 from ers section.
tool kit into threaded holes in guide ring
Pos. 19J. S Check that gasket Pos. 19K is in position
on frame.
S Carefully pull out cylinder lining with suc-
S Lubricate piston, piston rings and cylinder
tion valve, checking that gasket Pos. 19K
face with clean refrigeration machine oil.
remains in frame.
Likewise, grease O-ring Pos. 19M on HP
cylinder of TSMC compressor with clean
S Insert protective plate no. 5 (from tool kit)
refrigeration oil.
between piston and frame so the piston
can rest on it. This will enable piston and S Rotate piston rings on piston in order to
piston rings to slide onto the protective stagger ring gaps at 120° to each other.
plate without being damaged when the Press cylinder lining down over piston
crankshaft is turned. carefully. The chamfering on the cylinder
60 0178-910-EN
interior will catch the piston rings and S Remove nuts Pos. 17D; following this, the
squeeze them to the diameter of the cylin- bottom part of the connecting rod can be
der. If possible, fit cylinder in same place taken out by hand.
from which it was taken.
S Piston and connecting rod can then be
S Press cylinder lining down manually, and lifted out through the top cover opening on
with no rotary movements, until it makes the frame.
contact with gasket Pos. 19K. The connecting rod Pos. 17 is equipped with
independent bearings at both ends. The big
S Check clearance volume, which is de- end is fitted with two bearing half bushes
scribed in section Control measurements Pos. 17A, consisting of a half-cylindrical steel
for insertion of new cylinder lining. plate internally coated with white metal.
These bearing half bushes are secured in the
S Discharge valve Pos. 20 and safety head
connecting rod, partly through their fit in the
spring Pos. 21 can then be fitted.
connecting rod bore and partly by a spring
S Fit gasket and top cover. which fits into a milled groove in the connect-
ing rod. The opposite end of the connecting
S Once top cover is in position - see Top rod is fitted with the gudgeon pin bearing
covers section - remove long threaded Pos. 17B, of which the following two types
plug and screw in short plug, having first are found: See spare-parts drawing.
checked aluminium gasket Pos. 12E and S The bearing bushing Pos. 17B-1 is made
found it fit for use. of special bronze and is also used in
R717 compressors.
The bearing bushing is used in all SMC
Connecting rod
compressors and in the low pressure
The connecting rod pos. 17 is made of two stage on TSMC compressors.
parts carefully adapted to each other.
The two parts are held together by means of S The needle bearing Pos. 17B-2 is 2 mm
two bolts secured with lock nuts. greater in outside diameter than the above
bearing bush and must therefore be fitted
in a piston rod bored to the diameter of
Procedure for removing piston and
this bearing. The needle bearing has no
connecting rod inner ring but fits the diameter of the gud-
S Bleed compressor of oil and refrigerant geon pin directly.
and safeguard against any unintended
S If the bearings in the connecting rod are
start-up.
worn so that the clearance is greater than
that prescribed in the table entitled Vari-
S Disconnect any water hoses and other
ous clearances and adjustment measure-
piping connections to top and side covers.
ments, they must be replaced with new
S Dismantle top and side covers. bearings. In this connection, note that un-
dersized half sections of bearing can be
S Remove spring Pos. 21, discharge valve supplied for use in the crankshaft where
and cylinder liner. the journals have been ground to a corre-
0178-910-EN 61
sponding undersize. See table in section S Introduce connecting rod down through
on Diameters for undersized bearings. top cover opening in frame and guide into
position on crankshaft manually. Take care
Fitting bearings so that connecting rod bolts do not leave
S The bearing bushing or needle bearing marks in crankshaft journals.
can be squeezed into or out of the con- S Position connecting rod interior through
necting rod in a vice or hydraulic press. lateral opening on frame, and fit nuts.
Use softjaws in the vice and use tools
which do not damage any components. Note:
The bearing bushing must be fitted as The two parts of the connecting rod are
shown on the sketch, with the lubricating numbered with the same number; this is
ducts facing sideways. only of importance when assembling.
Parts with different numbers must not be
Fig. 1 assembled and it is important that the
Note:
numbers are fitted in the same direction
Sleeve to be
fitted with lubri- as shown in Fig. 2.
cating ducts
positioned as Fig. 2
shown on dra-
Note:
wing. Stamped number on
the same side on as-
sembly
T0177131_0 v2,a
Fitting connecting rod

916 916
Before fitting the connecting rod in the com-
pressor stand, piston and piston rings must be
fitted onto the connecting rod. See the follow- T0177131_0 v2,b
ing sections. In addition, the two connecting
rod bolts Pos. 17C must be fitted as shown on
the spare parts drawing. S Tighten nuts Pos. 17D alternately with in-
creasing torque and finish off with torque
S Fit bearing bushes into both parts of con- wrench.
necting rod. Torque: 4.4 Kpm @ 43 Nm.
62 0178-910-EN
Piston For compressors with:
The piston is made of aluminium and fitted 80mm stroke lengths, type S,
with two piston rings, nearest the piston top, 100mm stroke lengths, type L, and with
and an oil scraper ring. 120mm stroke lengths, type E.
The difference is clearly seen from fig. 3.
The piston comes in three versions:
Fig. 3
Piston Piston Piston

Type S Type L Type E
70 60 60
120 110 100
50 50 40
T0177131_0 v1
The same piston and piston pin are used, S Fit one of the circlips pos. 18D into bore
irrespective of whether the connecting rod reserved for piston pin.
contains a sleeve or a needle bearing.
S Heat piston to 70°C in oil or on hotplate.
Fitting piston rings in piston S After inserting bearing bush or needle

bearing, guide connecting rod into place in
Before mounting the piston rings in the pis-
heated piston. The piston pin can now be
ton, their fit in the cylinder lining should be
positioned without the use of tools.
checked by measuring the ring gap. See sec-
It is sometimes possible to fit the piston
tion entitled Various clearances and adjust-
rod by hand without a preliminary heating
ment measurements.
of the piston.
Assembling and stripping down piston S Fit last Seeger ring

and connecting rod To strip, reverse sequence; however, do not
Adopt the following procedure when assem- heat piston, but press piston pin out using a
bling piston and connecting rod: punch or mandrel.
0178-910-EN 63
Shaft seal
5.5 mm
8C
8H
2 mm
8A
8F
10F
10D
10E
10H
10J
10A
10G
10B
8G
8B
3126-176-R T0177131_0 V13
The purpose of the shaft seal is to create a

It is recommended to exercise great care
tight seal along the crankshaft between the
with the lapped slide surfaces. Even the
inside of the compressor and the atmo-
slightest scratch or other damage to the
sphere. slide surfaces will result in leaks.
It comprises a slide ring Pos. 10E, manufac-

tured from special-purpose cast iron, which is The O-ring Pos. 10D creates a seal between
secured to the crankshaft by means of the the slide ring Pos. 10E and the crankshaft.
locking ring Pos. 10H, tightening flange Pos. O-ring Pos. 10G seals between the carbon
10A and the four screws Pos. 10J with spring slide ring Pos. 10F and the shaft seal cover
washers Pos. 10K. Pos. 8A.
The carbon slide ring Pos. 10F is pressed When the shaft seal is operating, a tiny
against the flat-machined, lapped slide ring at amount of oil drifts out between the slide
the end of Pos. 10E by a series of springs faces to lubricate them. An oil throw ring Pos.
Pos. 10B. The carbon slide ring is prevented 8F has therefore been fitted to prevent this oil
from rotating by means of the retention pin migrating along the axle to the transmission
Pos. 8H. linkage.
The spring pressure, combined with the The thrower ejects the oil into the groove in
flat-lapped faces of the two slide rings, ensur- the shaft seal cover Pos. 8A and the oil is
es an optimal seal between the faces, either piped via the plastic hose to a plastic bottle
when rotating or stationary. positioned under the compressor.
64 0178-910-EN
1. Dismantling and stripping down shaft Fig. 3
seal
8G 10F 10G 8A 8C
1.1. Once the gas pressure in the compres-
sor has been eliminated and the motor
· ·
safeguarded against inadvertent start-up,
dismantle coupling or V-belt disk.
Note: ·
On units featuring coupling, there is no ·
·
A
need to move the motor, as the coupling
and the shaft seal can be taken out be- ·
tween the two shaft ends.
1.2. Dismantle shaft seal cover Pos. 8A by

alternately loosening bolts Pos. 8C so as 1.5. Dismantle slide ring 10E by turning the
to displace shaft seal cover outwards wit- four Allen screws 10J a max. of 2-3
hout jiggling. This will avoid damage to turns; the entire unit can then be taken
internal parts of the shaft seal. out with the fingers or using two screwd-
1.3. Once the spring force is equalized and rivers inserted into the external groove
the bolts removed, the shaft seal cover on the slide ring Pos. 10E and moved in
can be taken off the shaft end by hand. the direction of the arrow as illustrated in
Take care so that no damage is done to fig. 4.
the carbon slide ring Pos. 10F which co-
mes out with it.
Fig. 4
1.4. The carbon slide ring Pos. 10F can be
extracted by dismounting circlip pos. 8G
as follows:
10A
Mount tool no. 2 as illustrated in fig. 3
and tighten screw A so that the carbon
slide ring does not touch the locking ring.
Take care not to tighten screw A too ·

much as this could damage the car-
bon ring.
Circlip pos. 8G is now easily extracted by 1.6. O-ring Pos. 10D can now be removed.
means of a screw driver without damag-
ing the slide surface of the carbon slide Assembling and mounting shaft seal
ring. After thoroughly cleaning the crankshaft,
check that its sealing faces are smooth and
After removing tool no. 2, the carbon free of scratches, blows and wear marks.
slide ring pos. 10F, O-ring pos. 10G and Then oil the crankshaft and the shaft seal
springs pos. 10B (see fig. 2) can now be components thoroughly with the same type of
dismantled. oil as used in the compressor.
0178-910-EN 65
2. Unit with slide ring, Pos. 10E measure distance from gasket Pos. 8B to
2.1. Before fitting slide ring Pos. 10E, tighten sealing face of shaft seal cover.
screws Pos. 10J until there is approx. 2 This distance must be about 3 mm.
mm spacing and parallelism between the Make sure the hose branch Pos. 8D fa-
two flanges. Check also that locking ring ces down.
Pos. 10H is mounted as shown in the 3.5. Mount screws Pos. 8C and tighten even-
drawing and that O-ring Pos. 10D is in ly, crosswise. This will avoid damaging
position. the carbon slide ring. Tighten screws
2.2. Position slide ring Pos. 10E on shaft and Pos. 8C to prescribed torque according
ensure tightening flange makes contact to table in instruction manual.
with shaft shoulder. 3.6. Mount oil throw ring, as shown in
2.3. Crosswise, tighten screws Pos. 10J alter- drawing.
nately with Allen wrench from tool kit. 3.7. After mounting coupling half or V-belt
The torque is specified in the instruction disk, it must be possible to turn the
manual. crankshaft easily by hand.
2.4. Check axial position of shaft seal by
measuring distance from frame sealing Crankshaft
face to slide face on Pos. 10E. This must
The crankshaft is made of heat-treated SG
measure approx. 5.5 mm, as shown in
cast iron with fine strength and glide proper-
the drawing.
ties. The bearing journals are superfinished
and oil channels are bored for all lubricating
3. Unit with shaft seal cover Pos. 8A
points.
3.1. Mount O-ring Pos. 10G and the ten spiral
springs 10B in shaft seal cover Pos. 8A, At the centre and end of the crankshaft, the
then position carbon slide ring Pos. 10F oil channels are blanked off with 3 blind plugs
carefully. Rotate carbon slide ring so slot on the SMC 104 - 106 - 108, and 6 plugs on
fits in over retention pin Pos. 8H. the SMC 112 and 116.
3.2. With tool no. 2 fitted as shown in fig. 3
press carbon slide ring pos. 10F against When fitting the crankshaft, it should be
spring pos. 10B. Locking ring Pos. 8G checked that the plugs are mounted and
can now be fitted. Observe closely that tightened. By way of bores in the counter-
the carbon slide ring is not overloaded by weights, the crankshaft is dynamically bal-
misbalanced pressure and that its slide anced with regard to 1st and 2nd order
face is not damaged. forces.
3.3. Give complete shaft seal cover an extra
oiling on slide face of carbon slide ring The crankshaft is available in three versions:
and guide it in over shaft together with an S type for compressors with short strokes
gasket Pos. 8B. (80mm), an L type for longer stroke (100mm)
3.4. Gently pressing shaft seal cover and car- and an E type for the longest strokes
bon ring in against slide ring Pos. 10E (120mm). The crankshafts have an S, L or E
without compressing springs Pos. 10B, stamped into the connecting end.
66 0178-910-EN
Dismantling crankshaft Inspection
Dismantle the crankshaft through the pump Check bearing journals on connecting rods
end of the frame in the following way: for wear and tear and, if necessary, measure
diameter of journals. The maximum wear on
S Bleed compressor of oil and refrigerant the bearings is shown in the section Various
and safeguard against inadvertent clearances and adjustment measurements.
start-up. In most instances, the permissible play in the
S Dismantle top and side covers. bearing can be obtained by replacing the
bearing half bushes. The bearing journals on
S Dismantle all cylinder linings. the main bearings are normally subject to
very little wear, but should be check mea-
S Extract all pistons and connecting rods.
sured during main overhauls. If wear and tear
S Pull off V-belt pulley or coupling half . exceeds the play stated, the crankshaft can
normally be ground to 0.5 mm undersize. For
S Dismantle shaft seal cover and shaft seal. the ground crankshaft, main bearings and
connecting rod bearings with an undersize of
S Dismantle cut-outs and pipes to manome-
0.5 mm can be supplied as stated in the
ters, or piping connections to UNISAB.
parts list.
S Dismantle end cover, Pos. 4A.
The drawing for grinding the crankshaft to
S Dismantle oil filter. undersize is found in this instruction manual.
S Dismantle oil pump drive and oil pump. Note:

After grinding the crankshaft, all lubricat-
S On SMC/TSMC 112-116 loosen the ing channels must be thoroughly cleaned
middle bearing by dismantling the plugs with an approved cleansing fluid and
pos. 49H as well as gasket pos. 49J in blasted with compressed air. Remember
both sides of the compressor. to refit the blind plugs.
Next, dismantle screws pos. 49F and lock-
S Check sealing face for O-ring seal, Pos.
ing plates pos. 49G.
10D, on shaft seal. The surface must be
S Rotate crankshaft to place connecting rod bright and free of scratches and marks.
journals on horizontal level.
Refitting crankshaft
S Dismantle bearing cover at pump end and Refit the crankshaft in the reverse order to
support the crankshaft by means of a that for dismantling. Note the following,
board inserted through the side openings. however:
S After this the crankshaft can be drawn out S After the crankshaft has been inserted into
of the framne. The crankshaft must still be the housing, mount main bearing cover
supported. Pos. 5A using gasket Pos. 5D as a shim.
S The middle bearing on SMC/TSMC S Check end play on crankshaft by pressing

112-116 can be dismantled by removing shaft up against pressure bearing Pos.
screws pos. 49B and shims pos. 49C as 6C and measure clearance in the other
well as guide pins pos. 49D. bearing, using a feeler gauge.
0178-910-EN 67
The permissible end play is indicated in Fig. 1
Mounting of bearing bushing pos. 6C
the section Various clearances and adjust-
ment measurements.
End play adjustment is achieved by

means of the gasket Pos. 5D.
12 o’clock
The gasket can be supplied in the follow-
ing thicknesses, see the spare parts list:
0.25mm 0.50mm 0.75mm 1.0mm
4 o’clock
Main bearings
The main bearings pos. 5C and 6C are
mounted on the main bearing covers and
Cover pos. 6A seen from the inside T0177167_0
their purpose is to guide the crankshaft both of the compressor
radially and axially.
The bearing bushings can be delivered with
crankshafts ground to undersize. See Spare
They consist of a steel bushing with collar.
Parts List.
The collar and the inside of the bushing are
provided with a thin white metal coating. The crankshaft for the SMC 112 and 116, and
for the TSMC 116, is fitted with a centre bear-
ing. This is fitted with four sets of bearing half
The bushing can be pressed out and re-
bushes of the same type as used in the con-
placed by new ones and need no further
necting rods. The centre bearing housing is
machining after mounting.
made up of two half parts which must be
clamped around the crankshaft before this is
On mounting the bushings it is recommended inserted into the compressor stand.
to secure them with Loctite 601.
The half parts are assembled by means of
four screws and guided together with the aid
When a new bearing bushing pos. 6C at the of cylindrical guide pins. The bearing housing
shaft seal end is put into place in cover pos. is prevented from rotating by two screws
6A the in- and outlets of the lubricating chan- Pos. 49F. These screws are accessible only
nels must be positioned in a four o’clock when the threaded plug Pos. 49H has been
position as illustrated on fig. 1 below. removed. The screws can be removed using
The bearing bushing pos. 5C is positioned a box wrench NV 17 and crank from the tool
with in- and outlets in a 12 o’clock position. set.
68 0178-910-EN
Compressor lubricating system
19D
15D
19B
15A
15B 12
13
22
11 38A
33A
33
33J/K
T0177131_0 V10
The oil pump pos. 11 sucks oil from the Excess oil is returned through a bored chan-
crankcase, through the filter element Pos. 33, nel to the crankcase.
where the oil passes the filter element pos.
33A and past the magnetic filter pos. 33J/K, From the shaft seal housing, the oil is distrib-
as shown on the spare parts drawing. The uted as follows:
pump forces the oil through an internal pipe,
S Through the bored channels in the crank-
pos. 38A, until it reaches the shaft seal hous-
shaft to lubricate main and connecting rod
ing.
bearings. Lubrication of piston pin bear-
The filter element Pos. 33A is a disposable ings is done by splash lubrication through
filter which cannot be cleaned. See descrip- a countersunk hole in the top of the con-
tion of oil filter. necting rod.
The shaft seal housing forms a distribution S To the differential oil pressure cut-out and
chamber for the oil. The oil pressure in the the pressure gauge. The effective oil pres-
shaft seal housing is adjusted by means of sure can be read straight off the manome-
the oil pressure regulating valve Pos. 22, ter (the suction pressure gauge of the
which is mounted in the shaft seal housing. compressor).
The regulating valve can be adjusted from
the outside by means of a screwdriver. S Through external oil pipes, on to the regu-
Clockwise rotation increases the pressure; lating cylinders Pos. 12 for unloaded start
anticlockwise rotation lowers the pressure. and capacity regulation.
0178-910-EN 69
Oil pump
·
4A
11H
11Q
11R
11G
11M 11T ·
··
11J ·
11L
·
11N
· 11P
11S
The oil pump is a gearwheel pump driven by S When the four M6 screws pos. 11M secur-
the crankshaft via a pinion drive. ing the oil pump to the bearing cover have
been removed, it can be taken out by
It is therefore important to ensure that the
hand.
direction of rotation of the crankshaft is as
indicated by the arrow on the bearing cover Note:
Pos. 6A. The oil pump normally has a very long
service life. Therefore, it is not worthwhile
If the crankshaft is to turn in the opposite di-
repairing it. Rather replace it with a new
rection of rotation, the oil pump can be fitted
one.
with a chain drive. See next section.
Dismantling the oil pump Mounting the oil pump

Having bled the compressor of oil and refriger- Before finally tightening the oil pump firmly to
ant and secured it against inadvertent start-up, the bearing cover, the following adjustment
proceed as follows: must be made to the gearwheel drive:
S Dismantle end cover Pos. 4A and side The play between the two teeth when en-
covers Pos. 3. gaged must be 0.05-0.08mm measured with
a feeler gauge. Repeat the measurement six
S Dismantle internal oil pipes and nipples
times, turning the crankshaft 60° between
screwed into pump.
each measurement, and adjust until the
S Dismantle nut Pos. 11J and extract gear- smallest play is measured to be as started
wheel pos. 11G. above.
70 0178-910-EN
Chain-driven oil pump with inverse stores no. 3141-127. This set contains a chain,
direction of rotation a chain wheel (springs for old shaft seals only)
and a baffle for lubricating oil, as well as all
If the SMC 100 compressor is to run in the screws needed.
opposite direction of rotation to that shown by
the arrow on the bearing cover Pos. 6A, the In case the compressor is driven by an elec-
gearwheel drive on the oil pump must be re- tric motor, attention should be paid to the pre-
placed with a chain drive. scribed direction of rotation of the motor.
See section: Direction of rotation of the com-
To this end, use a set of replacement parts, pressor.
5
3
1
6
7
8
4
2
1 Hub for the chain wheel 5 Endless chain

