Technical Manual SABROE

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SMC /TSMC 100 Mk4 - Engineering Manual

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Specifications for SMC and TSMC Mk4, S-L-EThe SMC/TSMC-type piston compressor can be fitted with a range of equipment, depending on the function and requirements it is expected to meet.

Some of these variants are discussed in this in-struction manual, even if they are not featured on your particular unit.

The variants featured on the unit are marked with an 'x' in the following diagram, with the compres-sor number stated below.

Compressor type SMC ❑ TSMC ❏ S ❏ L ❏ E ❏

104 ❑ 106 ❏ 108 ❏ 112 ❏ 116 ❏

Designation

Compressor no.

Refrigerant R717 ❑ Other _________ ❏

Control UNISAB II Control- and regulating system

Electro Mechanical System

Compressor cooling

Thermopump

Water cooled top and side covers

Air cooled top and side covers

Oil cooling (water-cooled side covers)

Oil cooling OSSI/OOKH

Drive type Coupling

V-belts

Explosion-proof electrical design

Equipment for parallel operation

SABROE OVUR-type oil separator

1. Introduction

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1. IntroductionThe purpose of this manual is to provide the oper-ating personnel with a thorough knowledge of the compressor as well information about:

• The function and maintenance of eachcomponent.

• Service schedules.

This manual describes the compressor and its component parts as well as safety instruc-tions/regulations. Moreover, the manual explains the different settings that can be of assistance to those who are responsible for the daily operation and maintenance of the equipment.

To prevent any accidents, assembly and disas-sembly of components should only be carried out by authorized personnel.

It is essential that the operating personnel famil-iarize themselves with the contents of this manual in order to ensure a proper and efficient operation. YORK Refrigeration is not liable for damage oc-

curring during the warranty period where this is at-tributable to incorrect operation.

YORK Refrigeration's manual concept covers six standard manuals: Engineering, Operating, Serv-ice, Installation and Commissioning, Transport and Spare Parts. Therefore, references may be made to sections which are not part of this manu-al.

This manual was produced by:

YORK RefrigerationChr. X’s Vej 201DK-8270 HoejbjergDenmark

Copyright © 2003 YORK Refrigeration

This manual must not be copied without the writ-ten permission of YORK Refrigeration and the contents must not be imparted to a third party nor be used for any unauthorised purpose. Contravention will be prosecuted.

In the space below you may enter the name and address of your local YORK Representative

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Table of Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Signs and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Identification of YORK Refrigeration Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Unit Pipe System Name Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Compressor Name Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Vessel Name Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Signs in Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14The Sign: CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14The Sign: High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14The Label: The Temperature of Tangible Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15The Label: Internal Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Other Warning Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Safety during Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Warnings in Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Texts Marked with Danger! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Texts Marked with Warning! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Texts Marked with Caution! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19General Safety Instructions and Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Personal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Work Area Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Tool Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Lifting and Carrying Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Installation and Relocation Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Set-Up and Operation Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Maintenance Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Materials Used with this Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22First Aid for Accidents with Ammonia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Basic Rules for First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23First Aid Measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23First Aid for Accidents with HFC/HCFC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Refrigerant no.: R134a - R505A - R507 - R22, etc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Basic Rules for First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Protecting the Operator as well as the Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Furthermore, it can be said about refrigerants: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Purging a Refrigeration Plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Cooling Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Lubricating Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

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Technical Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Areas of Application of the Reciprocating Compressor Unit . . . . . . . . . . . . . . . . . . . . . . . . 29Description of the Compressors Compressor Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Compressor Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33One-stage Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33Two-stage Compressors Type TSMC 100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Compressor Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Piston Pin Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44Suction Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45Conversion of TSMC Compressors from Two-stage to One-stage . . . . . . . . . . . . . . . . . . . 46Oil Separator Type OVUR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47Mode of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47Selecting an Oil Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47Oil Return to the Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48Thermodynamic Liquid Trap (TLT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50Oil Return in Connection with Parallel Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51System A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52System B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55System C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57Capacity Regulation of Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58Capacity Regulation and Unloading of Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58Start Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60Regulating Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61Schematic Drawings, Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62Variable speed drive (VSD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70Compressor Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71Instrumentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72Manometers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74Cooling of the Intermediate Discharge Gas on TSMC Compressors . . . . . . . . . . . . . . . . . 77Automatic Regulation of Intermediate Pressure IP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79Determining the Intermediate Pressure IP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79Cooling Systems for Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81Standard Cooling Systems for Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81Mounting of Cooling Water Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83Pressure Loss in the Cooling System in SMC/TSMC Compressors . . . . . . . . . . . . . . . . . . 881c: Cooling with Thermo Pump - R717 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89Description of the Pumping Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92Ensuring Liquid to the Thermo Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94Power Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95Types of Spare Parts Set: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Physical and Connection Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100Connection Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100Connections on SMC / TSMC Mk4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105Connections for T/SMC104-116 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

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Control of the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1111. Pressure Transmitters marked PT1, PT2 and PT3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111Heating Element for Oil Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115Technical Data for the SMC 100 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116Weight of Electric Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118Compressor Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119Dimension Sketches of Compressor Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120Planning the Machine Room . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124Operating Limits Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125Direction of Rotation of the Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140Choice of Electric Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141Motor Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141Starting Torque of the Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143Start up torque SMC 100 R717 25% load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144Moment of Intertia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146Direction of Rotation of Electric Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147Handling of Compressor and Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148Compressor Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151V-Belt Drive for SMC/TSMC 100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153Transmission Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153Power Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155Construction of V-Belt Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158Laying the Foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159Mounting of Vibration Dampers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161Marine Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164Noise from Compressors and Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166Noise Data for Reciprocating Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170Reverberation Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171Vibration Data for Compressors - All Compressor Types . . . . . . . . . . . . . . . . . . . . . . . . . . 173Test Pressure Levels for Standard Compressors and Components . . . . . . . . . . . . . . . . . 175Charging the Compressor with Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176Oil Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177Selecting Oil Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177Data Sheet for Listed Sabroe Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186List of Part Numbers for Available Sabroe Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187List of Major Oil Companies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191Selecting Lubricating Oil for SABROE Reciprocating Compressors . . . . . . . . . . . . . . . . . 192Oil Changing Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197Data Sheet for Listed Sabroe Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198List of Part Numbers for Available Sabroe Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199List of Major Oil Companies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213Installation Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213