2 Hub for bottom chain wheel 6 Baffle for lubricating oil
3 Top chain wheel 7 Set screw M6 x 12
4 Bottom chain wheel 8 Spring washer for M6
Assembling instructions S On older compressors, the oil pump is

The chain system can be mounted on all linked to the principal bearing cover Pos.
types of SMC/TSMC compressor. On older 5A by 2 guide pins and retained by four
compressors, however, a little adjustment M6 screws. Remove two guide pins here
may be necessary, as detailed below: and bore the free holes for screws up to a
diameter of 8 mm. This should be done
S Dismantle the two gear wheels by remov- after the oil pump has been dismantled.
ing screws Pos. 11Q and nut Pos. 11J. On more recent compressors, the free
0178-910-EN 71
holes are oval-cast to give scope for ad- Adjusting the chain drive:
justment, and there are no guide pins.
S Tighten chain by shifting oil pump. The
S Mount lubricating oil baffle as shown on
correct tension of the chain is shown on
drawing. Drill two M6 threaded holes and
the sketch.
tap, using baffle as template; position so
that the baffle is at a tangent to the exter-
nal diameter of the bearing bush D = 92
mm.
D92
3.5 -- 5.5mm
T0177085_0
Screw dimensions: M6 x 12 mm T0177085_0
Thread depth: 5 mm
Drilling depth: 20 mm
Core drill: 5 mm
Finally, when the proper centre distance
Secure screws with spring washers.
has been established, secure oil pump
S Slightly tighten four screws securing oil tightly.
pump to bearing cover.
S Place chain wheel with hub Pos. 4 and 2 S Tighten chain wheel on oil pump.
on pump shaft. The retainer nut can be
tightened once the entire chain drive has
been mounted. Marking direction of rotation
S Place the assembled chain, hub and chain The arrow on the end cover of the compres-
wheel, Pos. 5, 1 and 3, in position; tighten sor should be cancelled out and replaced by
wheel firmly with screws Pos. 11Q from one painted on the indicate the new direction
gearwheel drive. of rotation.
72 0178-910-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. 6A, it connects directly with
pressure 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 val-

locking screw ve should be replaced.
22A
22B
T0177083_0
0178-910-EN 73
By-pass valve pos. 24 Thus, watch out that hole pos. B does not
get covered or clogged.
The compressor is equipped with a built-in
mechanical by-pass valve, fig. 1, which safe- In case the pressure on the discharge side
guards it against any inadvertent excess exceeds the set pressure so that the by-pass
pressure if the electrical safety equipment valve opens, the valve will remain open until
fails. The by-pass valve safeguards against the pressure on the discharge side has fallen
any excess pressure between the discharge to approx. half the set pressure. The valve
and suction sides of the compressor. then closes automatically. However, at great
differential pressures across the compressor
If the by-pass valve goes into action, the the valve may remain open. In that case,
compressor must be immediately stopped stop the compressor and close the discharge
and the cause established. stop valve entirely. The equalization of pres-
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
temperature settings. The actual set pressure The by-pass valve is supplied factory-set and
is stamped on the rating plate, pos. A. sealed and need normally not be disassem-
bled and readjusted.
The by-pass valve is of the high-lift type
If necessary, control of function and set pres-
which makes it very sturdy and durable.
sure must be made in accordance with local
regulations for safety valves.
Further, the by-pass valve is independent of
the pressure on the compressor suction side. On the outside the by-pass valve is sealed
Consequently, it only opens when the pres- with two O-rings, pos. 24B and 24C. Fasten
sure on the discharge side exceeds the set it to the compressor housing by means of
pressure in relation to atmospheric. screws pos. 24D and washers pos. 24E.
Fig. 1 24C 24B
·
·
A B T3137T02I_1
74 0178-910-EN
Oil filter The filter cartridge is fastened to bracket pos.
33F by means of a lock nut pos. 33M and a
All oil to the lubricating system of the com-
washer pos. 33L. The gasket pos. 33B seals
pressor is filtered through a oil filter installed
off the filter cartridge and the bracket pos.
in the crankcase. The filtration element is a
33F.
filter cartridge (Pos. 33A on the drawing)
which is non-cleanable and must be replaced Changing filter cartridge
with a new one when the filter capacity is
The filter cartridge should be replaced at reg-
used up.
ular intervals. See the section entitled Servic-
It is important, therefore, always to have ing compressors on this point. In particular, it
an extra filter cartridge available. should be remembered that the filter car-
tridge must often be replaced after a relative-
Filter cartridge
ly short operation time following initial start-
As shown in fig. 1 the filter cartridge pos. 33A up.
is a single unit consisting of a 60 μ primary
filter, a magnetic filter and a shield which co- This is due to small particles of dirt origina-
vers half of the filter. ting from the plant during the initial operating
period.
Fig. 1
33B 33A
33L
33F 33M
Before changing the oil filter cartridge all pre- filter cartridge pos. 33A and the gasket
parations in connection with the opening of pos. 33B.
the compressor must be carried out in accor-
dance with the instruction manual. Proceed as follows:
S Dismount the lock nut pos. 33M and S Let the bracket pos. 33F stay mounted in
washer pos. 33L and remove manually the the compressor.
0178-910-EN 75
S When mounting the new oil filter cartridge the closed shield on the filter faces up-
as illustrated in Fig. 1, first place the gas- wards.
ket pos. 33B on the bracket pos. 33F. Then fasten the filter by means of the lock
nut pos. 33M and the washer pos. 33L.
S Then place the oil filter cartridge pos. 33A S Tighten the nut pos. 33M to a torque of
on the bracket pos. 3Fand turn it so that 4.5 Nm.
76 0178-910-EN
Suction filters Note:
Do not forget to remove the filter cartridge
The purpose of the filters is to collect impuri-
after 50 operating hours, as a blocked fil-
ties conveyed from the plant to the compres-
ter bag may cause the suction filter to
sor with the suction gas and thus prevent
burst and thus contaminate the compres-
them from penetrating into the compressor.
sor to an extreme degree.
The suction filters therefore have a very fine
mesh and as an additional precaution have a There are always two suction filters in the
filter bag insert, which should normally be compressor and these are removed through
used for 50 operating hours from the initial the flanged opening in the bottom end of the
start-up of the compressor. The filter bag is filter housing. Attention is drawn to the fact
then removed and disposed of. that there are two types of suction filter, as
If the filter bag is badly soiled after the 50 op- detailed below:
erating hours mentioned, it is recommended
that a new bag be fitted for an additional 50 On SMC compressors, the two suction fil-
operating hours. Similarly, a filter bag ought ters are identical and should only be fitted
to be fitted for a period of 50 operating hours with an O-ring in the end facing up towards
after any major repair work to the refrigera- the suction stop valve. The filters are open at
tion plant. both ends.
TSMC 108 TSMC 116
LP HP
LP HP
On TSMC compressors, the suction filter The suction filter fitted on the righthand side
located on the lefthand side opposite the low- opposite the high-pressure cylinders has a
pressure cylinders (see drawing) is the same closed end-bottom which must face upwards
type as on SMC compressors, i.e. open at and close towards the suction stop valve.
both ends and having an O-ring in the end This suction filter must be fitted with O-rings
facing up towards the suction stop valve. at both ends.
0178-910-EN 77
Stop valves
AK AC A AJ L P K R
AD
E S
F T
D U
C M
H B
Y J
POS. 25
Z AG Q G N T0177131_0 V14
The suction and discharge stop valves are S Mount threaded piece Pos. 25G in a
used to isolate the compressor from the re- soft-jawed vice and dismantle screw Pos.
frigeration plant. 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
The valve seat is sealed with a teflon ring dismantling the screw, as the guide pin
Pos. 25H which, if necessary, can be re- Pos. 25N will be overloaded.
placed as follows:
S The front and rear pieces Pos. 25C and
Dismantling of valve: 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.
removed.
S If required, the Teflon ring can be reversed
S Turn spindle clockwise until cone and when reassembling so that the other outer
threaded piece Pos. 25G can be removed edge seals towards the valve seat in the
by hand. housing.
78 0178-910-EN
Reassembly of valve: Pos. 25M to be serviced even when there
Reassembly is done in the reverse order to is excess pressure in the valve housing.
that above. Note the following, however:
Adopt the following procedure:
S Before mounting the complete valve in-
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 with
then be screwed out for inspection or re-
a new one.
placement of the O-ring Pos. 25R and
The stop valve has a so-called retroseal, 25P. Thoroughly lubricate all parts with oil
which enables the packing screw joint before reassembling.
0178-910-EN 79
Unloaded start and capacity regulation on SMC
and TSMC 100 and 180 compressors
SMC and TSMC compressors are equipped The unloader system is also used to regulate
with an automatic unloader system to provide the capacity of the compressor.
full relief to the compressor during the
start-up phase. This reduces the starting The following schematic outline shows the
torque of the compressor considerably. lubrication and hydraulics system on the
compressors together with unloader me-
chanism.
Fig. 1 12
2
12J
50
20 13 2
19D
96.02
15D
19B 2
15A
15B
0171-907-EN
1
3
22
11
38
33
T0177131_0 V10
Description of unloader mechanism See the blue spare parts drawing of the cylin-
and capacity regulation der linings at the end of this manual.
No-load starting and capacity regulation are

achieved by keeping the suction valve ring Around each pair of cylinder linings a frame
plate in the open position; the refrigerant gas Pos. 13 is fitted, controlling two sets of rocker
thus aspired into the cylinder is not com- arms Pos. 15A. The frame is connected by
pressed but thrust back out through the suc- means of a piston rod to the regulating piston
tion valve. in the unloading cylinder pos. 12.
80 0178-910-EN
When the regulating piston is unaffected by the ate freely and close during the compression
oil pressure - i.e. when the connected solenoid phase.
valve is de-energized or when the compressor
During operation, the unloader system can
is at standstill - the regulating piston and the en-
therefore regulate the capacity of the com-
tire frame are shifted to the right by the pres-
pressor by causing the solenoid valve - which
sure from the springs Pos. 12J (see fig. 1) .
is linked to the relief cylinder - to open or
The tension springs Pos. 15D will thus raise close for oil pressure to the relief cylinders,
the rocker arms Pos. 15A into the vertical po- controlled by an electrical regulation system.
sition, as these rotate in the ball sockets Pos.
On TSMC compressors, attention is drawn to
15B.
the two types of relief cylinder - for the LP
This movement lifts the relief ring and the and HP stage, respectively, as shown on the
pins Pos. 19B, opening the suction valve by spare parts drawing.
force.
Note:
If oil pressure is placed on the relief cylinder Adjust the oil pressure on the regulating
during operation, the unloader system is valve Pos. 22 to 4.5 bar. At an oil pressure
shifted to the left (see sketch). This lowers lower than 3.5 bar (the breaking pressure
the rocker arms Pos. 15A, and the relief ring for the safety automatices), there is a risk
with pins Pos. 19B is moved away from the of the unloader system not being moved
suction valve ring plate, allowing this to oper- effectively and thus being damaged.
0178-910-EN 81
Pilot solenoid valves The solenoid valves are integrated in blocks
The pilot solenoid valve is an electromagnet- (fig. 2) with 1,2,3, or 4 solenoid valves in
ic three-way valve which with a dead coil each block. In these blocks the solenoid
connects the unloading cylinder to the crank- valves have a collective supply of pressure
case (the path for the oil flow from pipe 2 to oil (pipe 1) and a collective connection to the
pipe 3 is open). See fig. 1. If the coil is ener- crankcase (pipe 3). Each individual solenoid
gized, the valve switches so that the path for valve has its own oil connection to the rele-
the oil flow from pipe 1 to pipe 2 is open and vant unloading cylinder (pipe 2).
the connection to pipe 3 is closed off.
Sectional drawing of capacity regulating valve
Fig. 2
Danfoss 034F9034_1
82 0178-910-EN
Schematic outlines The S-valve is connected to the regulating
cylinder(s) not involved in capacity regula-
The following schematic outlines shows the
tion.
oil pipe connections and the wiring diagram
with cut-out functions.
The valve is designed to prevent fast rising
The schematic outlines also indicate the per- oil pressure actuating the compressor cylin-
centual capacity at which the compressor op- ders before the motor starter has changed
erates at the various capacity stages. over to the delta position, or a gas or diesel
motor has reached full rotation speed.
The lowest capacity percentage indicated on
schematic outlines 1 corresponds to the low- TSMC compressors are always equipped
est permissible capacity step at which the with S-valves and thus feature totally un-
compressor may work by continous opera- loaded start as standard.
tion.
Note:
In special instances, e.g. where the start-up Please note that the solenoid valve S
phase is lengthy, it may prove necessary to must not be wired so as to form part of
relieve the compressor altogether until the the capacity regulation.
motor has achieved a sufficient torque. In The compressor may operate totally un-
such cases, an extra solenoid valve marked loaded for no more than 5 minutes, as its
’S’ can be mounted as shown on schematic operating temperature will otherwise be-
outlines 2. come too high.
0178-910-EN 83
Standard unloaded start and capacity regulation
The SMC and TSMC compressors always Regulating sequence
start totally unloaded and in their standard
The unloading is effected for two cylinders at
design will activate a number of cylinders
a time by cutting off the voltage to the ac-
corresponding to the lowest capacity stage
companying solenoid valve.
once the oil pump has built up the necessary
oil pressure. The unloading must be effected in numerical
order (1 - 2 - 3 - 4), while loading should be
done in reverse order (4 - 3 - 2 - 1).
See discussion of the ’S’ solenoid valve in
the Totally unloaded start and capacity regu- Note:
lation section, however. TSMC 116 must always have valves 3
and 4 connected simultaneously, as this
capacity stage includes both low- and
It is recommended that solenoid valves be
high-pressure cylinders.
wired so as not to receive the opening
signal until the drive motor has achieved The regulating sequence may be seen from the
full torque. schematic drawings.
Schematic drawings 1
SMC/HPC 104 SMC 112 TSMC 108

TSMC 188
5
2 1 % 1 3
% 100 1
100 1 3
HP 1 S
50 % S
S 2
N
L 83 100 1
67 2
33
4 0
67 2 6 N
L
SMC/HPC 106 50
2
4
SMC 186 33
N
3 L
1 2
%
100 1
67 2
33 SMC 116 TSMC 116
N
L %
% 3 7 100 1
2 S
1 5 1 5
100 1 83 2
3 5
SMC/HPC 108 87 5 S
67
SMC 188 75
HP
% 4 1
2 3 63 4 6 S 4
100 1 50
75 2 8 3 S
2 50 2 S
50 3 3
4
25 37 6 33 4
N
L 25
N 0
L L N
T1534070_1 rev.3
84 0178-910-EN
Totally unloaded start and capacity regulation
Futher to the standard equipment, as shown pacity. The ’S’ solenoid valve may therefore
on the previous page, the compressor may be used only as follows:
feature an extra solenoid valve marked S.
S Where total unloading is required until the
TSMC compressors, however, are invariably
motor has achieved max. torque.
equipped with this S-valve.
S Where a refrigeration plant is occasionally
The ’S’ solenoid valve makes total unloading
subject to brief operating stops and com-
of the compressor possible, i.e. 0% capacity
pressor stop is not desirable. The com-
over a shorter period during operation. How-
pressor may then be allowed to run for a
ever, the ’S’ solenoid valve must never be
maximum of 5 minutes at 0% capacity.
involved in normal capacity regulation, as
there is a risk of the compressor overheating The regulating sequence may be seen from
if operated for some length of time at 0% ca- the schematic drawings:
Schematic drawings 2
SMC/HPC 104 SMC 188

Compressor seen from
the shaft end
S 1 S 1
% S
% S
2 3
100 1
100 1 75 2
50 50
0 3
2 25
N Relief cylinder 0
L N
3 L
Oil return
1
Oil pressure
SMC/HPC 106
SMC 186
S SMC 112 SMC 116
1 2
% S
100 1
67 2 % S
33 S 3 S
1 3 100 1
0 1 5
N % S 3
L
100 1 87 5
3
75
83
SMC/HPC 108
63
67 4 4 6
% 1 2 S 50 2
S 2 S
100 1 50 S 4
2 3
75 2 2 37 6
50 3 33 4 25 S
25 S S 0 0
N
L L N
0
N
L
T1534070_2 rev.3
0178-910-EN 85
Service rent to the number of solenoid valves needed
to supply the compressor with the capacity
It will normally not be necessary to service
required.
the solenoid valves, and it is therefore re-
commended not to strip them down. Should it
be considered necessary to replace the sole- Note:
noid valve, however, unscrew it from the When starting a compressor this must be
block and replace by a new one. See the done at the lowest capacity stage and it
spare parts list. should be allowed to run for a few minutes
(e.g. 3 to 5 minutes) before its capacity is in-
Regulating sequence creased. This will prevent the oil in the com-
pressor from heavy foaming and the refriger-
The schematic outlines show that disconnec- ant from being sucked into the compressor
tion of a cylinder pair is done by cutting off from the evaporating system; something
the current to the relevant magnetic coil. Dis- which can lead to liquid strokes. For the
connection must be done by numerically as- same reasons the compressor should al-
cending sequence, while connection should ways, when a new stage has been loaded,
be done by numerically descending se- be allowed to run for 3 to 5 minutes at this
quence.
stage before the next higher capacity stage is
The automatic gear which controls the sol- loaded. Unloading of capacity on the com-
enoid valves must cut off or connect the cur- pressor can usually take place more quickly.
Automatic capacity regulation

Where there is an automatic capacity regulat- Relief cylinders
ing facility, solenoid valve control can be ef-
The relief cylinders vary in type, depending
fected in the following ways:
on the position they have on the compressor.
- using pressure cut-outs The chart below shows the number and di-
- using thermostats mensions of the relief cylinders for the indi-
- using microelectronics such as e.g. vidual compressor types.
the UNISAB II.
Piston rod Relief Number in each compressor
Pos. 1) Cylinder
Dimensions SMC 100 TSMC 100 SMC 180 TSMC 180
S mm L mm Part no. 104 106 108 112 116 108 116 186 188 188
12-1 21.5 75 3135-149 1 1 1 2 2 1

12-2 46.5 100 3135-150 1 1 1 2 2 1 1
12-3 71.5 125 3135-151 1 1 2 2 1 2
12-4 96.5 150 3135-152 1 2 1 2
12-5 24.5 82 3135-161 1 1
12-7 49.5 107 3135-154 1
12-1 49 122 3135-019 1 1

12-2 94 167 3135-020 1 1 1
12-3 139 212 3135-021 1 1 1
12-4 184 257 3135-022 1 1
1) See spare parts drawing at the end of this instruction manual
86 0178-910-EN
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
The purge valve is fitted either directly on
spindle.
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.
88 0178-910-EN
Monitoring cylinder lining insertion
When reassembling the slide linings, it is im- no. 1 from the tools kit.
portant to check the clearance volume as Fit the locking devices diagonally as
described in section 1 below. shown in fig. 1.
When mounting new cylinder linings, both
the clearance volume and the so called lift- Fig. 1
ing reserve must be checked in the order S-L for SMC 100 type S og L
· E for SMC 100 type E
mentioned and as described in sections 1
and 2. It is recommended that the cylinder
linings be marked so that they can be reas-
sembled in the same place as before.
1. Checking clearance volume ·
After each cylinder lining assembly, it is rec-

ommended that the clearance volume be
98.01
checked. pos. 19K
Adjustment of the clearance volume is done

0171-467-EN
by means of gasket pos. 19K which, in addi-

tion to its sealing function, is also used as an
adjusting element. Consequently, the gaskets
come in two sizes and may sometimes be
used at the same time under the same cylin-
der lining. S Turn crankshaft until piston is in top posi-
tion.
Gasket HPC SMC 180
thickness SMC 100 S Using a depth or slide gauge, measure ”X”
19K part no. part no. as shown in fig. 2
0.5mm 2356-111 2356-116
Fig. 2 Cylinder lining
0.8mm 2356-233 2356-249
X
Adjustment is made as follows:

S The rocker arm system is lowered by fit-
ting the long plug no. 4 from the tools kit in
the unloading cylinder pos. 12 instead of
screw pos. 12D.
Piston T0177131_0 v6
S Insert an 0.5mm gasket pos. 19K and
mount cylinder lining.
S ”X” must lie between the below mentioned
S Press cylinder lining against gasket pos. limits and may, as mentioned earlier, be
19K by means of two locking devices -- adjusted by the use of gasket pos. 19K.
0178-910-EN 89
Clearance The rocker arms must be in their vertical
min. max.
volume position i.e. with the short screw pos. 12D
”X” mm mm
HPC and gasket 12E fitted. The measured dis-
SMC 100
0.6 1.0 tances ”Y1 and Y2” may not vary more
Mk1, Mk 2, Mk 3
SMC 180 than max. 0.25mm.
0.9 1.5
Mk1, Mk 2
S Adjustment of the lifting reserve can now In case this difference is greater, a shim
be performed if necessary. See point 2. Pos. 15E must be placed under the lowest
rocker arm bearing pos. 15B or a shim re-
2. Checking lifting reserve moved from the highest bearing. Normally,
When fitting a new cylinder, or if the com- there is no shim or max. 2 shims under
pressor is to be changed from running on the rocker arm bearing.
R717 to some other refrigerant, or vice versa,
or in the event of any major overhaul to the
compressor, the lifting reserve must be
checked.
Check lifting reserve:
Note:
The lifting reserve must not be checked S The lifting reserve of the rocker arm is im-
until the clearance volume has been ad- portant in order to make sure that the
justed. Start by checking that the mutual rocker arm in its upright position can keep
height of the rocker arms is the same as the suction valve ring plate open while the
described in the following: cylinder is unloaded. However, it must not
Having removed the cylinder lining, mea- be possible for them to be so upright that
sure distance ”Y” from the contact face of there is a risk of their jamming, this mak-
the cylinder lining in the frame to the top of ing them unable to be lowered again
the two rocker arms which interact on ei- when the cylinder is put into service. Per-
ther side of the cylinder lining. See fig. 3. form the adjustment as follows:
Fig. 3
S Position cylinder lining incl. the correct
Block
gasket pos. 19K in the compressor block
and press down against rocker arms by
hand.
Y1 Y2
S The rocker arms are in their upright posi-
Rocker arms tion as the normal plug pos. 12D as well
as gasket pos. 12E have been mounted in
T0177131_0 v4
the unloading cylinder.
90 0178-910-EN
S The difference in the two measurements
Fig. 4
of ”Z” must be within the limits stipulated
in the following table.
Z
Lifting reserve Min. Max.

”Z” mm mm
·
HPC
pos. 19K SMC 100 0,6 1,0
Mk 1, Mk 2, Mk 3
SMC 180 0,8 1,5
Mk 1, Mk 2
T0177131_0 v5
S If the difference between the two mea-

surements does not fall within the parame-
S Measure distance ”Z” as shown in fig. 4. ters stated, it must be regulated by insert-
Note down the ”Z” measure. ing or removing shims pos. 15E under the
S Replace normal plug pos. 12D with the rocker arm bearings.
long plug no. 4 from the tools kit, lowering S It is important that the long threaded plug
rocker arms in the process. is fitted while the top cover is being
mounted.
S Press cylinder lining down against gasket
pos. 19K using the two locking devices no. Note:
1 as shown in fig. 1, and repeat measure- Remember to put the normal plug in once
ment ”Z”. the top cover has been tightened.
0178-910-EN 91
Pressure gauges
The analog instrumentation on the compres- temperature under which the instrument will
sor includes two pressure gauges: one that be functioning.
measures the discharge pressure on the
compressor and one combined suction and Example:
oil pressure gauge. These pressure gauges If the mid--compensation range is to be
are filled with glycerine, which both attenu- moved from 20°C to 10°C, equalization must
ates the deflections of the indicators and lu- be performed at 10°C. When the screw is
bricates the gauge works. then retightened, the middle of the com-
pensation range will have been moved down
However, a fluctuating ambient temperature to 10°C. The total stretch of the compensa-
has an influence on the volume of the glycer- tion range remains unchanged.
ine (warm glycerine takes up more space
The middle of the compensation range.
than cold glycerine), which can affect the Tighten the balancing screw at this temperature
measuring accuracy of the gauge.
10°C
Furthermore, it is essential that no excess -10°C 50°C
95.06
pressure can possibly occur in the gauge
20°C
housing, as this involves a risk of explosion
0°C 60°C
of the housing.
0170-161-EN
30°C
+10°C 70°C
Both these considerations have been effec-
tively solved in the gauges by a combination T0177086_0
of internal temperature compensation and

the so-called blow-out safety device which is Cleaning and refilling glycerine-
fitted in the back plate of the pressure gauge
filled gauges
housing.
S Remove blow-out disk and temperature
compensator from back of housing.
Adjustment to other temperature
ranges: S Wash gauge interior with warm water and
allow to dry carefully.
A balancing screw on the rear of the instru-
ment is firmly tightened at a temperature of S Fill gauge housing with fresh glycerine un-
20°C -- the normal ambient temperature. til it flows out of bleeder hole.
Note:The glycerine must be absolutely wa-

If ambient temperatures change considerably
terfree.
thus requiring a general shift in the com-
pensation range, slacken the balancing S Refit compensator and blow-out disk in
screw for approx. 1 minute, then retighten. gauge housing and cover centrehole in
This must be done at the average operating blow-out disk with a piece of tape.
92 0178-910-EN
Note: Compensator
Glycerine should be refilled at a room tem-
perature of 20°C; when mounted, and the +20°C
compensator must be its normal shape as

shown at the top of the following drawing. -10°C
Balancing screw
S Clean gauge exterior with warm water.
+60°C
S Remove tape from centrehole.
T0177086_0 Blow-out
S Refit gauge.
0178-910-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
b
°
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 0178-910-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.
0178-910-EN 95
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
96 0178-910-EN
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 A Torque (A)

Compressor type Coupling Thread
type Kpm. ft.lbf. Nm
HPO/CMO/TCMO AMR225 5/16” 3.5 25 34
104-108 AMR312S 7/16” 5.6 40 55

HPC/
SMC/ 112-116 AMR350S 1/2” 13 95 128
TSMC
A 186-188 AMR450S 11/16” 28 200 275
NORMEX
NORMEX
128 H148 M8 2.2 16 22
163 H168 M8 2.2 16 22

SAB
128 225 5/16” 3.5 25 34
Series 52
163 262 3/8” 4.2 30 41

Series 52 A
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

depending
Series 52
VMY on the 312 7/16” 5.6 40 55

motor size
350 1/2” 13 95 128
375 9/16” 18 130 177
425 5/8” 25 175 245
450 11/16” 28 200 275
0178-910-EN 97
Refrigeration Plant Maintenance
Operational reliability bled of refrigerant. Adjust any constant-

pressure valves to bring evaporator pres-
The prime causes of operating malfunctions
sure down to atmospheric.
to the plant are:
1. Incorrect control of liquid supply to the 3. Start up the compressor. Adjust regulat-
evaporator. ing system to lower suction pressure.
2. Moisture in the plant. 4. Keep a close eye on the suction pres-

sure gauge! When the suction pressure is
3. Air in the plant. equal to atmospheric, stop the compres-
sor and quickly shut off the discharge stop
4. Anti-freezing liquid is missing.
valve. Shut off any stop valve in the oil re-
5. Congestion due to metal shavings and turn line.
94.05
dirt.
If the receiver has an extra stop valve in
6. Congestion due to iron oxides. the feed line, this can be closed; practical-
0171-464-EN
ly the entire refrigerant charge will then
7. Congestion due to copper oxides. remain shut off in the receiver.
8. Inadequate refrigerant charge. Note:
Below, some information is given about ways The receiver must not be overfilled! There
of keeping contaminants out of the refrigera- should be a minimum gas volume of 5%.
ting system and at the same time facilitating 5. A slight overpressure should normally re-
day-to-day supervision of the refrigeration main in the piping system - this safe-
plant. guards the system against the penetration
of air and moisture.
Pumping down the refrigeration
6. Before dismantling parts, the operator
plant
should put a gas mask on.
Before dismantling any parts of the refrigera-
tion plant for inspection or repair, pump-down
must be carried out.
Dismantling plant
In order to prevent moisture penetrating into
1. Open suction and discharge stop valves the refrigeration plant during any repair work,
on compressor. it is advisable to follow the rules below:
2. Close liquid stop valve after condenser or 1. No component should be opened un-
receiver so that liquid refrigerant can be necessarily.
collected in the tank. Any solenoid valves
in the liquid line should be opened by 2. When dismantling the system, the pres-
force, adjusting the thermostat to its low- sure in the system should be a little higher
est position so that the liquid line can be than atmospheric.
98 0178-910-EN
3. Note: Tightness testing and pump-down
If the piping system is colder than the sur- of refrigeration plant
roundings, there is a considerable risk of
Before charging refrigerant into that part of
damp precipitation (condensation) on cold
the refrigeration plant which has been
plant parts. Plant components to be dis-
opened, this should be pressure-tested as
mantled must be warmer than the ambi-
described in the section entitled Pressure
ent temperature.
testing.
4. No two points in the system should be Afterwards, pump down in order to eliminate
opened at the same time. air and moisture. In this regard, consult the
section on Evacuation.
5. Plug, close or at least cover opening with
Otherwise, follow the instructions given in the
oiled paper or suchlike.
separate instruction manual on plant compo-
6. Be aware of the possibility of filters nents.
being very moist. Note:
If the oil in the crankcase of the piston
compressor or the oil separator of the
screw compressor has been in contact
with the atmospheric air for any length of
time, it must be replaced with fresh oil of
the same grade and make.
0178-910-EN 99
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.
100 0178-910-EN
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.
0178-910-EN 101
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
102 0178-910-EN
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.
0178-910-EN 103
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.
104 0178-910-EN
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.
0178-910-EN 105
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.
106 0178-910-EN
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.
0178-910-EN 107
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
108 0178-910-EN
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
0178-910-EN 109
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.
110 0178-910-EN
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.
0178-910-EN 111
Selecting Lubricating Oil for SABROE Compressors
During the past few years YORK 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 YORK Refrigeration during the past ant.
99.02
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, YORK 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 YORK Refrigeration’s will indicate the limits for Sabroe oils at which
own or alternative oil brands which fulfil the this stratification occurs. The oil concentra-
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
112 0178-910-EN
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 YORK 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 YORK
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
ants. Once the general conditions concern- YORK Refrigeration to give a general ap-
ing the lubrication of the compressor and oil proval of the various oil brands.
type in the plant have been considered, the
specific plant conditions must be taken For this reason YORK 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. YORK 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 YORK
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 YORK
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
0178-910-EN 113
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. YORK 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.
114 0178-910-EN
YORK Refrigeration can supply a calculation YORK 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 YORK Refrigeration has therefore decided to
cartain operating conditions: 7cSt)
market a brand of mineral oil which has been
S Max. permissible viscosity during the tested and found to be suitable for most gen-
starting of the compressor = 500 cSt eral 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, YORK 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:
YORK 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.
0178-910-EN 115
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 YORK
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
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 14 32 50 68 86 ° F en in connection with a careful procedure in-
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 YORK Refrigeration as well as from a num-
code number for the appropriate oil type. In ber of oil companies.
116 0178-910-EN
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 YORK
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 YORK 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 YORK Refrigeration
SH : Suction gas superheat, K (Kelvin)
: Zone in which both oils are useable
: Calculation must be performed using COMP1
0178-910-EN 117
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
not ppossible to present
p typical
yp data for these oils. When using
g another oil brand than the one
E9 recommended by YORK 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 YORK Refrigeration’s Sabroe compressors.
118 0178-910-EN
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)
0178-910-EN 119
R717 TC
one-stage
°F °C
reciprocating
122 50
compressors
104 40
86 30
68 20 1
50 10
32 0
Code no Area no 14 -10

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 note -76 -58 -40 -22 -4 14 32 50 68 °F
Note: YORK Refrigeration recommends that the use of M oils is restricted to moderately loaded compressors and
that the oil quality is monitored carefully via regular oil analyses.
120 0178-910-EN
R717 TC
two-stage
°F °C
reciprocating
122 50
compressors
104 40
86 30
1
68 20
50 10
32 0

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 note -76 -58 -40 -22 -4 14 32 50 68 °F
0178-910-EN 121
R717 TC
HPO and HPC
°F °C
reciprocating
176 80
compressors
158 70
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
Please observe: PAO 5 oil is the only oil which can be used in the HPO and HPC compressors.
122 0178-910-EN
R22 TC Contact YORK Refrigeration
one-stage
°F °C
reciprocating 2
122 50
compressors
104 40
86 30
1
68 20
50 10
32 0
14 -10 A
Code no Area no -4 -20
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

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.
0178-910-EN 123
R22 TC
two-stage
°F °C
reciprocating
122 50
compressors
104 40
86 30 1
A
68 20
50 10
32 0
14 -10

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

124 0178-910-EN
TC
R134a
°F °C
one-stage
158 70
reciprocating
140 60 2
compressors
122 50
104 40
86 30
68 20 1
50 10
32 0
14 -10
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
Y: In case of a new plant. Very suitable.

0178-910-EN 125
R134a TC
two-stage °F °C
reciprocating 158 70
compressors 140 60
122 50
Condensing temperature 1
104 40
86 30
68 20
50 10
32 0
14 -10
-4 -20
Code no Area 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
126 0178-910-EN
R407C TC
one-stage
°F °C
reciprocating
122 50
compressors
104 40
86 30
68 20
1
50 10
32 0
14 -10
B
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

0178-910-EN 127
R407C TC
two-stage
°F °C
reciprocating
122 50
compressors
104 40
86 30 1
68 20 B
50 10
32 0
14 -10

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

128 0178-910-EN
R404A TC
one-stage
°F °C
reciprocating
122 50
compressors
104 40 2
86 30
68 20
50 10 1
32 0
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

: Zone in which both oils are useble
0178-910-EN 129
R404A TC
two-stage
°F °C
reciprocating
122 50
compressors
104 40
86 30
1
68 20
50 10
32 0
14 -10

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

130 0178-910-EN
R410A TC
HPO og HPC
°F °C
reciprocating
122 60
compressors
50
104
40
86
30
68 20
10 1
50
0
32
A
-10
14
-20
Code no Area no -4
-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

A: Max oil concentration in liquid phase at: TE: 2%
0178-910-EN 131
R507 TC
one-stage
°F °C
reciprocating
122 50
compressors
104 40
86 30
68 20
1
50 10
32 0
14 -10

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: Min suction temperature --50°C: at TE< --50°C superheating must
most be introduced.
132 0178-910-EN
R507 TC
two-stage
°F °C
reciprocating
122 50
compressors
104 40
86 30
1
68 20
50 10
32 0
14 -10

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

0178-910-EN 133
R717 TC
screw compressors °F °C
122 50
104 40
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 note -76 -58 -40 -22 -4 14 32 50 68 °F
HLI: Calculation must be performed using COMP1
: Calculation must be performed using COMP1.
134 0178-910-EN
R22 TC
SH10 SH20 SH25 SH5 SH10
with journal bearings 122 50
or roller bearings
2
104 40
SH5
86 30
68 20
1
50 10
32 0 A
14 -10
Code no Area 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
Using the calculating programme COMP1 it is possible to optimize the requirement for suction superheat values
(SH) as stated in the diagram. See Oil types and oil companies in this section. Due to the ongoing development of
lubrication oils, please contact YORK Refrigeration for an update on the requirement for superheat.
HLI: Calculation must be performed using COMP1.

0178-910-EN 135
R22 TC
with roller bearings 122 50
only
104 40
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
(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 YORK Refrigeration for an update on the requirement for superheat.

136 0178-910-EN
R134a TC
screw compressors °F °C SH30

158 70
140 60 SH20
122 50
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
Note: For the compressors type ”S”, ”Rotatune”, ”SAB 81”, ”SAB 83”, and ”SAB 85” only Sabroe oil H is approved.
(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 YORK Refrigeration for an update on the requirement for superheat.
0178-910-EN 137
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

138 0178-910-EN
R407C TC
screw compressors
°F °C
122 50
SH10
104 40
SH5
Condensing temperature 2
86 30
68 20
50 10
32 0 1
B
14 -10

(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
B : Max oil concentration in liquid phase: contact YORK Refrigeration
0178-910-EN 139
R507 TC
screw compressors
°F °C
104 40
2
86 30 SH5
68 20
SH5
50 10 1
32 0
SH15
14 -10

(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

140 0178-910-EN
List of Major Oil Companies
The oil from the companies listed below are NOT tested by YORK Refrigeration and are there-
fore NOT approved by YORK Refrigeration either. The following list reflects the information pro-
vided by the companies themselves. The assessment of durability and suitability of specific oils
for specific purposes are entirely at the companies’ own discretion. Oils tested and approved by
YORK 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
· ·
0178-910-EN 141
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:
95.03
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 .
142 0178-910-EN
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!
0178-910-EN 143
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.
144 0178-910-EN
FOR JOHN CRANE TSK METASTREAM T SERIES COUPLINGS, PLEASE REFER
TO THE METASTREAM FITTING, OPERATIONS AND MAINTENANCE
INSTRUCTIONS, ATTACHED ON THE END.
Fitting and alignment of AMR-type coupling

Installation and alignment Important
Before any work on the coupling, ensure
In principle, alignment involves manoeuvring
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
Max. variation measured with a feeler