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Installation Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213Personnel Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213Preparing the Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214Tools and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214Ordinary Hand Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214Local Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214Space Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214Preparing the Mounting Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214Lifting Accessories and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215Preparing Lifts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215Lifting and Loading Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215Unpacking and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215Disposal of Materials which are not Reusable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215Moving the Equipment to the Mounting Site after Unloading and Unpacking . . . . . . . . . . . 215Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2161. Alignment of Unit against Foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216Mounting on Vibration Dampers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217Mounting Directly on Foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2182. Alignment of Compressor on Base Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2183. Alignment of Motor on Base Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218Fitting and alignment of coupling type AMR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2194. Installation and alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219Preliminary installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221Achieving correct centre height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222Achieving parallel shafts in vertical plane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222Final installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222Preliminary Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223Achieving Parallel Shafts in Horizontal Plane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223Achieving Correct Centre Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224Achieving Parallel Shafts in Vertical Plane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224Final Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2245. Piping Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2256. Connecting Electricity Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2267. Pressure Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2288. Oil Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230Final Check of the Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233Regulating Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234Transmission Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234Directly Driven . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234Belt Driven . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234

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0178

_931

TO

C.fm

Oil Separators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234Oil Coolers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234Regulating Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235Electromechanical Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235UNISAB II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236Pressure Transducers, marked PT1, PT2, PT3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236Temperature Sensors, marked TT5, TT6 and TT7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236Heating Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236

Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237Qualification Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237UNISAB II Reading, Safety and Capacity Regulating System . . . . . . . . . . . . . . . . . . . . . . 239Notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240

Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243Hot and Cold Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244Qualification Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244Compressor Control and Alarm Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245Alarms and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245UNISAB II Reading, Safety and Capacity Regulating System . . . . . . . . . . . . . . . . . . . . . . 245Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247Control Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247Recording Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248Menu Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249Preparations for Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251Operating Mode UNISAB II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251Checks during Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259

Transport Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261Transport Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262Personnel Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263Loading Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263Preparations before Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264Transport Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264Unloading Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264

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Commissioning Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265Preparations for Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266Final Check of Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266Personnel Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266Preparations on the Mounting Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266Final Check of the Plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266Commissioning Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266Preparations before the First Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266Evacuation and Charging of Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267Checks to be Performed after Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268

Compliance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269Conformity with EU Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269

Certificates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271

Final Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273Disposal of Machine Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273Disposal of Oil and Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273Disposal of Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274Disposal of Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274Appendix - SMC/TSMC 100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275Torque Moments for Screws and Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277Sundry Clearances and Check Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279

2. Signs and Warnings

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2. Signs and WarningsThe purpose of this document is to describe:

• How YORK Refrigeration equipment can be identified.

• All warning signs used on equipment deliv-ered by YORK Refrigeration.

• How information important to the safety of personnel and equipment is presented in in-structions belonging to equipment delivered by YORK Refrigeration.

This document is intended for all user categories.

This document describes the importance of the in-dividual signs which are attached to the YORK Refrigeration products.

Before a compressor/unit is put into operation it must be provided with the warning signs corre-sponding to the actual type of compressor/unit in accordance with the rules and regulations in force.

This document was produced by:



This document must not be copied without the written permission of YORK Refrigeration and the contents must not be imparted to a third party nor be used for any unauthorised purpose. Contra-vention will be prosecuted.

WDanger!

Risk of injury to personnel and damage to equip-ment! Always read the safety precautions belong-ing to this equipment before starting the installa-tion process. Failure to comply with safety precau-tions may cause death or injury to personnel. It may also cause damage to or destruction of the equipment


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Identification of YORK Refrigeration Equipment

All YORK Refrigeration equipment can be identified by one or several name plates placed as illustrated by the following drawing:

Fig. 2.1

3

2 1

1. Compressor name plate

2. Vessel name plate

3. Unit pipe system name plate


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Unit Pipe System Name Plate

Fig. 2.2 Unit Pipe System Name Plate

The unit pipe system name plate is positioned on the frame - (see 3. Unit pipe system name plate). The name plate contains the following informa-tion:

• TypeManufacturer's type designation.

• YearYear of manufacture.

• Identification noIndividual no for identification of supplied pipe system.

• Design codeFor PED orders: EN 378-2

If the unit has been approved by an author-ity, the design code will be shown here.

• Approval noIf the unit has been approved by an author-ity, the approval no will be shown here.

• Pressure systemLow pressure side of compressor piping is referred to as LP. High pressure side of compressor piping is referred to as HP.

• Fluid/GroupRefrigerant designation according to ISO817 or fluid group according to directive 67/548/EEC.

• Max allowable pressureShows max allowable pressure relative to atmospheric pressure for which the pipe system has been designed.

• Leak test pressure, PTShows the pressure with which the pipe sys-tem has been leak tested.

• Design temperature, TSShows min and max temperatures for which the pipe system including components have been designed.

• CE xxxxThe four digits compose the registration no of the notified body in charge of the assess-ment modules for the vessel.

DK 8270 Højbjerg 2516-328

Type

Identification No

Unit Pipe System Year

Design Code

Approval No

BarAllowable PressureMax

Leak Test Pressure

PS

PT

0062

Fluid/GroupPressure System

Design TemperatureTS

Bar

Min/max

LP HP

°C

Refrigeration


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Compressor Name PlateFig. 2.3 Compressor Name Plate

The compressor name plate is positioned on the compressor - (see 1. Compressor name plate). The plate contains the following information:

• Compressor noCompressor manufacturing number.



• Nominal speedShows rotational speed of drive shaft at typ-ical running condition.

• Swept volumeShows swept volume of compressor in m3/h at nominal speed.

• Allowable pressureShows max working pressure of compres-sor.

• Test pressureShows pressure at which compressor en-closure has been strength tested.

Vessel Name PlateFig. 2.4 Vessel Name Plate

The vessel name plate is positioned on the shell of the vessel (see 2. Vessel name plate). The name plate contains the following information:

• Vessel noVessel number stated by YORK Refrigeration.



• Design codeShows the design code according to which the vessel was manufactured.

• Approval no/CATShows the approval no of the vessel issued by the relevant authority as well as the cat-egory according to PED 97/23/EEC, Article 9.

• SideRefers to the columns “Shell” and “Tube”.

DK 8270 Højbjerg 2516-327

Compressor

Nominal Speed

Swept Volume

Allowable Pressure

Test Pressure

RPM

m3/h

bar

bar

YearNo

Type

Refrigeration2516-326DK 8270 Højbjerg

Beholder/Vessel/Behalter

Beregningsnorm/Design code/ Berechnungsnorm

GodkendelsesnrApproval noAbnahme nr

Side/Seite Medie/MediaTilladeligt tryk/Allowa-ble pressure/Zuläs-siger DruckTilladelig temp./Allowable temp./Zulässiger Temp.