Compressor AMR Distance Torque moment gauge at a 180° turning of the af coupling
type of C
coupling Pos. 1 Pos. 2
nominal* A B Horizontal Vertical
max. min./max. max.
mm Nm Nm mm mm mm
HPO/CMO 2 225 76,0 34 0,1 0,1/0,2 0,1
HPC/SMC
312 S 103,5 147 55 0,2 0,1/0,3 0,2
104-108
SMC
350 S 114,5 147 128 0,2 0,1/0,3 0,2
112-116
SMC
450 S 149,0 295 275 0,3 0,1/0,4 0,3
180
* See Final mounting, pt. 4
0178-910-EN 145
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.
146 0178-910-EN
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.
0178-910-EN 147
Boring of motor flange for AMR coupling
A MAX. 0.02 mm
92.03
MAX. 0.02 mm
T0177131_0 V12
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-
010-502-EN
the AMR coupling will not be supplied in ances:
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 60 mm 95 mm 110 mm
Boring tolerance H7 H8 H8
148 0178-910-EN
V-Belt Drive for SMC/TSMC 100
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.
0171-593-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.
0178-910-EN 149
Transmission Ratio
Table 1 shows the pulley diameters used for must be used for the different combinations
SMC/TSMC 100 units. With these diameters of belt pulley diameters. The length of the
the compressor speeds mentioned in V-belts is stamped on the outside of the belts
columns 3 and 4 can be achieved. Columns as shown in fig. 2.
5 and 6 show the length of the V-belts which
Table 1 - Standard Programme for V-Belts and Pulleys for SMC/TSMC 100
Standard Belt Pulley Compressor Speed Length of V-belts
Diameter mm Compared to Motor Speed
50 Hz
1460 rpm
60 Hz SMC 104 to SMC 112 -
Compressor Motor rpm
1760 rpm 108 and 116 and
SMC/T
112- rpm TSMC 108 TSMC 116
104-
108 116
180 -- -- 792 2650 1900
190 -- -- 836 2650 1900
200 730 -- 880 2650 1900
224 817 985 2650 2000
250 912 1100 2800 2000
400 265 976 1166 2800 2000
280 1022 1232 2800 2000
315 1150 1386 2800 2120
335 1273 1474 3000 2120
355 1295 3000 2240
400 1460 3000 2240
Power Transmission S The compressor pulleys, however, are

only delivered with the number of grooves
A correctly dimensioned V-belt drive must be
shown below. Thus it may occur that there
able to transmit the max. power of the motor,
are more grooves on the compressor
which corresponds to the nominal capacity
pulley than on the motor pulley.
of the motor, which is stamped on the name
plate. The number of V-belts for which the SMC/TSMC 100 compressor pulleys are
belt drive is dimensioned must, therefore, delivered with 4, 6 or 8 grooves.
always be mounted. This can be checked by
means of the following rules:
Servicing and Alignment of the
S The motor pulleys are always delivered V-Belt Drive
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.
150 0178-910-EN
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.
0178-910-EN 151
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
2 visible 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
abnormal 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 sur-
ing can be placed on the motor shaft faces in the conic belt grooves and should,
manually. Never beat the bushing onto the therefore, be checked every time the belts
motor shaft as the impact may damage are replaced. This is done by means of a
the bearings in the motor. measuring gauge, which is placed in the belt
The bushing is tightened to the motor shaft 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 surfaces
ding on the size of the belt pulley) in the in the conic grooves. If the grooves are dam-
hole/s where there is a thread only in the aged in any other way, it should be
side of the holes facing the bushing. considered to replace the belt pulleys.
152 0178-910-EN
Fig. 6 - Wear on the 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 on
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
Before mounting the V-belt drive, it is neces- in fig. 8.
sary to clean and degrease all machined sur-
faces of the belt pulleys, shafts and bushing. Fig. 8
Then proceed as follows: Bush no. Bush no.
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 200 Nm. so much that it is still possible to move
0178-910-EN 153
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.
Table 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
154 0178-910-EN
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.
0178-910-EN 155
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 table 3. 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.
Table 3
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 to 6 consists of two columns, which
to the value stated in the column
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.
156 0178-910-EN
Table 3 SMC/TSMC 104-108, four-pole 50 Hz motor
Belt Tension
Motor Pulley N
Di
Diameter
t New V-Belts Remounting
mm
Min. Max. Min. Max.
200 700 800 500 550
224 800 900 550 600
250 800 900 550 600
265 800 900 550 600
280 800 900 550 600
335 900 1000 600 700
315 900 1000 600 700
355 900 1000 600 700
400 1000 1100 700 800
Table 4 SMC/TSMC 112 og 116, four-pole 50 Hz motor
Belt Tension
Motor Pulley N
Di
Diameter
mm
Min. Max. Min. Max.
224 700 800 500 550
250 800 900 550 600
265 800 900 550 600
280 800 900 550 600
315 900 1000 600 700
335 800 900 550 600
355 900 1000 600 700
400 1000 1100 700 800
Table 5 SMC/TSMC 104-108, four-pole 60 Hz motor
Belt Tension
Motor Pulley N
Di
Diameter
mm
Min. Max. Min. Max.
180 700 800 500 550
190 700 800 500 550
200 700 800 500 550
224 800 900 550 600
250 800 900 550 600
265 800 900 550 600
280 900 1000 600 700
315 900 1000 600 700
335 1000 1100 700 800
0178-910-EN 157
Table 6 SMC/TSMC 112 og 116, four-pole 60 Hz motor
Belt Tension
Motor Pulley N
Di
Diameter
mm
Min. Max. Min. Max.
180 600 700 400 450
190 600 700 400 450
200 600 700 400 450
224 700 800 500 550
250 800 900 550 600
265 800 900 550 600
280 800 900 550 600
315 900 1000 600 700
335 900 1000 600 700
158 0178-910-EN
Oil Separator OVUR for SMC/TSMC 100
HPC - SMC/TSMC 180
Application sumption. Further, oil products with a low

flame point can lead to an increased oil con-
The purpose of the oil separator is, under all
sumption 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 Functioning

is going to leave the oil separator - the so-
The discharge gas from the compressor
called oil consumption.
flows through the oil separator, fig. 1, from
With a normal standard oil separator the oil pos. A to pos. B. On its way it passes
consumption will be approx. 35 to 45 ppm through a number of filters in which the oil
(parts per million) for R717 compressors. is separated from the discharge gas.
The filters consist of stainless steel wire
The oil consumption depends, however, on mesh which, as a rule, needs no cleaning,
97.01
the discharge gas temperature. Rising tem- nor does it get worn. Consequently, the filters
peratures often lead to an increased oil con- cannot be removed from the oil separator.
0171-475-EN
Fig. 1 A
L
A: Discharge gas inlet B: Discharge gas outlet L: Oil return to the compressor
0178-910-EN 159
Oil return to the compressor a: Solenoid valve controlled oil return
As illustrated in fig. 2 the oil is conveyed from
The separated oil leaves the oil separator
the oil separator through the screwed con-
through the pipes pos. L, and can be regu-
nections pos. 80A and 80B. Fig. 2 pos. also
lated by the following systems:
shows that pos. 80A is of such a length that it
pierces the base plate by approx. 10mm. In
a: Solenoid valve controlled oil return this way any dirt particles may be collected
on the bottom of the oil separator instead of
b: Float valve controlled oil return being returned with the oil to the compressor.
Fig. 2 Compressor with Compressor with

1 oil separator 2 oil separators
80M
Oil separator
Solenoid valve
80M 80C
stop
valve 80M
Filter
80A
dia. 8/6 dia. 8/6

80B
At point A the oil flows into the valve block 80E, which can be removed by dismounting
pos. 80 and from point B is led to the com- cover pos. 80F. The filter can be cleaned in a
pressor as illustrated in fig. 3. cleansing fluid and blown clean with com-
pressed air.
The valve block consists of a stop valve pos.
80D, which is closed and opened by turning On remounting of the cover tighten it with a
of the spindle. This valve may be dismantled 60 Nm torque. Remember gasket pos. 80G.
by unscrewing the big union nut from the val-
Before removing the oil filter, close stop valve
ve block. On mounting, tighten it once more
pos. 80D and evacuate the compressor to
with a 60 Nm torque.
atmospheric pressure as described earlier on
From the stop valve the oil passes filter pos. in this manual.
160 0178-910-EN
Fig. 3 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
during start-up.
60 Nm 80L
50 Nm
10 Nm
The seat of the solenoid valve pos. 80I also
80Q acts as a nozzle that regulates the oil flow
80I back to the compressor.
80
80D
Select the nozzle size on the basis of table 4.
We recommend not to use a bigger nozzle
size than prescribed. In order to replace the
nozzle the compressor must first be depres-
B
80E
surized. Next, dismantle coil pos. 80J and
80G armature tube pos. 80P.
60 Nm 80F
The nozzle is screwed into the valve block
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. 3.
After the oil has been cleaned, it flows to the On mounting the coil keep it in place by
solenoid valve, which is always closed at using hand screw pos. 80N and O-ring pos.
compressor standstill. 80K and 80M.
Fig. 4
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
0178-910-EN 161
b: Float valve controlled oil return
Fig. 5
To the compressor
A D
As shown in fig. 5, the separated oil is The filter pos. D and the float valve can be
drained to the float valve pos. C while valves cleaned by dismantling the threaded nipple
pos. A and B are open. At a rising oil level on the stop valve housing and removing the
the float valve will open and lead the oil back cover on the float housing after the valves
to the compressor crankcase. pos. A and B are closed and the pressure in
the compressor equalized to atmospheric.
162 0178-910-EN
Connections on SMC 104-106-108 Mk3,
HPC 104S-106S-108S
X 1 AF, S
1
Z
· · S
2
2
· · AC
· ··
·
L
F · H, Q
· S
·
S
· ·
·
· ··
K
· ·
· ·
· J
· ·
P
·· ·
O
AM
· T
· · U
V
AB G N
E C D B A T0177087_0/V1
97.10
Air- Air-
Thread Oil, cooled cooled Ther- Booster
Pos. RG Pressure gas or Water- w/built-in mo- with Normal application
0171-414-EN
(Inch) liquid cooled oil cooler pump oil cooler

A 1 1/4 suction oil + + + + Heating rod
B 3/4 suction oil + + + + Oil charging valve
C 1/2 suction oil + + + + Oil temperature
D 1/2 suction oil plugged + plugged + Oil temperature
E 1/4 suction gas plugged plugged plugged plugged Available
F 1/4 oil oil + + + + Oil pressure to unloading cylinder
G 1/2-1/4 suction gas plugged + + + Return from built-in oil cooler *
H 1/4 discharge gas + + + + High pressure connection (HP)
J 1/4 suction gas + + + + Oil return from solenoid valves
K 1/4 oil oil + + + + Oil pressure to solenoid valves
L 1/4 suction gas + + + + Low pressure connection (LP)
N 1/4 suction gas + + + + Oil return from oil separator
O 1/2-1/4 oil oil + + + + Oil pressure connection
P 1/4 suction gas plugged + + plugged Return from built-in oil cooler/
equalization from thermopump *
Q 1/4 discharge gas plugged plugged + plugged Return from oil cooler
(thermopump cooled)*
S 1/4 discharge gas plugged plugged + plugged Refrigerant cooling to top covers *
T 1/4 discharge gas -- -- + -- Equalization to suction pressure end from
thermopump
U 1/4 discharge liquid -- -- + -- Liquid inlet to thermopump*
V 1/2-1/4 suction liquid plugged + + + Supply to built-in oil cooler*
X 1/2 discharge gas + + + + Discharge gas temperature
Z 3/4 discharge gas + + + + Purge valve
AB 1/4 oil oil + + + + Prelubrication of bearings
AF 1/4 discharge gas plugged + + + Return from oil cooler (booster) *
AC 1/2 suction gas Used in connection with UNISAB II Suction temperature (superheat temp.)
AM 1/4 oil oil plugged plugged plugged plugged Available
1 Suction stop valve * These connections are not applied on HPC compressors
2 Discharge stop valve
0178-910-EN 163
Connections on TSMC 108 Mk3
1 AC Y 1 S
AF
· Z 2 · Q
H M
S
· · ··
· L X ·
· · ·
AL
· S
· 4
· ·
·
· F · · · ·
· · ·
O K · ·
· · J · · P
·· ·
T
3
AM
· U
E C D B A
R AB G N
Thread Oil, Air-cooled Air-cooled Ther-

Pos. RG Pres- gas or Water- w/built-in mo- Normal application
(Inch) sure liquid cooled oil cooler pump
A 1 1/4 suction oil + + + Heating rod
B 3/4 suction oil + + + Oil charging valve
C 1/2 suction oil + + + Oil temperature
D 1/2 suction oil plugged + plugged Oil temperature
E 1/4 suction gas plugged plugged plugged Available
F 1/4 oil oil + + + Oil pressure to unloading cylinder
G 1/2-1/4 suction gas plugged + plugged Return from built-in oil cooler
H 1/4 high gas + + + High pressure connection (HP)
J 1/4 suction gas + + + Oil return from solenoid valves
K 1/4 oil oil + + + Oil pressure to solenoid valves
L 1/4 suction gas + + + Low pressure connection (LP)
M 1/4 suction gas + + + Intermediate pressure connection (IP)
N 1/4 suction gas + + + Oil return from oil separator
O 1/2-1/4 oil oil + + + Oil pressure to manometer and cut-outs
P 1/4 suction gas plugged + plugged Return from built-in oil cooler
Q 1/4 suction gas plugged plugged plugged Available
R 1/4 suction gas + + + Suction pressure to rear of unloading
cylinder
S 1/4 high gas plugged + + Refrigerant to HP top covers
T 1/4 suction gas -- -- + Equalization to suction pressure end from
thermo-pump
U 1/4 high liquid -- -- + Liquid supply from thermopump
V 1/2-1/4 suction liquid plugged + plugged Connection to built-in oil cooler
X 1/2 high gas + + + Discharge gas temperature
Y 1/2 interm. gas plugged plugged plugged Intermediate pressure temperature (IP)
Z 1/4 interm. gas + + + Purge valve
AB 1/4 oil oil + + + Prelubrication of bearings
AF 1/4 interm. gas plugged + + Return from built-in oil cooler (Booster)
AL 3/4 high gas + + + Purge valve
AC 1/2 suction gas Used in connection with UNISAB II Suction temperature
AM 1/4 oil oil plugged plugged plugged Available
1 Low pressure suction stop valve 3 Connection from intermediate pressure
2 Low pressure discharge stop valve 4 High pressure discharge stop valve
164 0178-910-EN
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
0178-910-EN 165
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.
166 0178-910-EN
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.
0178-910-EN 167
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
168 0178-910-EN
Water-cooling of reciprocating compressors
SMC 104-106-108 and TSMC 108
SMC 186-188 and TSMC 188
HPC 104 S-106 S and 108 S
The reciporcating compressor can be cooled sket. This will prevent water flowing into the
with water on the top and side covers, the compressor block.
cooling requirement being dependent on the
operating conditions and the refrigerant on Salt water-cooling
which the compressor operates. If it is expedient not to use fresh water for the
See page 1 for details. cooling of the top and side covers, salt water
dan be used to cool the side covers. The top
Water cooling is obtained by mounting an ex- covers must never be cooled with salt water
tra cover (water cover) Pos. 2B on the outsi- as the high temperature combined with the
de of top and side covers with an intervening salt water will corrode the covers in a short
seal Pos. 2D. period of time. For R717 compressors the top
99.11
covers may in some cases be cooled by me-

Tighten top and water covers with the bolts
ans of a thermal pump, see the diagram of
Pos. 2E, which are longer than the bolts for
0171-411-EN99
the operating range of the compressor in

the air-cooled version. See the Spare-parts
quistion.
list at the back of this instruction manual for
details. Fitting cooling water hoses
S When supplied, the compressor is not
For water cooling of the side covers, a spe-
fitted with cooling water hoses or any rele-
cial finned side cover Pos. 3A is used toget-
vant assembling parts. These are pro-
her with a water cover Pos. 3B and a seal
vided loose. This avoids damage to the
Pos. 3D. These are also listed in the spare-
parts in transit. Fit the cooling water hoses
parts list.
as shown in the following drawing, corre-
The water cover, together with the cover on sponding to the specification enclosed
which it is mounted, forms a channel system with the delivery.
in which the water is channelled back and
forth and effectively cools the top or side co- Please note:
ver. By virtue of their large surface area, the S The direction of water throughflow is
cooling fins on the interior of the side cover shown by arrows on the drawing.
Pos. 3A provide excellent cooling of the oil in
S The hose length is indicated opposite the
the crankcase.
respective Pos. nos. on the drawing.
When dismantling top or side covers with wa- S The hoses must not be in contact with the
ter covers, it is a good idea first to dismantle frame, covers, discharge pipe or similar
the topmost covers on the compressor. In components.
addition, you should ensure that the two co-
vers are kept tight against the intervening ga-
0178-910-EN 169
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
SMC 108
1
1 TSMC 108 SMC 188
HPC 108 TSMC 188
Pos Length Length
2 Nr. (mm) (mm)
1 300 325
3 *)2 790 1300
3
4 3 400 470
5 4 160 300
5 700 1100
SMC 106
HPC 106 SMC 186
1
6 Pos Length Length
Nr. (mm) (mm)
1 500 760
2
*)2 820 1300
3 3 325 525
3
4 4 150 300
5 5 670 1100
6 380 550
1 SMC 104
HPC 104
Pos Length
2 Nr. (mm)
3
1 610
3 *)2 750
4
3 370
5 4 160
5 670
Cooling of side covers only

SMC 104- SMC 186/
106-108 188
TSMC 108 TSMC 188
Pos Length Length
Nr. (mm) (mm)
1 300 400
2 1 3 2 200 300
3 800 1170
4
4 700 1100
*) To be secured to the vertical oil pipe using two pieces of plastic tape. T0177088_0/1
170 0178-910-EN
Necessary water consumption Max. permissible inlet temperature:
+40°C
To achieve satisfactory distribution of cooling
water and hence good compressor cooling, Min. permissible inlet temperature:
the following limit values should not be ex- +10°C
ceeded:
Max. permissible outlet temperature:
+55°C
Min. water through flow:
5.5 litres per hour per Kw motor output. Max. permissible temperature rise from
On water circulation plants, greater water inlet to outlet on the compressor:
throughflow is recommended. 15°C
0178-910-EN 171
Pressure loss in water cooling
on SMC/TSMC/HPC compressors
TSMC 108
Pressure loss SMC 108
p(mVS) HPC 108
SMC 106/HPC 106 SMC 104/HPC 104
4
SMC
112
T/SMC
116
3
2
SMC
186
T/SMC
1 188
100 500 1000 1500

Volumetric flow
V(l/hour)
T0177130_0
172 0178-910-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
0178-910-EN 173
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
174 0178-910-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.
0178-910-EN 175
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.
176 0178-910-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.
0178-910-EN 177
Oil cooling of SMC and TSMC-type reciprocating
compressors with an OSSI or HE8S oil cooler
Depending on the operating conditions and Fig. 1 T KP 77/UNISAB II

type of refrigerant, the SMC and TSMC com-
pressors can be designed with an oil cooling Oil separator
system. This includes a heat exchanger of
LT CT
the OSSI (R717) or HE8S (HCF/HCFC) type CT
built into the crankcase of the compressor.
In the heat exchanger (oil cooler), the refri-

80
gerant is expanded and cools the oil pumped
B
out by the oil pump into the oil system of the
Oil cooler
compressor. The oil cooler is mounted in- HE8S
stead of the oil pressure pipe Pos. 38. TX 2-0.5 (R22)
R22
SMC 100 compressor
The oil cooling system is controlled by a ther-
97.02
mostatic injection valve or expansion valve
as shown in the following drawings. A ther- Fig. 2 T KP 77/UNISAB II
mostat KP77 (or UNISAB II Control) ensures
0171-480-EN
Oil separator
that the oil cooling system is not activated
until the oil temperature in the crankcase ex- CT
MT HT
ceeds +55°C. LT MT
A valve block pos. 80 is built into the liquid

system.
80
S Connection, pos. B, pipe dimension OD
B
10 mm, emerges from receiver or priority
vessel and is conveyed to valve block pos. Oil cooler
HE8S TX 2-0.5 (R22)
80 which is the same type as the one de- R22
scribed in section entitled: Solenoid con- TSMC 100 compressor
trolled oil return of this instruction manual.

Before putting the oil system into operating
S The solenoid valve should always be
for the first time, the superheating of the TX
closed whenever the compressor is idle.
valve must be adjusted from 4K, which is the
Please note: factory setting, to 10K. This is achieved by
that nozzle size pos. 80I must be 3.3mm. rotating the spindle 1,5 turn clockwise
(1 revolution = 4K).
HFC and HCFC compressors:
S The SMC 180 and TSMC 180 have no
S On SMC 100 and TSMC 100 compres- built-in HE8S-type oil cooler.
sors, the oil cooling system is designed as
shown in fig. 1 and 2.
178 0178-910-EN
Cooling of the 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
Oil separator ·
cooling is done with the systems described
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-
quid stroke in the HP cylinders and result in
97.03
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.
0178-910-EN 179
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.
180 0178-910-EN
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.
0178-910-EN 181
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.
182 0178-910-EN
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 = 10.5 revolutions
10
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.
0178-910-EN 183
Ordering Spare Parts
When placing an order for spare parts, ber. If you are in any doubt, add the spare
please state the following: part no. too.
1. Shop No. 3. Forwarding instructions

All compressors are fitted with an identifica- When ordering spares, please advise the for-
tion plate, which states the type and shop no. warding address, and the address to which
of the compressor and indicates what refrig- the invoice should be sent. If appropriate,
erant is to be used. please state the name of your local bank, the
way in which you want the goods transported
2. Part No. and required delivery date.
Spare parts drawings and parts lists inserted
in an instruction manual identify spare parts 4. Classification certificate
94.05
with the following: If you require a certificate from a Classifica-
tion authority, please mark the order
a) Spare part no. -- which is a reference
appropriately, as the inspection and issuing
0171-466-EN
number to facilitate finding a part in the
procedures take extra time and incur extra
drawing and cross-referencing in the parts
expenses.
list or vice versa.
b) Designation of the part.
5. Quotation No.
c) Part no. -- a 7-digit number which refers to
If a quotation no. has been given during earli-
SABROE’s stores.
er correspondence, please refer to this when
When you order spare parts, please always placing your order -- it will help us to identify
advise at least the designation and part num- and execute your order quickly.
184 0178-910-EN
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.
0178-910-EN 185
00.10
Spare parts for SMC 104-106-108 & TSMC 108 Mk3

Type S-L and E
Relevant drawings for compressor SMC TSMC

SMC 100 Mk 3, S-L-E (delivered after 89.10) 0661-521 0661-522
Cylinder liner ect. SMC -- TSMC 104, 106, 108 Mk 3 (after 89.10) 0661-520
SMC 100 Mk 3 0661-755 0661-756
Cylinder liner ect. SMC -- TSMC 100 Mk3 0661-605
*) If the compressor runs as heat pump, this must be mentioned when ordering, to ensure a
correct delivery
Pos. Designation Weight Number each compressor Part no.

each in SMC SMC SMC TSMC
kg 104 106 108 108
Compressor frame
1A-1 Frame SMC 104 240.000 1 3111-065
1A-2 Frame SMC 106 274.000 1 3111-066
1A-3 Frame SMC 108 285.000 1 3111-067
1A-4 Frame TSMC 108 290.000 1 3111-068
1B-1 Oil level glass dia. 80 0.230 1 1 1 1 1226-015
1C-1 O-ring PRP 137 - 52,07 x 2,62 *) 0.002 1 1 1 1 1331-140
1D-1 Hexagon head M6 x 18 0.010 4 4 4 4 1424-148
Top cover - air cooled
2A-1 Top cover S-L 19.000 1 2 3 2 3113-191
2A-2 Top cover with flange S-L 20.500 1 1 1 2 3113-192
2A-3 Top cover E 19.000 1 2 3 2 3113-177
2A-4 Top cover with flange E 20.500 1 1 1 2 3113-176
2C-1 Gasket for top cover 0.020 2 3 4 4 2353-151
2E-1 Hexagon head M14 x 90 0.120 30 46 62 60 1424-083
2F-1 Hexagon head M14 x 120 0.165 2 2 2 4 1424-090
2G-1 Washer for M14 dia. 28/15 x 2,5 0.010 32 48 64 64 1436-076
WATER COVERS
2B-1 2B-2 2B-3 3B-1
SABROE SABROE SABROE
T0177125
0661-680-EN 1/20
each SMC SMC SMC TSMC
in kg 104 106 108 108
Top cover - water cooled
(see sketch below)
2A-1 Top covers S-L 19.000 1 2 3 2 3113-191
2A-2 Top cover with flange S-L 20.500 1 1 1 2 3113-192
2A-3 Top cover E 19.000 1 2 3 2 3113-177
2A-4 Top cover with flange E 20.500 1 1 1 2 3113-176
2B-1 Water cover for cover with flange 5.800 1 1 1 2 3113-195
2B-2 Water cover left 5.800 1 1 2 2 3113-193
2B-3 Water cover right 5.800 1 1 3113-194
2C-1 Gasket for top cover 0.020 2 3 4 4 2353-151
2D-1 Gasket for water cover pos. 2B-1 0.020 1 1 1 2 2353-176
2D-2 Gasket for water cover pos. 2B-2/2B-3 0.020 1 2 3 2 2353-175
2E-2 Hexagon head screw M14 x 110 0.150 30 46 62 60 1424-087
2F-1 Hexagon head screw M14 x 120 0.165 2 2 2 4 1424-090
2G-1 Washer for M14, dia. 28/15 x 2,5 0.010 32 48 64 64 1436-076
2H-1 Hexagon head screw M10 x 35 0.050 4 6 8 8 1424-193
2J-1 Washer for M10, dia. 21/10,5 x 2 0.008 4 6 8 8 1436-035
Side cover - air cooled
3A-1 Side cover 10.900 2 2 2 2 3113-148
3C-1 Gasket for side cover 0.020 2 2 2 2 2353-151
Side cover - water cooled
3A-2 Side cover 15.000 2 2 2 2 3113-140
3B-1 Water cover 5.800 2 2 2 2 3113-138
3C-1 Gasket for side cover 0.020 2 2 2 2 2353-151
3D-1 Gasket for water cover 0.020 2 2 2 2 2353-154
3F-1 Hexagon head screw M14 x 35 0.045 4 4 4 4 1424-240
3H-1 Hexagon head screw M12 x 40 0.050 2 2 2 2 1424-217
3J-1 Washer for M12, dia. 24/13 x 2,5 0.008 2 2 2 2 1436-036
End cover at pump end
4A-1 End cover 17.950 1 1 1 1 3113-028
4B-1 Gasket 0.020 1 1 1 1 2353-011
4C-1 Hexagon head screw M14 x 100 0.150 14 14 14 14 1424-085
4D-1 Washer for M14 dia. 28/15 x 2,5 0.010 14 14 14 14 1436-076
Bearing cover at pump end
5A-1 Bearing cover 9.100 1 1 1 1 3113-031
5B-1 Hexagon head screw M14 x 35 0.055 6 6 6 6 1424-240
5C-1 Bushing 1.200 1 1 1 1 2132-021
5C-2 Bushing for repair (0,5 mm undersize) 1.220 1 1 1 1 2132-022
2 0661-680-EN
in kg 104 106 108 108
5D-11 Gasket - 0,3 mm 0.005 1 1 1 1 2353-013
5D-2 Gasket - 0,5 mm 0.006 1 1 1 1 2353-100
5D-3 Gasket - 0,75 mm 0.010 1 1 1 1 2353-014
5D-4 Gasket - 1,0 mm 0.015 1 1 1 1 2353-015
Bearing cover at shaft seal end
6A-1 Bearing cover 23.000 1 1 1 1 3113-124
6B-1 Hexagon head screw M14 x 60 0.085 14 14 14 14 1424-245
6C-3 Bushing 1.200 1 1 1 1 2132-021
6C-4 Bushing for repair (0,5 mm undersize) 1.200 1 1 1 1 2132-022
6D-1 Gasket 0.020 1 1 1 1 2353-011
6E-1 Washer for M14, dia. 28/15 x 2,5 0.010 14 14 14 14 1436-076
6F Valve for prelubrication 1 1 1 1 2412-585
6G Nut 1 1 1 1 2313-045
6H Special joint 1 1 1 1 2334-027
6J Cap 1 1 1 1 2313-027
6K Joint 3/8” 1 1 1 1 1349-053
6L Alu gasket 1 1 1 1 2356-123
Shaft seal type SB100
Revision 1 for compressor nos. up to
98379
Spare parts kit: 1 1 1 1 3184-225
Consist of: -- see Revision 3
Revision 2 for compressor nos. after
98379 incl.
Spare parts kit: 1 1 1 1 3126-178
Consist of: 1 1 1 1
10E-2 Slide ring, steel
10F-1 Slide ring, carbon 1 1 1 1
10D-1 O-ring dia. 75,79 x 3,53 1 1 1 1
10G-2 Sealing ring 1 1 1 1
10J-1 Hex. socket screw M5 x 16 4 4 4 4
13 Allen key - NV 4 x 90 x 90 1 1 1 1
8B-1 Gasket for cover 1 1 1 1
Mounting instruction 0171-934
Revision 3
Spare parts kit: 1 1 1 1 3184-225
Consist of:
10E-1 Slide ring, steel 1 1 1 1
10F-1 Slide ring, carbon 1 1 1 1
10D-1 O-ring dia. 75,79 x 3,53 1 1 1 1
10G-1 O-ring dia. 82,14 x 3,53 1 1 1 1
10J-1 Hex. socket screw M5 x 16 4 4 4 4
0661-680-EN 3
in kg 104 106 108 108
13 Allen key - NV 4 x 90 x 90 1 1 1 1
8B-1 Gasket for cover 1 1 1 1
Mounting instruction 0171-930
Shaft seal complete: SMC/TSMC 1 1 1 1 3184-226
100
Consist of:
8A-2 Cover (SMC/TSMC 100) 1 1 1 1 3113-175
8B-1 Gasket for cover 1 1 1 1 2353-005
8C-1 Hex. head screw M10 x 40 - DIN 933 6 6 6 6 1424-194
Allen key - NV 4 x 90 x 90 1 1 1 1 1612-392
8D-1 Hose connection 1/4” 1 1 1 1 1345-143
8E-1 PVC hose 3/16” x 400 1241-190
8F-1 Spirolox ring dia. 76 1 1 1 1 1437-295
8G-1 Lock spring 1 1 1 1 3126-169
8H-1 Groover pin dia. 4 x 20 1 1 1 1 1446-081
10A-1 Retaining flange 1 1 1 1 3126-166
10B-1 Spring 10 10 10 10 2142-058
10D-1 O-ring dia. 75,79 x 3,53 1 1 1 1 1331-075
10E-2 Slide ring, steel 1 1 1 1 3126-167
10F-1 Slide ring, carbon 1 1 1 1 3126-168
10G-1 O-ring dia. 82,14 x 3,53 1 1 1 1 1331-077
10H-1 Locking ring 1 1 1 1 3126-153
10J-1 Hex. socket screw M5 x 16 4 4 4 4 1413-329
Oil pump
11-1 Oil pump complete 2.400 1 1 1 1 3141-004
Contains:
- Oil pump
11J - Lock nut, M10 x 10,7
11L- Washer for M10 dia. 21/10,5 x 2
11N - Key 5 x 5 x 12
11P - Gasket dia. 32/27 x 1,5
11S - Threaded nipple
11G-1 Gear whell for pump pinion 0.660 1 1 1 1 3141-046
11H-1 Gear wheel for crank shaft 0.530 1 1 1 1 3141-047
11M-1 Hexagon head screw M6 x 25 0.010 4 4 4 4 1424-153
11Q-1 Hexagon head screw M12 x 30 0.040 2 2 2 2 1424-215
11R-1 Spring washer dia. 12 0.002 2 2 2 2 1437-081
11T-1 Spring washer - dia. 11,1/6,1 x 1,6 0.005 4 4 4 4 1437-022
4 0661-680-EN
in kg 104 106 108 108
Unloading cylinder
12-1 Unloading cylinder 1.765 1 1 1 3135-149
Complete L=75, S=21,5
12-2 Unloading cylinder 1.790 1 1 1 1 3135-150
12-3 Unloading cylinder 1.815 1 1 1 3135-151
12-4 Unloading cylinder 1.840 1 1 3135-152
12-5 Unloading cylinder (HP) 1.800 1 3135-161
12A-1 Unloading cylinder 1.700 2 3 4 3 3135-147
(SMC and TSMC LP)
12A-2 Unloading cylinder 1.800 1 3135-148
(TSMC HP)
12B-1 Piston 0.220 2 3 4 4 3135-034
12C-1 Piston rod 75 mm (SMC only) 0.065 1 1 1 3135-041
12C-2 Piston rod 100 mm 0.090 1 1 1 1 3135-042
12C-3 Piston rod 125 mm 0.115 1 1 1 3135-043
12C-4 Piston rod 150 mm 0.140 1 1 3135-044
12C-5 Piston rod 82 mm, grounded 0.090 1 3135-140
(TSMC HP only)
12D-1 Threaded plug - 3/8” BSP 0.065 2 3 4 4 2314-025
12E-1 Gasket - dia. 25/17 x 1,5 0.002 2 3 4 4 2356-130
12F-1 Seeger ring dia. 52 0.008 2 3 4 3 1437-155
(SMC and TSMC LP)
12G-1 Spring guide 0.040 2 3 4 4 2145-004
12H-1 Spring retainer (SMC and TSMC LP) 0.110 2 3 4 3 3135-057
12J-1 Spring (outer) 0.065 2 2 4 4 2142-056
12J-2 Spring (inner) 0.035 2 3 4 4 2142-055
12K-1 Benzing ring - dia. 9 mm 0.002 2 3 4 4 1437-105
12K-2 Benzing ring - dia. 7 mm 0.001 2 3 4 3 1437-103
(SMC and TSMC LP)
12L-1 Hexagon head screw M10 x 30 0.030 8 12 16 16 1424-192
12M-1 Cover (TSMC HP only) 0.800 1 3135-105
12N-1 Gasket for cover (TSMC HP only) 0.010 1 2353-025
12P-1 Look nut - UNF 3/8” (TSMC HP only) 0.010 1 1433-100
12Q-1 Socket cap screw M4 x 16 0.010 6 1413-007
(TSMC HP only)
12R-1 O-ring PRP 112 12,37 x 2,62 0.001 1 1331-013
(TSMC HP only)*)
12S-1 Gasket 100 x 100 x 2 0.010 2 3 4 4 2354-023
Frame for unloading mechanism
Frame complete incl. pos. 13E-1 3184-216
13A-1 Suspension rod 0.290 2 3 4 4
0661-680-EN 5
in kg 104 106 108 108
13B-1 Suspension rod 0.290 2 3 4 4
13C-1 Cross piece 0.330 2 3 4 4
13D-1 Cross piece 0.330 2 3 4 4
13E-1 Countersunk screw M6 x 16 0.020 8 12 16 16 1413-092
Bracket for unloading mechanism
14A-1 Bracket with pin 0.065 4 6 8 7 3135-060
14B-1 Spacing ring 0.005 8 12 16 14 2124-003
14D-1 Spring washer - dia. 6 0.005 8 12 16 14 1437-022
Rocker for unloading mechanism
15A-1 Rocker 0.050 8 12 16 16 3135-096
15B-1 Bearing for SMC and TSMC LP 0.006 8 12 16 12 3135-099
15B-2 Bearing for TSMC HP 0.006 4 3135-101
15C-1 Spring retainer 0.001 8 12 16 16 2145-001
15D-1 Spring 0.007 8 12 16 16 2142-061
15E-1 Washer for bearing cup - 0,5 mm 0.001 2114-003
Crankshaft - all without certificate
16A-1 Crankshaft for SMC 104S, complete 42.400 1 3121-018
16A-2 Crankshaft for SMC 106S, complete 45.400 1 3121-019
16A-3 Crankshaft for SMC 108S 47.600 1 1 3121-020
and TSMC 108S, complete
16A-4 Crankshaft for SMC 104L, complete 45.600 1 3121-104
16A-5 Crankshaft for SMC 106L, complete 47.800 1 3121-105
16A-6 Crankshaft for SMC 108L 50.600 1 1 3121-106
and TSMC 108L, complete
16A-11 Crankshaft for SMC 104E, complete 1 3121-213
16A-12 Crankshaft for SMC 106E, complete 1 3121-214
16A-13 Crankshaft for SMC 108E 1 1 3121-215
and TSMC 108E, complete
16B-1 Plain washer with pin 0.800 1 1 1 1 2125-084
16C-1 Key - 18 x 11 x 55 0.080 1 1 1 1 2123-005
16D-1 Hexagon head screw M16 x 55 0.050 1 1 1 1 1424-104
16E-1 Spring washer - dia. 16 0.004 1 1 1 1 1437-027
16F-1 Plug M12 S-type 0.010 1 1 1 1 1413-260
16F-2 Plug 1/4” L-type 0.010 3 3 3 3 1343-141
Connecting rod
17-1 Connecting rod, complete 2.700 4 6 8 6 3123-004
SMC and TSMC LP
17-2 Connecting rod, complete 2.700 2 3123-006
TSMC HP
17A-1 Half-section of bearing 0.080 8 12 16 16 2133-003
17A-2 Half-section of bearing 0.080 8 12 16 16 2133-004
(0,5 mm undersize)
6 0661-680-EN
in kg 104 106 108 108
17B-1 Bushing for piston pin 0.200 4 6 8 6 2132-004
SMC and TSMC LP
17B-2 Needle roller bearing TSMC HP 0.200 2 1511-275
17C-1 Bolt for connecting rod 0.055 8 12 16 16 2111-068
17D-1 Lock nut - 3/8” UNF 0.010 8 12 16 16 1433-116
Piston with pin and rings
18-1 Piston with pin and rings S 1.320 4 6 8 8 3124-002
18-2 Piston with pin and rings L 1.320 4 6 8 8 3124-052
18-3 Piston with pin and rings E 1.320 4 6 8 8 3124-065
18A-1 Piston pin 0.500 4 6 8 8 3125-084
18B-1 Piston ring 0.025 8 12 16 16 3125-130
18C-1 Oil scraper rings 0.030 4 6 8 8 3125-065
18D-1 Seeger-ring - dia. 40 0.005 8 12 16 16 1437-150
(inside diameter)
0661-680-EN 7
in kg 104 106 108 108
Cylinder liner with sction valve
19-1 Cylinder liner with suction valve 4.100 4 6 8 6 3112-085
R717, SMC - TSMC LP, S and L
R717, SMC - TSMC LP, E
HFC/HCFC, SMC - TSMC LP, S and L
19-3 Cylinder liner with suction valve 4.100 2 3112-087
R717, SMC - TSMC HP, S and L
R717, SMC - TSMC HP, E
HFC/HCFC, TSMC HP, S and L
19A-1 Cylinder liner S and L 3.500 4 6 8 8 3112-065
19A-2 Cylinder liner, E 4.000 4 6 8 8 3112-080
19B-1 Unloading rings with pins, S and L 0.400 4 6 8 8 3135-054
19B-2 Unloading rings with pins, E 0.500 4 6 8 8 3135-173
19C-1 Washer - dia. 8/4,3 x 0,5 0.001 24 36 48 48 2114-001
19D-1 Spring for unloading ring 0.001 24 36 48 48 2142-034
19E-1 Tension spring - 342 mm 0.015 4 6 8 8 2142-048
19F-1 Ring plate for suction valve 0.035 4 6 8 8 3131-021
19G-1 Valve spring 0.001 24 36 48 48 2141-047
19H-1 Suction valve retaining plate R717 1.400 4 6 8 8 3132-083
19H-2 Suction valve retaining plate R12/R22 1.400 4 6 8 8 3132-084
19J-1 Guide ring for discharge valve 0.450 4 6 8 8 3134-008
19K-1 Gasket for cylinder liner - 0,5 mm 0.005 4 6 8 8 2356-111
19K-2 Gasket for cylinder liner - 0,8 mm 0.006 4 6 8 8 2356-233
19M-1 O-ring 107,55 x 3,53*) TSMC HP 0.002 2 1331-085
19N-1 Socket cap screw M6 x 30 0.010 24 36 48 48 1413-343
19T-1 Gasket - dia. 163/141 x 0,2 mm 0.001 4 6 8 8 2353-140
8 0661-680-EN
in kg 104 106 108 108
Discharge valve**)
20-1 Disharge valve - R717 - HP 1.200 4 6 8 2 3136-089
20-2 Disharge valve - R717 - LP 1.200 4 6 8 6 3136-087
20-3 Disharge valve - HFC/HCFC - HP 1.200 4 6 8 2 3136-088
20-4 Disharge valve - HFC/HCFC - LP 1.200 4 6 8 6 3136-086
20-5 Disharge valve - HFC/HCFC - VHP 1.200 4 6 8 3136-085
20A-1 Disharge valve seat 0.250 4 6 8 8 3133-027
20B-1 Retaining plate - R717 - HP 1.000 4 6 8 2 3132-092
20B-2 Retaining plate - R717 - LP 1.000 4 6 8 6 3132-090
20B-3 Retaining plate - HFC/HCFC - HP 1.000 4 6 8 2 3132-093
20B-4 Retaining plate - HFC/HCFC - LP 1.000 4 6 8 6 3132-091
20B-5 Retaining plate - HFC/HCFC - VHP 1.000 4 6 8 -- 3132-094
20C-1 Ring plate 0.030 4 6 8 8 3131-015
20D-1 Special screw M12 x 60 0.055 4 6 8 8 1413-121
20E-1 Nut M12 x 1,25 0.015 8 12 16 16 1432-075
20F-1 Spring guide 0.015 4 6 8 8 2145-008
20G-1 Valve spring - R717 - HP 0.001 32 48 64 16 2141-047
20G-1 Valve spring - R717 - LP 0.001 24 36 48 36 2141-047
20G-1 Valve spring - HFC/HCFC - HP 0.001 48 72 96 24 2141-047
20G-1 Valve spring - HFC/HCFC - LP 0.001 24 36 48 36 2141-047
20G-1 Valve spring - HFC/HCFC - VHP 0.001 64 96 128 2141-047
**) Compressors are fitted with disharge valves depending on the working conditions. The valve is se-
lected on the basis of the refrigerant and the condensing/intermediate pressure temperature of the
plant, indicated in the table in °C. For inst. R22 at TC=53°C=>VHP disharge valve.
Refri- Conditions Valve