ÅrYearJahr

No

Volumen/ Volume

0062

Refrigeration

Type

Svøb/Shell/Mantel Rør/Tube/Rohr

PS

V

/CAT.

°C

-L.

bar


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• MediaShows the refrigerant designation accord-ing to ISO817.

• Allowable pressure, PSShows min and max pressure relative to at-mospheric pressure for which the vessel or vessel part has been designed.

• Allowable temperature, TSShows min and max temperatures for which the vessel has been designed.

• VolumeShows volume of the vessel in litres.

• CE xxxxThe four digits compose the registration no of the notified body in charge of the assess-ment modules for the vessel.


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In the following section all signs which may be found on the equipment are described. How-ever, the number of signs may vary from prod-uct to product.

Signs in Instructions

The Sign: CAUTION A CAUTION tag like the one illustrated below is fixed to the compressor. The sign imposes the us-ers to read the Safety Precautions section in the manual before handling, operating or servicing the compressor and unit.

The Sign: High Voltage

WDanger

HIGH VOLTAGE!

Before working on any electrical circuits, turn the machine Main Disconnect Device “OFF” and lock it. Dismantle the main fuses to the compressor unit.

Unless expressly stated in applicable YORK Refrigeration documentation or by a YORK Refrigeration Field Service Representa-tive, do NOT work with the electrical power “ON”. Any work with the electrical power “ON” should be performed by a YORK Refrigeration Field Service Representative. The customer and subsequent transferees must make sure that any other person performing work with the electrical power “ON” is trained and technically qualified.

Antes de manejer, instalar, poner en mar-

cha o dar servicio al compresor y la uni-

dad, leer la sección Precauciones de

seguridad en el Libro de Instruc-

ciones.

Es respondabilidad del operarío o de su

patrón, que el libro de instrucciones

permanezca siempre al alcance de la

mano.

Esta señal no debe de ninguna manera

suprimirse o dañarse. 2516-297

Before handling, installing, operating or servicing the compressor and unit, read the Safety Precautions section in the Operating Manual.It is the responsibility of the operator or his employer that the Operating Manual is always available.This sign must not be removed nor be damaged in any way.

Caution


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The Label: The Temperature of Tangible SurfacesWhen a compressor is working, the surfaces which are in contact with the warm discharge gas will also get warm. However, the temperature de-pends on the refrigerants used as well as the op-erating conditions of the compressor. Often the temperature exceeds 70°C [158 °F], which for metal surfaces may cause skin burns even at a light touch.

Consequently, the compressors are equipped with yellow warning labels signalling that pipes, vessels and machine parts will become so hot during operation that your skin will get burnt if you touch them for one second or more.

The Label: Internal ProtectionCompressor blocks and units are usually deliv-ered without any refrigerant or oil.

To protect the compressors against internal corro-sion, they are delivered evacuated of all atmos-pheric air and charged with Nitrogen (N2) to an

overpressure of 0.2 bar [3 psi].

In such cases a yellow label like the one shown below is affixed to a visible spot on the compres-sor.

Other Warning Labels

Hazardous substance!

Dangerous noise level,use hearing protectors!

Internal overpressure!

Cold surfaces!

Påfyldt beskyttelsesgasCharged with inert gasEnthält SchutzgasChargé du gaz protecteurContiene gas protector

N20,2 bar3 PSI

1534-169


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Emergency StopFig. 2.5 Emergency stop on the reciprocating

compressor unit

Safety during ServiceBefore dismantling or servicing a compressor or unit attention should be paid to the following points:

• Read the Safety Precautions in section 3 before opening the compressor and other parts of the refrigeration plant.

• Make sure that the motor cannot start up in-advertently. It is recommended to remove all main fuses.

• Switch off all electric components on the compressor/unit before the disman-tling/servicing.

• Make sure that there is neither overpressure nor any refrigerant in the part to be disman-tled. Close all necessary stop valves.

• Use gloves and safety goggles and make sure to have a gas mask ready for use.

• Use the prescribed tools and check that they are properly maintained and in good working condition. In explosion-proof areas, use tools especially suited for this specific purpose.

• When dismantling the top covers, attention should be paid to the considerable spring force beneath the covers. When the screws are loosened, the cover must lift itself from the frame as described in the instruction manual.

Fig. 2.6

• Before dismantling the side covers, empty the crankcase of its oil content.

• Check that the heating rod in the crankcase is de-energized.

UNISAB II control system

Emergency stop

Electromechanical control system

Emergency stop, mounted when installing the unit

Top coverSprings


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Warnings in InstructionsThis section describes warnings used in instruc-tions pertaining to YORK Refrigeration equip-ment.

Information of importance to the safety of person-nel or equipment is given at three levels.

• Danger!

• Warning!

• Caution!

There is an important distinction between these three levels. However, as shown below, the prin-ciple is the same at all three levels.

Note: Information is sometimes given in a Note. A Note is used to emphasise information but it is never used for information vital to the safety of personnel and equipment.

Texts Marked with Danger!The example below shows how information vital to the safety of involved personnel is presented.

WDanger!

Risk of electrical shock! Always turn off the main switch before servicing the unit! Contact with high voltage may cause death or serious injury.

Failure to observe information marked with Dan-ger! may cause death or serious injury to person-nel or even to a third party.

Texts Marked with Warning!The example below shows how information of im-portance to the safety of involved personnel or of major importance to the safety of the equipment is presented.

WWarning!

Risk of damage to compressor! Always consult your supplier before using a compressor under operating conditions outside the specified working range.

Texts Marked with Caution!The example below shows how information vital to the safety of involved personnel is presented.

WCaution!

Risk of incorrect viscosity! Always make sure that all oils used are mixable without causing chemical reactions. Chemical reactions might have serious effects on the viscosity.

Failure to observe information marked with Cau-tion! may cause damage to the equipment.


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3. Safety Precautions

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3. Safety Precautions The purpose of this document is to provide gener-al safety precautions for this equipment. Additioal safety precautions relating to a specific task are given in the corresponding documents.

The safety precautions are intended for all user categories.