gerant type
TC < 15°C LP
R717
TC ≥ 15°C HP
TC < 15°C LP
45°C R404A-R507
HFC/ 15°C ≤ TC < 50°C R22 HP
HCFC 70°C R134a
45°C R404A-R507
TC ≥ 50°C R22 VHP
70°C R134a
0661-680-EN 9
in kg 104 106 108 108
Spring for safety head
21-1 Spring 0.400 4 6 8 8 2142-060
Oil pressure valve
22A-1 Oil pressure valve, complete 0.450 1 1 1 1 3142-150
22B-1 Gasket 90 x 44 x 1 0.001 1 1 1 1 2354-075
Oil charging valve
23A-1 Oil charging valve, complete 0.300 1 1 1 1 2412-585
23B-1 Threaded reducing nipple 0.155 1 1 1 1 2311-059
23C-1 Socket 0.075 1 1 1 1 2313-035
23D-1 Gasket 0.001 1 1 1 1 2356-123
23E-1 Gasket 0.001 1 1 1 1 2356-140
23F-1 Gasket 0.001 1 1 1 1 2356-283
23G-1 Nut 0.060 1 1 1 1 2313-027
By-pass valves
24-1 By-pass valve dia. 20 22 bar 2.400 1 3137-033
TSMC 108 HP
TSMC 108 HP
TSMC 108 LP
24-5 By-pass valve dia. 28 22 bar 3.600 1 1 1 3137-007
SMC
24-7 By-pass valve dia. 28 24 bar 3.600 1 1 1 3137-009
SMC
24B-1 O-ring for cylinder *) 0.001 1 1331-065
24B-4 O-ring for cylinder *) 0.002 1 1 1 1 1331-067
24C-1 O-ring for cover *) 0.002 1 1331-069
24C-4 O-ring for cover *) 0.003 1 1 1 1 1331-071
24D-1 Hexagon head screw M8 x 25 0.015 4 4 4 8 1424-168
24E-1 Spring washer dia. 14,2/8,2 x 2 0.002 4 4 4 8 1437-023
10 0661-680-EN
Pos. Designation Weight Valve Number each compressor Part no.
in kg dim. 104 106 108 108
Stop valves
25-1 Complete valve, disharge HP 50 1 2414-073
25-2 Complete valve, inlet HP 50 1 2411-261
25-3 Complete valve, disharge LP 65 1 1 1 1 2414-069
25-4 Complete valve, inlet LP 100 1 1 1 1 2414-070
25A-1 Valve housing 50 1 2432-141
25A-2 Valve housing 50 1 2432-141
25A-3 Valve housing 65 1 1 1 1 2432-159
25A-4 Valve housing 100 1 1 1 1 2432-160
25B-1 Valve bonnet 1.740 50-65 1 1 1 3 2433-028
25B-4 Valve bonnet 4.500 100 1 1 1 1 2433-030
25C-1 Front part for cone 0.095 50-65 1 1 1 3 2444-090
25C-3 Front part for cone 0.520 100 1 1 1 1 2444-094
25D-1 Rear part for cone 0.185 50-65 1 1 1 3 2444-091
25D-4 Rear part for cone 1.000 100 1 1 1 1 2444-095
25E-1 Screw for valve cone 0.020 50-65 1 1 1 3 2444-017
25E-4 Screw for valve cone 0.120 100 1 1 1 1 2444-018
25F-1 Gasket for screw dia. 31/24 x 1,5 0.0001 50-65 1 1 1 3 2356-138
25F-4 Gasket for screw dia. 36/28 x 1,5 0.001 100 1 1 1 1 2356-141
25G-1 Threaded connection 0.180 50-65 1 1 1 3 2445-053
25G-4 Threaded connection 0.400 100 1 1 1 1 2445-061
25H-1 Sealing ring dia. 62/45 x 3 0.004 50-65 1 1 1 3 2354-003
25H-4 Sealing ring dia. 110/90 x 3 0.020 100 1 1 1 1 2354-117
25J-1 Gasket for bonnet dia. 72,39 x 5,33 0.010 50-65 1 1 1 3 1331-154
25J-4 Gasket for bonnet dia. 116,84 x 7 0.015 100 1 1 1 1 1331-198
25K-1 Spindle 0.250 50-65 1 1 1 3 2442-023
25K-4 Spindle 0.480 100 1 1 1 1 2442-028
25L-1 Lock washer for spindle 0.010 50-65 1 1 1 3 2445-019
25L-4 Lock washer for spindle 0.015 100 1 1 1 1 2445-020
25M-1 Packing gland 0.120 50-65 1 1 1 3 2452-073
Compl. with o-rings pos. 25R-1
25M-4 Packing gland 0.250 100 1 1 1 1 2452-004
Compl. with o-rings pos. 25R-4
25N-1 Guide pin 0.002 50-65 1 1 1 3 1445-085
25N-4 Guide pin 0.002 100 1 1 1 1 1445-085
25P-1 O-ring dia. 21,8 x 3,5*) 0.002 50-65 1 1 1 3 1331-020
25P-4 O-ring dia. 28,2 x 3,5*) 0.002 100 1 1 1 1 1331-024
25Q-1 Nylon washer dia. 28,5/28 x 1,5 0.001 50-65 1 1 1 3 2354-018
25Q-4 Nylon washer dia. 48/34 x 1,5 0.002 100 1 1 1 1 2354-017
0661-680-EN 11
Pos. Designation Weight Valve Number each compressor Part no.
in kg dim. 104 106 108 108
25R-1 O-ring dia. 17,12 x 3,5*) 0.001 50-65 2 2 2 2 1331-016
25R-4 O-ring dia. 21,8 x 3,5 0.002 100 2 2 2 2 1331-020
25S-1 Hand wheel dia. 120 0.160 50-65 1 1 1 3 1365-036
25S-4 Hand wheel dia. 180 0.800 100 1 1 1 1 1365-035
25T-1 Screw for hand wheel M5 x 10 0.002 50-65 1 1 1 3 1424-140
25T-4 Screw for hand wheel M8 x 16 0.010 100 1 1 1 1 1424-166
25U-1 Washer for hand wheel 0.001 50-65 1 1 1 3 1436-024
25U-4 Washer for hand wheel 0.003 100 1 1 1 1 1436-026
25Y-3 Gasket for welding nipple 0.015 50-65 1 1 1 1 2356-087
25Y-4 Gasket for welding nipple 0.025 100 1 1 1 1 2356-104
25Z-1 Screw valve/compr. M14 x 40 0.050 50 4 4 4 4 1424-241
25AC-3 Counter flange 65 1 1 1 1 2344-019
25AC-4 Counter flange 100 1 1 1 1 2344-020
25AD-3 Welding nipple dia. 65 65 1 1 1 1 2322-103
25AD-4 Welding nipple dia. 100 100 1 1 1 1 2322-108
25AF-3 Threaded plug 3/4” BSP 65 1 1 1 1 2314-065
25AF-4 Threaded plug 3/4” BSP 100 1 1 1 1 2314-065
25AG-1 Gasket for valve/compr. 0.016 50 1 2354-105
25AG-3 Gasket for valve/compr. 0.016 65 1 1 1 1 2354-105
25AG-4 Gasket for valve/compr. 0.020 100 1 1 1 1 2354-106
25AH-3 Gasket for plug 0.002 65 1 1 1 1 2356-139
25AH-4 Gasket for plug 0.002 100 1 1 1 1 2356-139
25AJ-1 Screw bonnet/valve M10 x 25 50 8 1424-191
25AJ-2 Screw bonnet/valve M10 x 25 50 8 1424-191
25AJ-3 Screw bonnet/valve M10 x 25 65 8 8 8 8 1424-191
25AJ-4 Screw bonnet/valve M12 x 30 0.040 100 8 8 8 8 1424-215
25AK-3 Screw for counter flange M10 x 40 0.030 65 6 6 6 6 1424-194
25AK-4 Screw for counter flange M12 x 50 0.050 100 6 6 6 6 1424-219
12 0661-680-EN
in kg 104 106 108 108
Pressure gauges
Suction and pressure gauge
30A-1 R717 1.640 1 1 1 1 1541-108
30A-2 R12, R22 and R502 1.620 1 1 1 1 1541-232
30A-3 R22, R134a and R404A 1.620 1 1 1 1 1541-074
30B-1 Nozzle and gasket dia. 14/0,8 x 1,5 0.001 1 1 1 1 3146-013
30C-1 Gasket dia. 11/4 x 1,5 0.001 1 1 1 1 2356-119
SMC: discharge pressure gauge
31A-1 R717 1.380 1 1 1 1541-029
31A-2 R12, R22 and R502 1.400 1 1 1 1541-160
31A-3 R22, R134a and R404A 1.400 1 1 1 1541-075
31B-1 Nozzle and gasket dia. 14/0,8 x 1,5 0.001 1 1 1 3146-013
TSMC: disharge pressure gauge
31A-3 R717 1.600 1 1541-101
31A-4 R12, R22 and R502 1.660 1 1541-161
31A-5 R22, R134a and R404A 1.660 1 1541-076
31B-1 Nozzle and gasket dia. 14/0,8 x 1,5 0.001 2 3146-013
31C-1 Screws for gauges M4 x 20 6 6 6 6 1412-350
Oil filter
33-1 Oil filter complete (33A,33B.33L,33M) 1 1 1 1 3084-539
33A-1 Filter element 1 1 1 1 1517-129
33B-1 Gasket 1 1 1 1 2356-202
33F-1 Bracket with connection 1 1 1 1 3422-152
33L-1 Washer dia. 17/8,4 1 1 1 1 1436-034
33M-1 Nut M8 1 1 1 1 1433-073
33R-1 Cutting ring joint 1 1 1 1 1349-131
Suction filter
34A-1 Suction filter open, complete 0.365 2 2 2 1 3425-082
34A-2 Suction filter closed, complete 0.365 1 3425-084
34B-1 Filter bag 0.035 2 2 2 2 3425-083
34C-1 Inset for filter bag 0.025 2 2 2 2 3424-058
34D-1 O-ring PRP 337 - 75,56 x 5,33 *) 0.008 2 2 2 3 1331-042
34E-1 Cover for suction filter 2.400 2 2 2 1 3422-103
34F-1 O-ring PRP 239 - 91,67 x 3,53 *) 0.003 2 2 2 1 1331-080
34G-1 Hexagon head screw M12 x 40 0.050 8 8 8 4 1424-217
34H-1 Spring washer dia. 12 0.005 8 8 8 4 1437-026
Discharge pipe for oil filter
38A-1 Discharge pipe for oil pump 0.500 1 1 1 1 3141-110
38B-1 Inside pipe connection to control 0.090 1 1 1 1 3141-162
system (compr. without oil cooler)
0661-680-EN 13
in kg 104 106 108 108
system (compr. with OSSI oil cooler
R717)
system (compr. with HE8 oil cooler
HCFC)
38C-1 Connection for disharge pipe - 0.120 1 2333-025
SMC 104
38C-2 Connection for disharge pipe - 0.190 1 2333-025
SMC 106
38C-3 Connection for disharge pipe - 0.180 1 1 2333-026
SMC 108 and TSMC 108
38D-1 O-ring PRP 212 - 21,80 x 3,53*) 0.002 2 2 2 2 1331-020
38E-1 O-ring PRP 321 - 29,51 x 5,33*) 0.004 1 1 1 1 1331-039
38F-1 Gasket dia. 27/21 x 1,5 0.001 1 1 1 1 2356-133
38G-1 O-ring dia. 26,58 x 3,5*) 0.002 1 1 1 1 1331-023
Analogous control and safety
equipment
39A-1 Gauge panel 0.070 1 1 1 1 3146-042
39B-1 Socket cap screw M10 x 60 0.045 2 2 2 2 1413-382
39C-1 Console 1 1 1 1 2213-142
39D-1 Bar for controls (4 controls) 1 1 1 2213-143
39D-2 Bar for controls (5 controls) 1 1 1 1 2213-144
39D-5 Bar for controls (US, SMC) 1 1 1 2213-368
39D-6 Bar for controls (US, TSMC) 1 2213-369
39E-1 Hexagon head screw M6 x 12 2 2 2 2 1424-150
39F-1 Spring washer dia. 11/6 2 2 2 2 1437-022
39G-1 Socket cap screw M4 x 6 1412-200
39H-1 Spring washer dia. 7/4 1437-020
39J-1 Socket cap screw M5 x 10 4 4 4 4 1413-330
39K-1 Spring washer dia. 9/5 4 4 4 4 1437-021
Cooling water connection
See section: Water cooling of
reciprocating compressor
40A-1 Set of hoses for cooling water 1 3185-230
SMC 104
40A-2 Set of hoses for cooling water SMC 1 3185-231
106
40A-3 Set of hoses for cooling water 1 1 3185-232
SMC 108 and TSMC 108
40A-4 SMC 108 for SIDE COVER only 3185-235
14 0661-680-EN
in kg 104 106 108 108
Purge valve
42A-1 Purge valve 0.300 1 1 1 2 2412-585
42B-1 Threaded nipple 1 1 1 1 1349-078
42C-1 Cutting ring 0.135 1 1 1 2 1349-062
42D-1 Nut
42E-1 Nut 0.070 1 1 1 2 2313-045
42F-1 Connection pipe with collar 0.025 1 1 1 2 2334-027
42G-1 Gasket 0.001 2 2 2 4 2356-123
42H-1 Nut 0.060 1 1 1 2 2313-027
Pressure and temperature controls
Pressure controls for R717
45A-1 KP 5A 0.300 1 1 1 1 1373-125
45B-1 KP 15A 0.460 1 1 1 1 1373-142
45C-1 MP 55A 0.900 1 1 1 1 1373-162
42F-1 Connection pipe with collar 0.025 1 1 1 1 2334-027
42G-1 Gasket 0.001 2 2 2 2 2356-123
42H-1 Nut 0.060 1 1 1 1 2313-027
Pressure controls for R22, R134a
and R404A
45D-1 KP 5 0.300 1 1 1 1 1373-123
45E-1 KP 15 0.460 1 1 1 1 1373-135
45F-1 MP 55 0.800 1 1 1 1 1373-159
Temperature controls:
45G-1 KP 98 0.720 1 1 1 1 1373-043
45H-1 KP 77 0.350 1 1 1 1 1373-044
45J-1 Phail pocket for temperature controls 0.770 1 1 1 1 1377-171
45K-1 Gasket 1 1 1 1 2356-133
0661-680-EN 15
in kg 104 106 108 108
AMR 312 S coupling
48A-4 Disc pack 1.132 2 2 2 2 1524-157
48B-4 Bolt 0.054 16 16 16 16 1524-165
48C-4 Bevel washer 0.010 4 4 4 4 1524-187
48D-4 Lock nut 0.018 16 16 16 16 1524-173
48E-4 Washer 0.008 16 16 16 16 1524-181
Capacity regulation
50A-1 Valve body with 1 solenoid valve 1 3143-383
without coil
50A-2 Valve body with 2 solenoid valves 1 1 3143-384
without coils
50A-3 Valve body with 3 solenoid valves 1 3143-385
without coils
50A-4 Valve body with 4 solenoid valves 1 3143-386
without coils
50B-1 Coil 220/230V, 50/60 Hz, 10 W 0.260 1372-537
50B-2 Coil 110V, 50/60 Hz, 10 W 0.260 1372-538
50B-3 Coil 240V, 50 Hz, 10 W 0.062 1372-539
50C Solenoid valve 1372-424
(service kit for one solenoid valve)
Crankcase heater
57A-1 Crankcase heater - 270 W - 115 V, 1 1 1 1 3181-034
1 1/4” BSP
1 1/4” BSP
1 1/4” BSP
57B-1 Sealing ring dia. 42/49 x 6,5 0,022 1 1 1 1 1349-213
80 Solenoide valve blok, complete with 2.040 1 1 1 1 or 2 1372-179
0,6 mm orifice for oil return. excl. coil
Strainer kit consist of: 1 1 1 1 or 2 1372-089
80E Strainer
80G Al-gasket
Service kit consist of: 1 1 1 1 or 2 1372-086
80P Armature tube
80H Armature
80K O-ring
80M O-ring
80L Al-gasket
80N Snap fastener
Seal kit consist of: 1 1 1 1 or 2 1372-091
80G Al-gasket
80K O-ring
16 0661-680-EN
in kg 104 106 108 108
80M O-ring
80L Al-gasket
80Q Al-gasket
Orifice kit 0,6 mm consist of: 1 1 1 1 or 2 1371-034
80L Al-gasket
80Q Al-gasket
80I Orifice 0,6 mm
80L Al-gasket
80Q Al-gasket
80I Orifice 0,8 mm
80L Al-gasket
80Q Al-gasket
80I Orifice 1,0 mm
Orifice kit 3,3 mm 1 1 1 1 or 2 1371-037
(for thermopump only) consist of:
80L Al-gasket
80Q Al-gasket
80I Orifice 3,3 mm
80J-1 Coil 220/230V, 50/60 Hz, 10 W 0.285 1372-537
80J-2 Coil 110 V, 50/60 Hz, 10 W 0.285 1372-538
80J-3 Coil 240 V, 50 Hz, 10 W 0.285 1372-539
80J-4 Coil 24 V, 50 Hz, 10 W 0.285 1372-541
Intermediate pressure connections
90A-1 Mixing chamber with flange 9.500 1 3114-095
90B-1 Counter flange for mixing chamber 1.700 1 3115-084
90C-1 Intermediate ring 0.392 1 3422-100
90D-1 O-ring PRP 236 - 82,15 3,53 *) 0.002 1 1331-077
90E-1 O-ring PRP 241 - 98,02 x 3,5 *) 0.002 1 1331-081
90F-1 Hexagon head screw M12 x 65 0.065 4 1424-222
90G-1 Hexagon head screw M14 x 55 0.065 4 1424-246
90H-1 Spring washer dia. 12 0.005 4 1437-026
90J-1 Spring washer dia. 14 0.004 4 1437-030
90K-1 Nut M14 0.025 4 1432-066
90L-1 O-ring PRP 239 - 91,67 x 3,53 *) 0.003 1 1331-080
90M-1 Cap 0.065 1 2313-027
90N-1 Gasket dia. 18/10 x 1,5 0.002 1 2356-123
Oil cooling - type HE8 S for R22
92A-1 Oil cooler 1 1 1 1 4242-038
92B-1 Stop valve BMSL 10 0.300 1 1 1 1 1374-171
0661-680-EN 17
in kg 104 106 108 108
92C-1 Thermostatic expansion valve TX 2 - 0.400 1 1 1 1 1371-305
0,5
92D-1 Solenoid valve without coil 0.346 1 1 1 1 1372-422
92N-1 Coil 220/230V, 50/60 Hz, 10 W 0.260 1372-537
92N-2 Coil 110V, 50/60 Hz, 10 W 0.260 1372-538
92N-3 Coil 240V, 50 Hz, 10 W 0.260 1372-539
92E-1 Filter 0.320 1 1 1 1 4522-002
92F-1 Screwed connection GE 10-LR 1/4” 0.050 6 6 6 6 1349-051
92G-1 Single banjo connector DSVW 10-LR 0.160 1 1 1 1 1349-089
92H-1 Threaded nipple 0.110 1 1 1 1 2314-056
92J-1 Threaded plug for 8/6 mm pipe 0.015 2 2 2 2 2314-053
92K-1 Gasket dia. 19/14 x 1,5 - aluminium 0.001 8 8 8 8 2356-124
92L-1 Connection piece for 1 pipe dia. 8 mm 0.030 2 2 2 2 2333-021
92M-1 Gasket - dia. 27/21 x 1,5 - aluminium 0.001 3 3 3 3 2356-133
Oil cooling - type OOSI for R717
93A-1 Oil cooler 1 1 1 1 4242-029
93B-1 Stop valve SN 6 1 1 1 1 2413-010
93C-1 Thermostatic injection TEAT 20-2 0.400 1 1 1 1 1371-240
93D-1 Solenoid valve without coil 0.346 1 1 1 1 1372-422
93N-1 Coil 220/230V, 50/60 Hz, 10 W 0.260 1372-537
93N-2 coil 110V, 50/60 Hz, 10 W 0.260 1372-538
93N-3 Coil 240V, 50 Hz, 10 W 0.260 1372-539
93E-1 Filter 0.320 1 1 1 1 4522-002
93F-1 Screwed connection GE 10-LR 1/4” 0.050 6 6 6 6 1349-051
93G-1 Single banjo connector DSVW 10-LR 0.160 1 1 1 1 1349-089
93H-1 Threaded nipple 0.110 1 1 1 1 2314-056
93J-1 Threaded plug for dia. 8/6 mm pipe 0.015 4 4 4 4 2314-053
93K-1 Gasket dia. 19/14 x 1,5 - alunimium 0.001 8 8 8 8 2356-124
93L-1 Connection piece for 1 pipe dia. 8 mm 0.030 4 4 4 4 2333-021
93M-1 Gasket dia. 27/21 x 1,5 - aluminium 0.001 3 3 3 3 2356-133
Chain drive for oil pump
Chain drive complete 3141--127
96A-1 Hub for chain wheel (chranshaft) 1 1 1 1 2126-020
96B-1 Hub for chain wheel (oil pump) 1 1 1 1 2126-019
96C-1 Chain wheel (crankshaft) 1 1 1 1 2126-018
96D-1 Chain wheel (oil pump) 1 1 1 1 2126-017
96E-1 Chain 1 1 1 1 1521-102
96F-1 Hexagon head screw 5 5 5 5 1424-150
96G-1 Spring washer 5 5 5 5 1437-022
96H-1 Shield for oil 1 1 1 1 3141-128
18 0661-680-EN
in kg 104 106 108 108
98 Thermo pump
98A-1 Side cover for thermo pump 1 1 1 1 3113-145
98B-1 Monitor box 1 1 1 1 1553-215
Allen screw M4 x 16 2 2 2 2 1412-204
Spring washer dia. 4 2 2 2 2 1437-020
98C-1 Level indicator 2 2 2 2 3185-038
98D-1 Outer part for level indicator 2 2 2 2 3185-034
98E-1 Washer dia. 20/13 x 1,5 2 2 2 2 2356-125
98F-1 Rubber cap 2 2 2 2 1554-194
98G-1 Solenoid valve without coil 1 1 1 1 1372-422
98H-1 Solenoid valve without coil 1 1 1 1 1372-423
98J-1 Coil 220/230V, 50/60 Hz, 10 W 0.285 1372-537
98J-2 Coil 110V, 50/60 Hz, 10 W 0.285 1372-538
98J-3 Coil 240V, 50 Hz, 10 W 0.285 1372-539
98K-1 Check valve 2 2 2 2 1364-008
Straight joint 10 mm BSP 6 6 8 5 1349-051
Socket 10 mm BSP 5 5 4 4 1349-101
T-joint 10 mm 3 4 5 1 1349-041
Strap for stop valve 1 1 1 1 2212-059
Cable binder no. 10 1 1 1 1 1554-054
Allen screw M4 x 12 2 2 2 2 1412-203
Nut M4 2 2 2 2 1432-035
98L-1 Washer dia. 29/21 x 1,5 2 2 2 2 2356-136
98M-1 VA-joint with nozzle 1,2 mm 3 4 5 2314-097
98M-2 VA-joint with nozzle 0,6 mm 1 2314-100
Angle joint 3 3 2 1 1349-033
Angle swivel joint 8 mm 4 4 4 1349-087
Angle swivel joint 10 mm 3 3 2 1 1349-089
Angle joint 10 mm 1 1349-112
Bushing 1/4” x 1/2” RG 2 1 1 2312-013
Threaded nipple 1 1 2314-056
Gasket dia. 27/21 x 1,5 Al 2 2 2 2356-133
Gasket dia. 19/14 x 4 Al 3 3 3 1 2356-283
Pipe strap dia. 10 x 15 2 1 1377-117
Hexagon set screw M6 x 12 1 1424-150
Nut M6 1 1432-061
Allen screw M5 x 10 1 1413-330
Washer dia. 12,5/6,4 x 1,6 2 1436-033
Spring washer for M6 1 1437-021
98N-1 Filter 1 1 1 1 4522-002
98P-1 Stop valve 1 1 1 1 2412-277
0661-680-EN 19
in kg 104 106 108 108
98Q-1 Cooling cover 1 1 1 1 3113-143
98R-1 Gasket for side cover 1 1 1 1 2353-151
98S-1 Hexagon head screw M14 x 80 16 16 16 16 1424-081
98T-1 Oil cooler OSSI 1 1 1 1 4242-029
Socket 1/4” 1 1 1 1 1349-101
98U Solenoid valve without coil 1 1 1 1372-422
98V Solenoid valve without coil 1 1 1 1 1372-422
98AB-1 Coil 220/230V, 50/60 Hz, 10 W 0.285 1372-537
98AB-2 Coil 110V, 50/60 Hz, 10 W 0.285 1372-538
98AB-3 Coil 240V, 50 Hz, 10 W 0.285 1372-539
98X PT100 sensor 1 1 1 1 1373-253
98Y Stop valve 1 1 1 1 2412-277
98Z Non-return valve 1 1 1 1 1364-022
98AA Screw joint 1 1 1 1 2314-105
UNISAB
99A-1 Support for UNISAB 1 1 1 1 2213-500
99B-3 Distance washers 4 4 4 4 2212-130
99C-1 Screw for support M10 x 20 2 2 2 2 1424-190
99D-1 Screw for UNISAB M6 x 20 4 4 4 4 1424-152
99E-1 Washers dia. 22/7 x 1,5 4 4 4 4 1436-025
20 0661-680-EN
00.10
Spare parts set for compressor