This document must not be copied without the written permission of YORK Refrigeration and the contents hereof must not be imparted to a third party nor be used for any unauthorised purpose. Contravention will be prosecuted.

WDanger!

Risk of injury to personnel and damage to equip-ment! Always read the safety precautions belong-ing to this equipment before start. Failure to com-ply with safety precautions may cause death or in-jury to personnel. It may also cause damage to or destruction of the equipment.

WWarning!

Read related safety precautions before operating the compressor/unit. Failure to follow safety in-structions may result in serious personal injury or death.

Important!

The safety precautions for this YORK Refrigeration compressor have been pre-pared to assist the operator, programmer and

maintenance personnel in practicing good shop safety procedures.

Operator and maintenance personnel must read and understand these precautions completely be-fore operating, setting up, running or performing maintenance on the compressor/unit.

These precautions are to be used as a supple-ment to the safety precautions and warnings in-cluded in:

a. All other manuals pertaining to the compres-sor/unit.

b. Local, plant and shop safety rules and codes.

c. National safety rules and regulations.

General Safety Instructions and Considerations

Personal SafetyOwners, operators, set-up, maintenance and service personnel must be aware that constant day-to-day safety procedures are a vital part of their job. Accident prevention must be one of the principal objectives of the job, regardless of the activity involved.

Know and respect the compressor/unit. Read and carry out the prescribed safety and checking pro-cedures.

Make sure that everyone who works for, with or near you fully understands and - more importantly - complies with the following safety precautions and procedures when operating this compres-sor/unit.

Observe the safety warnings on the compres-sor/unit.

Use safety equipment. Wear approved eye or face protection as well as gloves when working with


20/288 0178-931 - ENGRev. 27.10.03


parts containing refrigerant and lubricating oil. Safety shoes with slip-proof soles can help you avoid injuries. Keep your safety equipment in good condition.

Never operate or service this equipment if affect-ed by alcohol, drugs or other substances or if in a condition which decreases alertness or judgment.

Work Area SafetyAlways keep your work area clean. Dirty work ar-eas with such hazards as oil, debris or water on the floor may cause someone to fall onto the floor, into the machine or onto other objects resulting in serious personal injury.

Make sure your work area is free of hazardous ob-structions and be aware of protruding machine members.

Always keep your work area tidy so you are able to escape should a dangerous situation arise.

Report unsafe working conditions to your supervi-sor or safety department.

Tool SafetyAlways make sure that the hand tools are in prop-er working condition.

Remove hand tools such as wrenches, measuring equipment, hammers, etc. from the compres-sor/unit immediately after use.

Lifting and Carrying SafetyContact YORK Refrigeration if you have any questions or if you are not sure about the proper procedures for lifting and carrying.

Before lifting or carrying a compressor/unit or oth-er parts, determine the weight and size by means of e.g. tags, shipping data, labels, marked infor-mation or manuals.

Use power hoists or other mechanical lifting and carrying equipment for heavy, bulky or unwieldy objects. Use hook-up methods recommended by your safety department and familiarise yourself with the signals for safely directing a crane opera-tor.

Never place any part of your body under a sus-pended load or move a suspended load over any other persons. Before lifting, be certain that you have a safe spot for depositing the load. Never work on a component while it is hanging from a crane or any other lifting mechanism.

If in doubt as to the size or type of lifting equip-ment, the method and procedures to be used in connection with lifting, contact YORK Refrigeration before proceeding to lift the compressor, motor, unit or its components.

Always inspect slings, chains, hoists and other lift-ing devices prior to use. Do not use lifting devices which are defective or in a questionable condition.

Never exceed the lifting capacity of cranes, slings, eyebolts and other lifting equipment. Follow standards and instructions applicable to any lifting equipment used.

Before inserting an eyebolt, be certain that both the eyebolt and the hole have the same size and type of threads. To attain safe working loads, at least 90% of the threaded portion of a standard forged eyebolt must be engaged.


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WWarning!

Failure to follow safety instructions on this page may result in serious personal injury or death.

Installation and Relocation SafetyBefore lifting the compressor, unit or other parts of the plant, consult the instruction manual or YORK Refrigeration for proper methods and pro-cedures.

An electrician must read and understand the elec-trical diagrams prior to connecting the machine to the power source. After connecting the machine, test all aspects of the electrical system for proper functioning. Always make sure that the machine is grounded properly. Place all selector switches in their O or neutral (disengaged) position. The doors of the main electrical cabinet must be closed and the main disconnect switch must be in the O position after the power source connec-tion is complete.

Before starting the compressor for the first time, make sure that all the motors rotate in the indicat-ed direction.

Set-Up and Operation SafetyRead and understand all the safety instructions before setting up, operating or servicing this com-pressor. Assign only qualified personnel instruct-ed in safety and all machine functions to operate or service this compressor.

Operators and maintenance personnel must care-fully read, understand and fully comply with all warnings and instruction plates mounted on the machine. Do not paint over, alter or deface these plates or remove them from the compressor/unit. Replace all plates which become illegible. Re-placement plates can be purchased from YORK Refrigeration.

Safety guards, shields, barriers, covers and pro-tective devices must not be removed while the compressor/unit is operating.

All safety features, disengagements and inter-locks must be in place and function correctly be-fore this equipment is put in operation. Never by-pass or wire around any safety device.

Keep all parts of your body off the compres-sor/motor/unit during operation. Never lean on or reach over the compressor.

During operation, pay attention to the compressor unit process. Excessive vibration, unusual sounds, etc. can indicate problems requiring your immediate attention.

Maintenance SafetyDo not attempt to perform maintenance on the compressor unit until you have read and under-stood all the safety instructions.

Assign only qualified service or maintenance per-sonnel trained by YORK Refrigeration to perform maintenance and repair work on the unit. They should consult the service manual before attempt-ing any service or repair work and contact YORK Refrigeration in case of questions. Use only YORK Refrigeration replacement parts; other parts may impair the safety of the compres-sor/unit.

Before removing or opening any electrical enclo-sure, cover, plate or door, be sure that the Main Disconnect Switch is in the O position and the main fuses are dismantled.

If any tool is required to remove a guard, cover, bracket or any basic part of this compressor, place the Main Disconnect Switch in the O position and lock it in the O position. If possible, post a sign at the disconnect switch indicating that main-


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tenance is being performed. Dismantle main fus-es to the unit.

When maintenance is to be performed in an area away from the disconnect, and the switch is not locked, tag all start button stations with a “DO NOT START” tag.

Adequate precautions such as warning notices or other equally effective means must be taken to prevent electrical equipment from being activated electrically when maintenance work is being per-formed.

When removing electrical equipment, place number or labelled tags on those wires not marked. If wiring is replaced, be sure it is of the same type, length, size and has the same current carrying capacity.

Close and fasten all guards, shields, covers, plates or doors securely before power is recon-nected.

An electrician must analyse the electrical system to determine the possible use of power retaining devices such as capacitors. Such power retaining devices must be disconnected, discharged or made safe before maintenance is performed.

Working space around electrical equipment must be clear of obstructions.

Provide adequate illumination to allow for proper operation and maintenance.

Materials Used with this ProductAlways use YORK Refrigeration original spare parts.

Please note the type of refrigerant on which the compressor operates as well as the precautions that need to be taken as described in the following sections:

• First aid for accidents with ammonia.

• First aid for accidents with HFC/HCFC.

• First aid for accidents with HC.

• First aid for accidents with CO2

• Protecting the operator as well as the environment.

WDangerHIGH VOLTAGE!

Before working on any electrical circuits, place the Main Disconnect Device of the compres-sor/unit in the "OFF" position and lock it. Dis-mantle the main fuses to the compressor unit. Unless expressly stated in applicable YORK Refrigeration documentation or by ap-propriate YORK Refrigeration Field Service Representative, do NOT work with the electri-cal power "ON". If such express statement or advice exists, work with the electrical power "ON" should be performed by a YORK Refrigeration Field Service Represent-ative. The customer and subsequent transfer-ees must make sure that any other person per-forming work with the electrical power "ON" is trained and technically qualified.FAILURE TO FOLLOW THIS INSTRUCTION MAY RESULT IN DEATH OR SERIOUS PERSONAL SHOCK INJURY.


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First Aid for Accidents with Ammonia

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

WWarning!

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

GeneralAmmonia is not a cumulative poison. It has a di-stinctive, pungent odour that even at very low, harmless concentrations is detectable by most persons.

Since ammonia is self-alarming, it serves as its own warning agent so that no person remains vol-untarily in hazardous concentrations. Since am-monia is lighter than air, adequate ventilation is the best means of preventing an accumulation.

Experience has shown that ammonia is extremely hard to ignite and under normal conditions a very stable compound. At extremely high, though limit-ed concentrations, ammonia can form ignitable mixtures with air and oxygen and should be treat-ed with respect.

Basic Rules for First AidAlways call a doctor immediately.

Be prepared: Keep an irrigation bottle available containing a sterile isotonic (0.9%) NaCl-solution (salt water). A shower or a water tank should be available near all bulk installations with ammonia.

When applying first aid, the persons assisting must be duly protected to avoid further injuries.

First Aid MeasuresInhalation: Immediately, move affected person-nel into fresh air and loosen clothing restricting breathing.

Call a doctor/ambulance with oxygen equipment.

Keep the patient still and warmly wrapped in blan-kets.

If mouth and throat are burnt (freeze or acid burn) and the patient is conscious, let him drink water in small mouthfuls.

If the patient is conscious and mouth and throat are not burnt, feed him sweetened tea or coffee (never feed an unconscious person).

Oxygen may be given to the patient, but only when authorised by a doctor. If the patient stops breathing, apply artificial respiration.

Eyes: In case of injuries from liquid splashes or concentrated vapour, immediately rinse with wa-ter (preferably using an eye rinser) and consult a doctor. Continue rinsing until otherwise stated by a doctor.

If the affected person wears contact lenses these must be removed before the rinsing.

Skin: In case of burns from liquid splashes or con-centrated vapour, immediately wash with large quantities of water until the pain stops.

Consult a doctor about actual burns.

After washing, apply wet compresses - wetted with a sterile isotonic (0.9%) NaCl-solution (salt water) - to affected areas until medical advice is available.


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First Aid for Accidents with HFC/HCFC

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

WWarning!


GeneralHFC/HCFC form colourless and invisible gasses which are heavier than air and smell faintly of chloroform at high concentrations.

Characteristics:• non-toxic

• non-inflammable

• non-explosive

• non-corrosive

When heated to above approx. 300°C, they break down into toxic, acid gas components, which are strongly irritating and aggressive to nose, eyes and skin and generally corrosive.

Besides the obvious risk of unnoticeable, heavy gases displacing the atmospheric oxygen, inhala-tion of larger concentrations may have an accu-mulating, anaesthetic effect which may not be im-mediately apparent. 24 hours medical observation is therefore recommended.

Basic Rules for First AidWhen affected persons are moved from low-lying or poorly ventilated rooms where high gas con-centrations are suspected, the rescuer must wear a lifeline and be under constant observation from an assistant outside the room.

Do not use adrenaline or similar heart stimuli.

Inhalation: Immediately move affected persons into fresh air. Keep them still and warm and loos-en clothing restricting breathing.

If the patient is unconscious, call a doctor/ambu-lance with oxygen equipment immediately.

Apply artificial respiration until a doctor authorizes other treatment.

Eyes: Immediately rinse with water (preferably using an eye rinser) and consult a doctor. Contin-ue rinsing until otherwise stated by a doctor.

If the affected person wears contact lenses these must be removed before the rinsing.

Skin: In case of frost-bite, immediately rinse with luke-warm water (max. 37°C) and remove all clothes impeding blood circulation.

Consult a doctor.

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


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Protecting the Operator as well as the Environment

WWarning!


Increasing industrialisation threatens our environ-ment. It is therefore absolutely imperative to pro-tect nature against pollution.

To this end, many countries have passed legisla-tion in an effort to reduce pollution and preserve the environment. This legislation applies to all fields of industry, including refrigeration, and must be complied with.

Pay extra attention to the following substances:

• refrigerants

• cooling media (brine, etc.)

• lubricating oils

Refrigerants usually have a natural boiling point considerably below 0°C. This means that liquid re-frigerants can be extremely harmful if they come into contact with skin or eyes.

High concentrations of refrigerant vapours can be suffocating when they displace air.

If high concentrations of refrigerant vapours are inhaled, they will attack the human nervous sys-tem.