SMC 104-106-108 & TSMC 108 Mk 3
Type S-L-E
Line no. A501 = Normal Set

Line no. A502 = Extended Set
Line no. A503 = Certificate Set
Line no. A504 = Special Set
Pos. Spare parts set line no.

No. Designation Part No.
A501 A502 A503 A504
1B - 1 Oil level glass dia. 80 1226-015 1
1C - 1 O-ring - dia. 52,07x2,62 no. 137 1331-140 2 2
2C - 1 gasket for top cover 2353-151 2 4 4 6
2F - 1 hexagon-head screw M14x120 8,8 DIN 931 1424-090 2
3H - 1 hexagon-head screw M12x 40 8,8 DIN 933 1424-217 2
4B - 1 gasket for end cover at oil pump 2353-011 1 1 1 2
4C - 1 hexagon-head screw M14x100 8,8 DIN 931 1424-085 2
5B - 1 hexagon-head screw M14x 35 8,8 DIN 933 1424-240 2
5C - 1 bearing bushing 2132-021 2
6B - 1 hexagon-head screw M13x 60 8,8 DIN 933 1424-245 2
8B - 1 gasket for cover for shaft seal 2353-005 1 1 1 2
8C - 1 hexagon-head screw M10x 35 8,8 DIN 933 1424-193 4
10 - 1 shaft seal (spare parts set) 3126-178 1 1 4 2
11P - 1 gasket - dia. 32/27x1,5 mm 2356-139 2 2 2
12K - 1 Benzing-ring - dia. 9 mm 1437-105 4
12K - 2 Benzing-ring - dia. 7 mm 1437-103 4 4 4
12S - 1 gasket for unloading cylinder 100x100x2 2354-023 4 4
13E - 1 countersunk screw M 6x16 1413-092 2
15D - 1 spring for unloading mechanism 2142-061 2 4 8
17 - 1 connecting rod complete 3123-004 1
17A - 1 half-section of bearing 2133-003 4 16
17B - 1 bushing for piston pin 2132-004 4
18 - 1 piston with pin and rings 1 1 2
0661-682-EN 1/4
A501 A502 A503 A504
18A - 1 piston pin 3125-084 4
18B - 1 piston ring 3125-130 4 4 4 12
18C - 1 oil scraper rings 3125-065 2 2 2 6
19 - 1 cylinder liner with suction valve 1 1 2
19F - 1 ring plate for suction valve 3131-021 4 8 8 8
19G - 1 valve spring 2141-047 30 60 60 90
19K - 1 gasket for cylinder liner - 0,5 mm 2356-111 2 4 8 8
19K - 2 gasket for cylinder liner - 0,8 mm 2356-233 2 4 4 8
19N - 1 socket cap screw M 6x30 8,8 DIN 912 1413-343 6
20 - 1 discharge valve 1 1 2
20C - 1 ring plates for discharge valve 3131-015 4 8 8 8
20D - 1 countersunk screw M12x60 1413-121 2
20E - 1 nut M12x1,25 1432-075 2
22G -1 gasket for oil pressure valve 2354-075 1 1 2
22H - 1 hexagon-head screw M12x35 8,8 DIN 933 1424-216 2
24A - 1 spring for safety valve (SMC TSMC LP) 2 1
24G - 1 hexagon-head screw M 8x25 8,8 DIN 933 1424-168 2
25H -1 sealing ring (only for SMC dia. 62/45x3) 2354-003 1 1 2
25H -4 sealing ring 110/91x3 2354-117 1 1 2
25J - 1 O-ring dia. 72.39x5.33 1331-154 1 1 2
25J - 4 O-ring dia. 116.84x7.0 1331-198 1 1 1
25K - 1 spindle for discharge stop valve 2442-023 1
25K - 4 spindle for suction stop valve 2442-028 1
25P - 1 O-ring dia. 21.8x3.53 No.212 1331-020 4 8 8
25P - 4 O-ring dia. 28.1x3.6 No.216 1331-024 1 2 2
25R - 1 O-ring dia. 17.12x2.6 1331-016 2 4 4
25Z - 1 hexagon-head screw M14x45 8,8 DIN 933 1424-242 2
25Z - 4 hexagon-head screw M16x45 8,8 DIN 931 1424-102 2
2 0661-682-EN
A501 A502 A503 A504
25AG--3 gasket for stop valve 2354-105 1 2 2 2
25AG-4 gasket for stop valve 2354-106 1 2 2 2
30 - 1 suction and oil pressure gauge 1 1
31 - 1 discharge pressure gauge 1 1
33A - 1 filter cartridge 1517-129 1 1 2 1
33B - 1 gasket 2356-202 1 1 2 1
34B - 1 filter bag 3425-083 2 4 2
34D - 1 O-ring dia. 75.56x5.33 1331-042 2 2 2 2
34F - 1 O-ring dia. 91.67x3.53 No. 239 1331-080 2 2 2 2
38E - 1 O-ring dia. 29.51x5.33 No. 321 1331-039 1 2 2
38F - 1 gasket dia.27/21x1.5 mm 2356-133 2 2 2
38P - 1 O-ring dia. 26.58x3.55 1331-023 1 2 2
50 - 1 coil for solenoid valve 1 1
for TSMC compressor further:
2D gasket for water cover (TSMC) 2353-176 1 2 2 2(1)
17 - 2 connecting rod complete (TSMC HP) 3123-006 1
17B - 2 needle roller bearing (TSMC HP) 1511-275 2
19M -1 O-ring for cylinder liner 1331-085 2 2 4 4
24A - 2 spring for safety valve (TSMC HP) 2 1
25H - 1 sealing ring 62/45x3 2354-003 1 3 2
90D - 1 O-ring dia. 82.15X3.5 1331-077 1 1 1 1
90E - 1 O-ring dia. 98.02X3.5 1331-081 1 1 1 1
for water cooled compressors, further:
2D gasket for water cover, R/L 2353-175 1 2 2 2(3)
2D gasket for water cover, top-side 2353-154 1 1 1 2
2E - 2 hexagon-head screw M14x110 8.8 DIN 931 1424-087 16
3E - 2 hexagon-head screw M14x 55 8.8 DIN 933 1424-244 6
3F -12 hexagon-head screw M14x 35 8.8 DIN 933 1424-240 2
0661-682-EN 3/4
A501 A502 A503 A504
for air cooled compressors, further:
for belt-driven compressors, further:
V-belts 1 set 1 set
for direckt driven compressors, further:
AMR coupling set 1524-152 1 set 1 set
The No. depends on the compressor to which the spare parts set belongs.
4 0661-682-EN
1
0661-666-EN
Spare parts survey

for
thermo-pump SMC 104-106-108 & TSMC 108
Pos. Designation Weight SMC SMC SMC TSMC Part

no. in kg. 104 106 108 108 no.
98A side cover for thermo-pump 13.800 1 1 1 1 3113-145
98B monitor box 0.960 1 1 1 1 1553-031
98C level indicator complete 0.100 2 2 2 2 3185-038
98D outlet part of level indicator 0.520 2 2 2 2 3185-034
98E gasket dia. 20/13x1,5 0.001 2 2 2 2 2356-125
98F rubber cap 0.007 2 2 2 2 1554-194
98G solenoid valve whitout coil 1 1 1 1 1372-453
98H solenoid valve whitout coil 1 1 1 1 1372-358
98J-1 coil 14W, 115V, 60Hz 0.130 2 2 2 3 1372-055
98J-2 coil 14W, 220V, 50Hz 0.130 2 2 2 3 1372-056
98J-3 coil 14W, 240V, 50Hz 0.130 2 2 2 3 1372-319
98J-4 coil 14W, 220V, 60Hz 0.130 2 2 2 3 1372-059
98K non-return valve 0.2 bar 2 2 2 2 1364-008
98L solenoid valve whitout coil 1 1 1 1372-453
98M nozzle 3 4 5 1 2314-097
98N filter 1 1 1 1 4522-002
98P stop valve 0.600 1 1 1 1 2413-118
98Q intermeadiate cover 12.500 1 1 1 1 3113-143
98T oil cooler OOSI 1 1 1 4242-029
98U O-ring for oil cooler 1 1 1 1331-020
dia. 21.8x3.53
98V nylon ring for level indicator 0.003 2 2 2 2 2353-152
98X O-ring for level indicator 0.001 12 12 12 12 1331-011
dia. 9,2x2.62
98Y gasket for side cover 2 2 2 2 2353-151
98Z hexagon-head screw M14x80 0.080 16 16 16 16 1424-081
98AC gasket dia. 19/14x1.5 0.001 4 6 8 2356-125
98AE gasket dia. 27/21x1.5 0.001 2 2 2 2 2356-136
98.11
Tools for compressor

SMC 104-116 Mk3 & TSMC 108-116 Mk3 - Type S-L-E
14
4
3 6
13
11
21
9
5 17
2
19
10 16
8 22
15
1 20
7
T0177095_0/1,2
0661-684-EN 1/3
Tools set for compressor
SMC 104-116 Mk3 & TSMC 108-116 Mk3 - type S-L-E
Line no. A600 = Normal set, tools set no 3183-109
Line no. A601 = Extended set, tools set no 3183-110
Line no. A602A = Tools for coupling (SMC 104-108)
Line no. A602B = Tools for coupling (SMC 112-116)
Line no. A603 = Tools for alignment of coupling
Line No.
Pos.
No. Designation Dimension Part No. A600 A601 A602 A603
A B
1-1 Clamp with screw, compr. type S and L 3183-144 4 4
1-2 Clamp with screw, compr. type E 3183-145 4 4
2 Tools for shaft seal 3183-139 1 1
3 Tommy screw for cylinder liner 3183-041 2 2
4 Theaded plug for unloading cylinder 3/8” BSP 2314-017 2 2
5 Supporting plate for pistons 3183-115 8 8
6 Spanner for heating cartridge NV 55 3183-060 1 1
7 Trigger for coupling or belt pulley 3183-059 1 1
8 Adjusting jig for coupling 3183-105 1
9-1 Wrench for cylinder screw NV 4 1
9-5 Special wrench for shaft seal NV 4 1612-392 1 1
10-1 Retaining-ring plier J 21/G 1
10-2 Retaining-ring plier A 11/G 1
11-1 Open end and ring spanner NV 10 1
2 0661-684-EN
Line No.
Pos.
No. Designation Dimension Part No. A600 A601 A602 A603
A B
13-1 Socket wrench NV 10 1
13-6 Socket wrench NV 24 1 1 1
13-10 Socket wrench NV 9/16” 1
13-11 Socket wrench NV 3/4” 1 1
13-12 Socket wrench NV 11/16” 1 1
14 Ratchet handle 1
15 Speed handle 1
16 Universal joint for socket wrench 1
17-1 Extension rod for socket wrench 1
17-2 Extension rod for socket wrench 1
19-1 Torque wrench 15-90 Nm 1
19-2 Torque wrench 40-200 Nm 1 1 1
20 Coupler for torque wrench 1/2 2 1 1
21-1 Open spanner for torque wrench NV 11/16” 1 1
21-2 Open spanner for torque wrench NV 3/4” 1 1
22 Feeler gauge 1
0661-684-EN 3/3
TSK
TSK
T Series Couplings
A – Stainless Steel
Flexible Membranes
B – Overload Collars
C – Cartridge
Transmission Unit
D – Anti-Fly Feature
E – Anti-Corrosion
Treatment A
F – Hubs with B
Puller Holes
G – Robust Hub Bolts G
C
D
Product Description Design Features

®
Metastream T Series Couplings, pioneered by John ■ Excellent power-to-weight ratio.
Crane Flexibox®, incorporate a scalloped, stainless ■ High misalignment capability.
steel, flexible membrane design. This design gives the
most flexible solution for high torque and misalignment. ■ Low imposed forces on machinery leading to:
—
Reduced machinery vibration
■ Easy to fit. —
Maximized bearing life
■ Meets API 610 8th edition. Can be supplied to meet ■ Stainless steel flexible membranes for maximum life.
API 671.
■ Cartridge transmission unit eases assembly and gives
■ Intrinsic balance meets AGMA class 9.
repeatable balance.
■ Ideally suited for electric motors and turbine drives in ■ Overload collars are fitted to protect the flexible
critical process industry, marine, and power generation
membranes in case of a more severe torsional
applications.
overload.
■ Anti-fly retention of the spacer in the unlikely event of
membrane failure.
■ Jacking bolt feature for easy installation and removal
of spacer assembly available.
■ Puller holes incorporated into hubs as standard.
TSK
TSK
T Series Couplings
TSK Technical Data

Max. Peak Weight - Transmission Unit Weight Unbored Hubs - Kg
Coupling
Rating kW/ Continuous Overload Max. Minimum Extra DBSE Standard Large Long
Size
1000 rpm Torque Nm Torque Nm rpm DBSE - Kg Kg/m
0013 13 124 310 25,500 1.4 3.2 0.9 1.8 -
0033 33 315 790 20,000 2.7 5.3 1.6 3.1 -
0075 75 716 1,790 16,500 5.1 6.8 3.4 5.7 3.7
0135 135 1,289 3,220 14,400 8.9 11.0 5.6 8.8 6.7
0230 230 2,196 5,490 12,000 12.8 13.1 8.8 13.9 11.1
0350 350 3,342 8,360 10,500 16.0 12.5 15.7 - 18.8
0500 500 4,775 11,940 9,500 20.1 15.7 20.6 - 26.2
0740 740 7,066 17,670 8,000 25.4 19.8 29.4 - 37.2
0930 930 8,881 22,200 7,000 32.6 23.4 37.9 - 50.3
1400 1,400 13,369 33,400 6,000 46.2 31.4 51.8 - 72.5
Note that for the complete coupling, weights of two appropriate hubs plus a transmission unit are required.
The standard parallel bore machining tolerance is Grade 7, to give a light interference on the shaft.
TSK keyways will be cut to BS 4235 Pt.1(metric) or BS 46 Pt. 1(inch).
TSK Typical Arrangement
OVERLOAD COLLAR
GUARD RING
ANTI-FLY FEATURE
A C A E
D
B ‡
STANDARD LARGE LONG
MAX. HUB HUB MAX. HUB
F
BORE BORE
‡ To Suit Specific Applications
TSK Dimensional Data (mm)