When halogenated gasses come into contact with open flame or hot surfaces (over approx. 300°C), they will decompose to produce poisonous chem-icals. These have a very pungent odour and will thus warn personnel of their presence.

At high concentrations R717 causes respiratory problems. When the amount of ammonia vapour in air is between 15 and 28 vol. % the combination is explosive and can be ignited by an electric spark or open flame.

Oil vapour in the ammonia vapour increases this risk significantly as the point of ignition falls below that of the mixture ratio stated.

Usually the strong smell of ammonia will warn personnel before the concentration becomes dangerous.

The following table shows the values for the max. permissible refrigerant content in air measured in volume %. Certain countries may, however, have official limits different from the ones stated.

Halogenated refrigerants Am-monia

CO2

HFC HCFC

R134a R404a R407C R410a R507 R22 R717 R744

TWATime weighted average during a week

Unit

0.1 0.1 0.1 0.1 0.1 0.1 0.005 0.5

Vol.%

Warning smell Vol.% 0.2 0.002


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Furthermore, it can be said about refrigerants:

HFC/HCFC • If released into the atmosphere, halogenat-

ed refrigerants of the type HCFC (e.g. R22) will contribute to the depletion of the ozone layer in the stratosphere. The ozone layer protects the earth from the ultraviolet rays of the sun. Refrigerants of the types HFC and HCFC are greenhouse gases which contrib-ute to an intensification of the greenhouse effect. They must, therefore, never be re-leased into the atmosphere. Use a separate compressor to draw the refrigerant into the plant condenser/receiver or into separate refrigerant cylinders.

Ammonia

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

• Even small amounts of ammonia in water (2-5 mg per litre) are enough to wreak havoc with marine life if allowed to pollute water-ways and lakes.

• As ammonia is alkaline, it will damage plant life if released into the atmosphere in large quantities.

Hydro Carbons (HC) • HC gasses are a group of B1 refrigerants

characterized as very flammable.

• Hydro carbons are odourless and non-toxic gasses. Specific mixtures of air and gas cre-ate danger of explosion. As the gasses are heavier than air, they will be concentrated at the lowest possible level in case of leaks.

Carbon Dioxide (CO2)

• Carbon dioxide (CO2) is a greenhouse gas

with a GWP (Global Warming Potential) fac-tor of 1. It is found in the atmosphere in a concentration of 0.036 vol. % (360 parts per million, ppm). As CO2 is extracted from at-

mospheric air, it can safely be released into the atmosphere and does not contribute to enhancing the greenhouse effect.

• The boiling point for CO2 is -78.5°C at 1.013

bar.

• CO2 is an odourless, non-toxic non-inflam-

mable gas. At concentrations higher than 5000 ppm the gas can be dangerous for hu-mans. The gas is heavier than air and will thus be concentrated on the lowest level of the room in case of a leak. In closed rooms the gas can displace oxygen and cause suf-focation.

Refrigerant evacuated from a refrigeration plant must be charged into refrigerant cylinders intend-ed for this specific refrigerant.

If the refrigerant is not to be reused, return it to the supplier or to an authorized incineration plant.

Halogenated refrigerants must never be mixed. Nor must R717 ever be mixed with halogenated refrigerants.


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Purging a Refrigeration Plant

If it is necessary to purge air from a refrigeration plant, make sure to observe the following:

• Refrigerants must not be released into the atmosphere (exept CO2).

• When purging an R717 plant, use an ap-proved air purger. The purged air must pass through an open container of water for any remaining R717 to be absorbed. The water

mixture must be sent to an authorized incin-eration plant.

• Halogenated refrigerants cannot be ab-sorbed by water. An approved air purger must be fitted to the plant. This must be checked regularly by use of a leak detector.

Note: The occurrence of air is usually an indica-tion of poor maintenance or lack of thoroughness at installation.


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Cooling MediaSalt solutions (brines) of calcium chloride (CaCl2)

or sodium chloride (NaCl) are often used.

In recent years alcohol, glycol and halogenated compounds have been used in the production of brine.

In general, all brines must be considered harmful to nature and they must be used with caution. Be very careful when charging or purging a refrigera-tion plant.

Never empty brines down a sewer or into the environment. The brine must be collected in suitable containers clearly marked with the contents and sent to an approved incineration plant.

Lubricating Oils

WWarning!

When charging oil, follow the safety instructions given by the oil supplier (MSDS: Material Safety Data Sheet). Always avoid direcst contact with the oil as this may cause skin allergies. Always use

protective equipment - goggles and gloves - when charging oil.

Refrigeration compressors are lubricated by one of the following oil types depending on the refrig-erant plant type, and operating conditons.

– Mineral oil (M oil)

– Hydro treated mineral oil (H oil)

– Semi-synthetic oil (mix of M oil and syn-thetic oil)

– Alkyl benzene-based synthetic oil (A oil)

– Polyalphaolefine-based synthetic oil (PAO oil)

– Polyalkylen Glycol-based synthetic oil (PAG oil)

– Ester oil (E oil)

See the section Selecting lubricating oil for YORK Refrigeration compressors in section 6, Technical Data.

When changing the oil in the compressor or drain-ing oil from the vessel of the refrigeration plant, al-ways collect the used oil in containers marked “waste oil” and send them to an approved inciner-ation plant. It is not recommended to re-use oil.

Note:

These instructions only provide general information. The owner of the refrigeration plant is responsible for ensuring that all codes, regulations and industry standards are complied with.

4. Technical Description

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4. Technical DescriptionThe purpose of this document is to describe the intended purpose, the physical characteristics and the functions of the unit.

This document is primarily intended for designers, service engineers, prospective customers, sales personnel and personnel undergoing training.


YORK RefrigerationChr. X's Vej 201DK-8270 HoejbjergDenmark



Areas of Application of the Reciprocating Compressor Unit

Application

In view of preventing an unintended application of the compressor, which could cause injuries to the operating staff or lead to technical damage, the compressors may only be applied for the following purposes:

• As a refrigeration compressor with the number of revolutions pr. minute specified by YORK Refrigeration and the operating limits as stated in this manual or in a written agreement with YORK Refrigeration.

• Compressor types SMC 100 and TSMC 100 in an S or L execution can - as standard compressors - be used with the following re-

frigerants: R717 - R22 - R134a - R407C - R404A - R507 - R600 - R600A - R290 - LPG. This manual only deals with the ones written in bold letters.

• Compressor types SMC 100 and TSMC 100 in an E execution are as standard compres-sors used with R717 only.

• The compressors can be used with other re-frigerants, but only following a written agree-ment with YORK Refrigeration.

• SMC 100 and TSMC 100 compressors in S, L or E executions may be used at a max dis-charge design pressure of 25 bar. See Test Pressure Levels for Standard Compressors and Components in section 6.

• The compressors are approved for applica-tion in an explosion-prone environment, pro-vided they have been fitted with explo-sion-proof equipment. This can be seen from the Ex nameplates, , fixed on each unit.

Fig. 4.1

Please, note that specially made tools which can-not cause any sparks must be used in connection with maintenance work on the compressor.

T2516273_0


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WDanger!

YORK Refrigeration does not take any responsi-bility for injuries to personnel or damage to equip-ment resulting from using this equipment for other purposes than the ones stated above.

Application of Combustion EnginesIf combustion engines are installed in rooms con-taining refrigeration machinery or rooms where there are pipes and components containing refrig-erant, make sure that in case of leakage the com-bustion air for the engine comes from an area in which there is no refrigerant gas.

Failure to do so will involve a risk of lubricating oil from the combustion engine mixing with refriger-ant; at worst this may lead to corrosion and dam-age of the engine.

WWarning!

The compressor must NOT be used:

• For evacuating the refrigeration plant of air and moisture,

• For putting the refrigeration plant under air pressure in view of a pressure test-ing,

• As an air compressor.


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Description of the Compressors Compressor TypesReciprocating compressor types SMC 100 and TSMC 100 represent a series of open compres-sors with 4 to 16 cylinders in one and the same block. The cylinders are positioned in a V or W po-sition and have the same internal diameter of 100

mm. The series comprises 15 one-stage and 6 two-stage compressors with the following type designations:

Compressors with 4, 6 and 8 cylinders are called short blocks whereas compressors with 12 and 16 cylinders are called long blocks.

Fig. 4.2

One-stage compressors are designated SMC which is an abbreviation of SABROE Multi-cylin-der Compressor. As for the two-stage compres-sors the letter T has been added to indicate Two stages.

Further, the compressors can be delivered with the following three strokes, designated S, L or E, respectively:

• Type S has an 80 mm piston stroke and is used with all approved refrigerants.

• Type L has a 100 mm piston stroke and is used with all approved refrigerants.

• Type E has a 120 mm piston stroke and is used only in connection with R717. The compressor has 50% more capacity than type S.

Short Block

SABROE

Long Block


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The operating limits (including number of revolu-tions) depend on the compressor type and refrig-erant. As the extension of the operating limits is an

ongoing process, please make sure that the dia-gram in question is the latest revision before mak-ing a conclusion.

Below are given some examples of type designations of the compressors:

An entire list of the compressor series can be seen in the table Technical Data for SMC 100 Se-ries in Section 6, Technical Data.

The type and version of the various compressors can be read from the name plate shown below. A name plate is fixed on every compressor.

Similarly, the serial number of each compressor is stamped into the compressor block. The letter S, L or E, which refers to the compressor stroke, is stamped into the end surface of the crankshaft.

Whenever contacting YORK Refrigeration about a compressor, please state its serial number.

Compressor type:Cylinder Diameter: 100 mm

Number of Cylinders: 4-6-8-12 or 16Stroke: S, L or E

SMC 108 L

Compressor type:Cylinder Diameter: 100 mm

Number of Cylinders: 8 or 16Stroke: S, L or E

TSMC 116 S

One-stage compressor

Two-stage compressor

DK 8270 Højbjerg 2516-327Refrigeration

Compressor

Nominal Speed

Swept Volume

Allowable Pressure

Test Pressure

No Year

RPM

m3/h

bar

bar

Type


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Compressor DescriptionWith a few exceptions, all compressors of the SMC 100 or TSMC 100 types use the same spare parts as the ones described in the following sec-tion.

One-stage CompressorsThe compressors are equipped with replaceable cylinder liners, pos. 19A, Fig. 4.3, which are made of special cast iron and are easy to disman-tle for inspection. They are honed and surface hardened, which makes them very wear resistant. Underneath each top cover there are always two cylinders.

Fig. 4.3 SMC 100 Cylinder Liner Complete

The pistons, pos. 18, are made of aluminium with two hard-plated piston rings and one oil scraping

ring ensuring optimum tightness, low oil consump-tion as well as long life.

19A

21

19H

20


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Fig. 4.4 Piston

Suction valve, pos. 19H, which is of the ring plate type, is fitted at the top of the cylinder liner and can be removed together with the cylinder liner.

Discharge valve, pos. 20, forms the top of the cylinder and is kept in place by a powerful spring, pos. 21. This spring is also called the safety spring as it enables the complete discharge valve to lift a little at particularly high pressures in the cylinder due to liquid or oil in the compressed gas (liquid slugging). Thus overloading of the bearings in the connecting rod is avoided.

The compressor is designed for operation with liq-uid slugging for a short time only. If liquid slugging occurs (the sound of hard metal hammering), the compressor must be stopped and the cause must be removed.

Connecting rod, pos. 17, Fig. 4.5 is made of cast iron with a large elongation after fracture. It has re-placeable slide bearings, pos. 17A and B, at both ends on single stage compressors and on the first stage (LP) on TSMC. On the second stage (HP) on TSMC, the small end bearing is of the rolling el-ement type.

The reason for this is that the top of the HP pistons are affected by the intermediate pressure, which is higher than the suction pressure, and thus gives

a downward force during suction. This is different from the top of the LP pistons which are affected by a pressure lower than the suction pressure which gives the piston an upward force during suction.

Fig. 4.5 Connecting Rod, SMC 100

Suction filter: All the compressors are equipped with very large built-in suction filters, pos. 34A, Fig. 4.6, with great filtering capacity which effec-tively filters off the dirt particles conveyed with the gas from the refrigeration plant to the compressor. The suction filters are made of stainless steel and, by dismantling the covers, pos. 34E, they are easy to pull out and clean.