Distance Between Shaft Ends MAXIMUM BORES
Coupling
A B C C-Preferred* D E F Standard Large Long
Size
Min. in. in. in. Hub** Hub** Hub***
0013 40 86 66 3.5 100 5.0 140 7.0 180 - 54 - - 36 51 -
0033 45 105 79 3.5 100 5.0 140 7.0 180 - 69 - - 46 70 -
0075 55 130 99 - - 5.0 140 7.0 180 250 90 62 82 65 90 65
0135 62 152 121 - - - 140 7.0 180 250 112 77 104 80 102 80
0230 70 179 130 - - - 140 7.0 180 250 131 91 123 90 121 90
0350 90 197 131 - - - - - 180 250 163 106 116 115 - 115
0500 95 222 133 - - - - - 180 250 181 121 132 127 - 127
0740 107 247 138 - - - - - 180 250 206 135 151 140 - 140
0930 115 272 148 - - - - - 180 250 223 153 166 155 - 155
1400 130 297 171 - - - - - 180 250 248 183 180 172 - 172
All dimensions in mm unless otherwise stated, and should not be used for construction. Certified dimensions furnished upon request.
NOTES: * These Distance Between Shaft End (DBSE) sizes are more readily available. Other lengths to suit specific shaft separations are available.
** Maximum bores shown are based on standard ISO/BS rectangular keys.
*** Based on typical taper shafts. Consult John Crane.
TSK
T Series Couplings
Selection Procedure
1. Select appropriate service factor SF.
2. Calculate coupling rating R from Example: 150 kW electric motor to centrifugal
R = kW x 1000 x SF pump at 2960 rpm
N R = 150 x 1000 x 1
where: 2960
kW = driver rated power R = 50.7 kW per 1000 rpm
N = speed (rev./min.)
3. Select a coupling with the same or higher rating. Selection: TSK - 0075
4. Check that the hub bore capacity is suitable.
Standard hub bore up to 65 mm.
5. Check peak torque capability is suitable for application. Large hub bore up to 90 mm.
6. Check speed capability. Peak torque capability - 1790 Nm
7. Check whether additional dynamic balancing is required.
Additional dynamic balancing should not be required.
8. Specify Distance Between Shaft Ends (DBSE).
Service Factor SF
Suggested service factors for electric motor, steam turbine, and
gas turbine drivers are given below.
Torque Variation Service Factor The examples given are for typical machines and are empirically
based guidelines. Knowledge of actual torque characteristics may
indicate a different service factor. For example, variable-speed electric
Constant Torque Centrifugal Pump 1.0*
motors may exhibit a fluctuating torque characteristic. Consult John
Centrifugal Compressor Crane for advice.
Axial Compressor
Centrifugal Blower
Slight Torque Screw Compressor 1.5

Fluctuation Gear, Lobe and
Vane Pumps
Forced Draft Fan
Medium Duty Mixer
Lobe Blower
Substantial Torque Reciprocating Pumps 2.0

Fluctuations Heavy Duty Mixers
Induced Draft Fans
*Use a minimum service factor of 1.25 on electric motor drives A Windows® based computer selection program for the TSK is
through a gearbox. available. This selection program provides all necessary technical
data, inertias, torsional stiffness, etc. Contact John Crane.
Available Options
■ Spark-resistant couplings for hazardous zone operation. ■ Torque limiting and shear pin designs.
■ Special materials for low temperature applications and/or Consult John Crane for any other special requirements.
higher corrosion resistance. Metastream couplings can be adapted to suit virtually all power
■ Electrical insulation. transmission coupling needs.
TSK
T Series Couplings
Coupling Alignment
Correct installation and alignment of couplings is essential for The angular and axial restoring forces in the table below left are given
reliable machinery performance. at maximum deflections. The chart can be used to determine forces
John Crane supplies a variety of shaft alignment equipment and across the full deflection range. The nonlinear characteristics can
offers alignment training courses. detune a system to prevent high amplitude axial vibration.
TSK MISALIGNMENT
Max. Axial Max. Parallel FORCE VS. DEFLECTION
Misalignment* Misalignment** 100
Coupling Equivalent Restoring
Size +/– mm. Thrust kN mm. Moment Nm
% Max. Restoring Moment

0013 1.00 210 0.30 4.1
0033 1.25 280 0.36 6.1
% Max. Axial Thrust

0075 1.50 360 0.45 8.8
L AR
0135 2.00 560 0.55 11.8 GU
50
0230 2.50 740 0.60 14.7 AN
0350 2.75 780 0.64 34.3 L
IA
0500 3.25 1080 0.65 40.7 AX
0740 3.75 1270 0.68 47.6
0930 4.25 1470 0.72 53.9
1400 5.00 2700 0.83 61.3 0
NOTES: * Meets NEMA end float specification without modification. 0 50 100
o
** Values based on angular deflection of 1/2 per end and minimum % Max. Displacement
DBSE. Greater misalignment accommodation is possible by
increasing dimension C.
Balance Recommendations
The inherent balance of the TSK range meets AGMA standard Coupling Size
9000-C90 class 9. The adjacent chart relates the TSK sizes to
operating speeds on the basis of this AGMA class 9 characteristic 1400
Balance
to provide a general guide to determine if dynamic balance 0930
Improvement
improvement is necessary. 0740 May Be Required
When balancing improvement is requested, John Crane will 0500
dynamically balance the transmission unit. Hubs may also be 0350
dynamically balanced, and this will usually be carried out after 0230
machining the bore but before cutting single keyways.
0135
Balance
Improvement
Clas
0075
Not Generally
s9
Required
0033
0013
1 2 3 4 5 6 7 8 9 10 15 20 30
Operating Speed (in thousand rpm)
John Crane
North and Latin Americas Europe, Middle East, Africa Asia Pacific
Morton Grove, Illinois USA Slough, UK Singapore
Tel: 1-847-967-2400 Tel: 44-1753-224000 Tel: 65-222-9161
Fax: 1-847-967-3915 Fax: 44-1753-224224 Fax: 65-223-5035
1-800-SEALING
For your nearest John Crane facility, please contact one of the locations above.
If the products featured will be used in a potentially dangerous and/or hazardous process, your John Crane representative should be consulted prior to their selection and use. In the
interest of continuous development, John Crane Companies reserve the right to alter designs and specifications without prior notice.
©1999 John Crane Print 11/99 www.johncrane.com ISO Certified S-TSK

METASTREAM FITTING, OPERATION and MAINTENANCE Datasheet Part No
INSTRUCTIONS 78257 / 99
TSK & TSC, TSP & TSA, TLK couplings Page 1 of 7
FITTING, OPERATING & MAINTENANCE INSTRUCTIONS for

METASTREAM™ TSK, TSP, & TLK• including TSA & TSC DESIGNS
T -SERIES FLEXIBLE ELEMENT SPACER COUPLINGS
DESCRIPTION
The ranges of Flexibox METASTREAM™ couplings covered by this data sheet are designed to transmit torque
between the rotating shafts of a driving and driven machine, whilst accommodating the inevitable lateral, angular and axial
misalignment, which will exist between two coupled machines.
The usual extent of supply comprises :-
• a hub for the DRIVING machine (motor) shaft

• a hub for the DRIVEN machine shaft
• a factory assembled transmission unit, comprising two packs of flexible metallic discs, each bolted to a "guard
ring" and to a common spacer (distance piece), which separates the two disc packs. The overall length of the
transmission unit is sized to suit the shaft end separation of the coupled machines.
• a set of fasteners to assemble the transmission unit to the two hub flanges.
•
Pre-2001 type using TSK components.
METASTREAM FITTING, OPERATION and MAINTENANCE
78257 / 99 INSTRUCTIONS
Page 2 of 7 TSK & TSC, TSP & TSA, TLK couplings
DRAWINGS
These instructions are written for standard catalogue products, generally designed in accordance with the following outline
drawings.
• METASTREAM TSK, TSC, TLK DESIGNS
REPLACEMENT
MEMBRANE PACK
• METASTREAM TSP AND TSA

DESIGNS
REPLACEMENT
MEMBRANE PACK
IMPORTANT - These instructions should be read in conjunction with any application specific general arrangement
drawing which may be supplied with the coupling.
SELECTION VERIFICATION
Although a coupling may be correctly specified at the time of order placement, the duty conditions can sometimes change
prior to the coupling being put into service. Information is available from FLEXIBOX to advise on the selection and
limitations of their power transmission products, but the USER is ultimately responsible for verifying the suitability of the
selection for the actual service conditions.
The coupling and its manner of use must conform to any legal or licensing requirements, and, where appropriate, meet
local health and safety requirements.
IMPORTANT If the conditions of operation are changed without approval from FLEXIBOX, then we would
decline responsibility for any consequent damage and the USER would assume all risks.
UNPACKING AND STORAGE
The coupling should be unpacked and examined for any signs of transit damage. Particular attention should be paid to hub
bores and spigot/recess location diameters.
If the coupling is not to be used immediately, it should be re-packed and stored in a dry building away from direct heat.
Documentation supplied with the coupling should be retained for future reference.
INSTALLATION
DANGER PRIOR TO INSTALLING THE COUPLING, ENSURE THAT THE

MACHINERY IS MADE SAFE
• Remove the coupling from its packaging and carefully inspect for signs of damage. Particular attention should
be paid to the hub bores and the spigot/recess location features, which should be free from burrs and other
damage.
• Fit the DRIVER (1) and DRIVEN (2) hubs to the corresponding machine shafts. Normally, FLEXIBOX
supply parallel bored and keywayed hubs, individually machined to give a light interference fit with the
associated shaft. If it is necessary to apply some heating to the hub to assist fitting, then a warm oil bath will
usually be adequate.
DANGER HUBS MUST BE ADEQUATELY SUPPORTED DURING INSTALLATION TO AVOID

ACCIDENTAL DAMAGE SHOULD THEY SLIP
It is usual to install the hub such that the hub face and shaft end are flush, but consult the arrangement
drawing, or other particular instructions, to check the configuration for individual designs.
• Align the centre lines of the DRIVING and DRIVEN machine shafts as follows:-
i) With one machine firmly bolted down, set the distance between shaft ends (DBSE) according to drawing
or catalogue dimension 'A'.
IMPORTANT - DBSE is usually measured between the inner face of the hubs and should not be taken
as the length of the transmission unit at its outer periphery.
ii) Align the shaft centre lines both horizontally and vertically by aligning the hub flanges. The Flexibox
METASTREAM™ coupling alignment kit and reverse periphery procedure allows rapid and accurate
alignment of shafts.
IMPORTANT - The misalignment tolerances quoted in literature and on drawings allow for dynamic
conditions and variations. For the best service from the coupling, FLEXIBOX
recommend that installed misalignment is no more than 10% of the maximum
allowable misalignment, allowance being made for any anticipated movements which
will occur during operation (eg. thermal movements on hot pumps).
• Check spigot and recess locations on the hubs and transmission unit for burrs or other signs of damage and
then fit the transmission unit (3) between the hubs.
DANGER - THE TRANSMISSION UNIT MUST BE ADEQUATELY SUPPORTED

DURING INSTALLATION TO AVOID ACCIDENTAL DAMAGE SHOULD IT
SLIP
It may be necessary to compress the transmission unit whilst sliding it between the hubs, and facilities are
provided to make this easier:-
i) on smaller units, lever slots are provided in the hub flanges
ii) on larger units, including the TLK, the spacer flanges are drilled so that the
hub bolts (4) may be used to compress the transmission unit sufficiently to
clear the spigot location (see sketch).
Maximum compression of the gap 'X' should not exceed 0.8 times the
COUPLING maximum axial misalignment value, unless indicated
otherwise on the general arrangement drawing.
IMPORTANT - always remove the compression bolts as soon as the

transmission unit is in position and before fully tightening the hub bolts.
• Fit the hub bolts (4) (and locking washers (5) if supplied) and tighten these evenly to locate the transmission
unit, ensuring that the spigots enter their recesses squarely. Bolts should be tightened in a "diametrically
opposite" sequence to the values quoted in Table 1. If a general arrangement drawing is supplied with the
coupling, then torque values quoted on that drawing take precedence.
BOLT TIGHTENING TORQUES

COUPLING HUB BOLTS (4) SPACER BOLTS (3C/3D) - FOR REFURBISHMENT
SIZES
TSK TSC TLK TSK TSP TSC TSA TLK
TSP TSA
N-m lb-ft N-m N-m N-m lb-ft lb-ft N-m
0011, 0013 13 7 - 11 - 8 - -
0027, 0033 25 14 - 23 9 17 7 -
0060, 0075 25 14 - 47 17 35 14 -
0110, 0135 25 14 - 75 31 55 26 -
0180, 0230 50 26 - 130 31 95 26 -
0260, 0350 25 14 - 150 58 110 41 -
0400, 0500 50 26 - 205 58 150 41 -
0560, 0740 50 26 - 285 145 210 125 -
0750, 0930 86 63 - 380 145 280 125 -
1120 86 63 - 490 277 360 220 -
1400 86 63 86 490 - 360 - 380
1850 - - 86 - - - - 490
TABLE 1 - STANDARD COUPLING BOLT TIGHTENING TORQUES
[Data given on general arrangement drawings takes precedence]
• Rotate the machinery two or three times slowly to ensure it moves freely.
The coupling is now ready for continuous and trouble free service.
OPERATION
ATTENTION: BEFORE STARTING THE MACHINERY, ENSURE THAT ALL NECESSARY

SAFETY PROCEDURES ARE BEING OBSERVED
When operated within the duty conditions for which they were designed, Flexibox METASTREAM™ flexible disc
couplings will give long and trouble free service. Routine examination should include a periodic check on the
tightness of fasteners and visual inspection of transmission components for signs of fatigue or wear.
If the coupled machinery is disturbed at any time, then shaft alignment should be re-checked as a matter of routine.
Alignment checking is also recommended if a deterioration of installation alignment during service is suspected.
INSPECTION AND MAINTENANCE
DANGER - MAINTENANCE WORK MUST ONLY BE CARRIED OUT BY SUITABLY QUALIFIED

PERSONNEL WHEN THE EQUIPMENT IS STATIONARY AND HAS BEEN MADE SAFE
Flexibox METASTREAM™ flexible power transmission couplings are designed to give long and trouble free service
if operated within the conditions for which they were specified. Failures are rare and can generally be attributed to:-
• excessive misalignment
• severe torsional overload
In all cases of coupling failure, the cause should be identified and corrected before replacing the coupling.
The usual mode of failure of flexible disc couplings is rupture of the flexing membranes. In such circumstances, it is
possible to repair the coupling by fitting a replacement disc pack assembly.
ATTENTION: WHEN REPAIRING Flexibox METASTREAM™ FLEXIBLE DISC COUPLINGS,

ONLY FLEXIBOX APPROVED PARTS SHOULD BE USED
• To replace the transmission unit (3), first remove the hub bolts (4) and then withdraw the transmission
unit using the lever slots in the hubs or compression bolt feature in the spacer as appropriate.
DANGER - TRANSMISSION UNIT MUST BE ADEQUATELY SUPPORTED DURING
REMOVAL TO AVOID ACCIDENTAL DAMAGE SHOULD IT SLIP
• Identify the bolts which connect the disc packs to the spacer piece. Slacken and remove these drive bolts
(3C) and nuts (3D) and carefully dismantle the disc pack assemblies from the spacer piece. Do not
attempt to dismantle the disc pack assemblies any further; replacement disc packs are always supplied
complete with a new guard ring.
• Subsequent refurbishment is dependent on the type of coupling involved and the precise configuration of
the replacement membrane pack. It is recommended that BOTH membrane packs be replaced, as failure
of one inevitably results in some damage to the other.
• TSP (TSA) REPLACEMENT PACK
• Complete the removal of the old disc pack assemblies by pressing the washers (3E) out of the holes in
each spacer flange.
• Identify the fasteners which attach the disc packs to the spacer. Disassemble the loosely assembled nuts
(3D) and separate the bolts (3C) and washers (3E).
• Fit new washers (3E) into the spacer.
• Carefully press the protruding sleeves in each disc pack into the holes in the spacer flange, taking care not
to over-strain the flexible discs. Insert the drive bolts (3C) from the guard ring side and secure using the
locknuts (3D). Tighten the locknuts evenly to the correct SPACER BOLT tightening torque value given
in Table 1.
• Complete the refurbishment of the transmission unit by replacing the second disc pack assembly.
• TSK [TSC] AND TLK REPLACEMENT PACK
• Complete the disassembly of the old disc packs by pressing the sleeves (3F) out of the holes in each
spacer flange.
• Identify the fasteners which attach the disc packs to the spacer flanges. Disassemble the loosely
assembled nuts (3D).
• With the bolts (3C) in position, carefully press on the bolt heads to push the new sleeves into the holes in
the spacer flange. Take care not to over-strain the flexible discs.
• Place a small amount of threadlocking compound (e.g. Loctite 242) on the protruding bolt threads and
then assemble the nuts (3D). Tighten these nuts evenly to the correct spacer bolt tightening torque value
given in Table 1.
• Complete the refurbishment of the transmission unit by replacing the second disc pack assembly.
• Having rebuilt the transmission unit, it is recommended that the shaft alignment be checked prior to re-
installation.
• The refurbished transmission unit should be installed in accordance with the instructions for fitting a new
coupling.
IMPORTANT - Hub bolts should be replaced every time the coupling is dismounted.
ATTENTION - REPLACEMENT OF THE DISC PACK ASSEMBLIES INEVITABLY

CHANGES THE INHERENT BALANCE OF THE TRANSMISSION UNIT.
HENCE, IF A BALANCED COUPLING NEEDS REFURBISHING, IT IS
RECOMMENDED THAT A FACTORY ASSEMBLED AND BALANCED
TRANSMISSION UNIT BE FITTED TO ENSURE FUTURE, VIBRATION
FREE OPERATION. IF REPLACEMENT DISC PACK ASSEMBLIES ARE
FITTED TO A BALANCED TRANSMISSION UNIT, THEN
CONSIDERATION MUST BE GIVEN TO REBALANCING OF THE
REFURBISHED TRANSMISSION UNIT OR IN-SITU BALANCING OF THE
COUPLING.
WARNING
All reasonable care has been taken in the design and manufacture of this coupling to ensure that it will be safe when
properly used. However, these instructions are of a general nature, and it is assumed that the USER is aware of the
statutory requirements of his plant.
FLEXIBOX will provide advice on the use of this coupling, but the following matters are the sole responsibility of the
USER:-
• Compliance with statutory plant requirements

• Compliance with other safety requirements
• Final choice of a coupling for a particular duty.
NOTES ON THESE INSTRUCTIONS
These instructions should be available to everybody who has need of them at the place where the coupling is used.
In accordance with European agreement, certain words or symbols have particular meanings, when used within these
Territories or when applied to actual coupling parts. They are used as follows:-
‘IMPORTANT’ is used for items of particular concern when using the coupling
‘ATTENTION’ where there is an obligation or prohibition concerning the avoidance of risk
'DANGER' (OR '!' printed in a triangle) - where there is an obligation or

prohibition concerning harm to people or damage to the equipment.

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Compressor York 104 Manual

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Instruction Manual

SMC 104 SMC 106 SMC 108

concentrations of refrigerant vapours are in-

Halogenated refrigerants Ammonia

R134a R404A R407C R410A R507 R22 R717

Warning smell vol.% 0.2 0.002

S Ammonia is easily absorbed by water: Cooling Media

The SMC 100 and TSMC 100 compressors

by the first digit in the type designation. The

is indicated by the following two digits, Type Refrigerant

In the TSMC 100 two-stage compressors, the

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

Direction of rotation clearly marked with red paint. The weight of

SMC 100-TSMC 100 Mk3, S, L, E

rotation is not indicated by an arrow but is In view of preventing an unintended applica-

The compressor may ONLY be used:

Other demands to the emergency device:

Consequently, the compressors will be equip-

The values for LW constitute an average of a S SAB 110:

1 meter Reflecting plane

Compressor block LW LP TCMO 28 81 66

Compressor block LW LP HPO 28 94 79

SAB 110 SM 98 81 SAB 163 BM 106 88

SMC 104S 4 100 80 1500/700 226 580

SMC 112S 12 100 80 1500/700 679 1250

SMC 188: 840--920 RPM not allowed

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

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

Thermopump: Water cooled:

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

Type Area rpm Cooling Note

Oil cooling is always necessary.

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

Top covers: Air cooled only

rpm OIL COOLING

Top covers: Air cooled only

Type Area rpm Oil-cooling Note

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

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

Type Area rpm Oil-cooling Note

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

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

Type Area rpm Oil-cooling Note

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

Type Area rpm Oil-cooling Note

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

Type Area rpm Oil-cooling Note

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

--94 --76 --58 --40 --22 --4 14

Area rpm Oil-cooling Note

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

Type Area rpm Oil-cooling Note

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

S Check oil level in crankcase. The oil level

S Start condenser cooling, brine pumps,

S Check correct setting of safety auto-

S Set capacity regulator to minimum capa-

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

S Shut off condenser cooling. If there is a

-- correct oil charging,

Observation Measuring point Measurement unit

Time Date and time

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