When a compressor is delivered, a fine-meshed filter bag, pos. 34B, has been fitted in the suction filters. The filter bag filters off the tiny rust particles that may pass the suction filters and is thus pro-viding the compressor with considerable protec-tion from dirt mixing with oil. The filter bags are used no longer than 50 hours after initial start up of the compressor. This also applies when chang-es, which may cause impurities in the suction gas, are made on the plant. After the 50 hours, the filter bags and the inserts for the filter bags pos. 34C must be taken out and discarded. Used filter bags

18

17A17B

17

SMC andTSMC LP

TSMC HP17B


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must be disposed of according to existing environ-mental legislation, see also Section 11 Mainte-nance Instructions and Section 20 Final Disposal.

Fig. 4.6 SMC 100 Filter Section and by-pass valve

By-pass valve: The compressor is equipped with a built-in mechanical by-pass valve, Fig. 4.6 and Fig. 4.7, pos. 24, which safeguards the compres-sor against unintended over-pressure in case the

electric safety equipment should fail. The bypass valve acts as a kind of over-pressure safeguard between the discharge and suction side of the compressor.

Fig. 4.7 SMC/TSMC 100 - By-pass Valve

34A

34E

34B

34C

24

24C

B

24B

A


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The by-pass valve is delivered pre-set, sealed and adjusted to the following opening pressures:

– Standard for SMC and TSMC (HP stage) compressors: 24 bar [348 psi].

– Special for SMC - and TSMC (HP stage) compressors: 22 bar [319 psi]; this is only delivered following a specific order and applied in accordance with local rules and regulations concerning pres-sure vessels as e.g. oil separators. The current set pressure is stamped into the name plate pos. A.

– Standard for TSMC (LP stage) compres-sors: 12 bar [174 psi].

The by-pass valve is of the high-lifting type, which makes it robust and durable.

Moreover, the by-pass valve is independent of the pressure on the suction side of the compressor. Consequently, it opens only when the pressure on the discharge side exceeds the set pressure com-pared to that of the atmosphere.

Note: The by-pass valve should not be consid-ered a safety valve.

Fig. 4.8 SMC 104-108 Short Block

Fig. 4.9 TSMC 112-116 Long Block

The crankshaft, pos. 16, Fig. 4.8, rests in large slide main bearings pos. 5 and 6 which are able to absorb both radial and axial loads. Both the main bearings and the connecting rod bearings at the large end of the connecting rod are easy to re-place in connection with an overhaul of the com-pressor and need no additional finishing after re-mounting. The bearings are available in 0.5 mm undersize to be used for crankshafts that are ground to 0.5 mm undersize during a renovation. After having been ground to undersize, the crank-shaft needs no surface hardening or the like, but can be used directly as bearing surface. The crankshaft is dynamically balanced for a smooth and vibration free operation and need no further balancing after the above-mentioned machining to undersize. In the SMC 112-116 compressors the crankshaft is also supported by an intermedi-ate bearing, pos. 49A, .

16

6

5

49A


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Fig. 4.10 SMC 112 - 116 and TSMC 116

The oil pump, pos. 11A, Fig. 4.13, is built into the compressor and driven by the crankshaft by means of a coupling. The oil pump is a self-prim-ing gear pump which takes the oil from the oil sump through an oil suction strainer in the crank-case, pos 33A, Fig. 4.12 and forces it through the full flow filter into the lubricating system.

The oil pressure regulating valve, pos. 22, Fig. 4.11 regulates the oil pressure in the com-pressor lubricating system. It can be adjusted from the outside by means of a screw driver when the pointed screw, which locks the regulating screw, has been loosened. For variable speed driven compressors, the oil pressure has to be ad-justed to the minimum oil pressure at minimum speed. Due to rising pressure drop at high oil flow, the pressure will rise when running at maximum rpm.

Fig. 4.11 Oil pressure regulating valve

The Oil suction strainer pos. 33A prevents dirt particles in the oil of the crankcase from entering the oil pump with a subsequent wear on the pump bearings. The filter is of the full flow filter type. The filter can be cleaned.

Fig. 4.12 oil suction strainer

External oil filter, pos. 9A. After the oil pump, the oil is furthermore filtered in an external oil filter of the full flow filter type, pos. 9A, before it is led into the lubricating system. The filter element is a dis-posable filter and must be replaced by a new one as soon as its filtering ability has been used up. The replacement can be carried out without re-ducing the refrigerant pressure on the compres-sor.

49A

Pos. 22

Pointed screw

Pos. 33A


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Fig. 4.13 Oil pump cover assembly

Shut-off valves, pos. 4K and pos. 4D are used for dismantling the oil filter. The shut-off valves must be completely open during operation to avoid pressure drops in the oil system. For additional information about function see oil diagram Fig. 4.15.

The air purge valve, pos. 4E is used to reduce the pressure in the oil filter before dismantling. The valve pos. 4E further acts as a prelubrica-tion valve.

Prelubrication of the compressor must always be carried out before the initial start up and after a long period of standstill.

This way the bearings and the oil system are lubri-cated and the oil pump is filled with oil. The hose from the prelubrication pump must be connected

to the branch pos. 4F on the pump housing. After this, the compressor is ready for start up.

The non-return valve, pos. 4L acts as a bypass valve when the differential pressure above the oil pump is too high.

Fig. 4.14 Valves and filter on oil pump cover

The shaft seal, pos. 10, is a sealing component which prevents oil and refrigerant from the com-pressor interior from leaking into the atmosphere. The shaft seal is of the slide ring type, consisting of a plane, lapped cast iron slide ring which ro-tates with the crankshaft and seals against a sta-tionary spring-loaded slide ring made of special carbon. The shaft seal is of the balanced type and consequently serves a universal purpose in view of operating conditions, refrigerants and oil types used for the compressor.

The design of the shaft seal and coupling of the motor is such that the shaft seal can be removed from the compressor without removing neither compressor nor motor. This facilitates mainte-nance considerably.

9A4K

4D

4E

4F

4L

11A

4Q

11B

9A

4D4E

4F4L 4k


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Fig. 4.15 Oil diagram

H H

H

4D-1 9A

4N-1PDI

4E-1

4K-1

4L-1

11A-1

33A-1


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Fig. 4.16 Shaft seal

The heating rod, pos. 57, Fig. 4.17 keeps the oil warm when the compressor is not in operation. This reduces the refrigerant content in the oil and eliminates starting-up problems caused by oil foaming and subsequent insufficient oil pressure. While the compressor is operating, the heating cartridge can be switched off, but if it is problem-atic to maintain the oil temperature sufficiently high, it may be an advantage to keep the heating cartridge on during operation.

Fig. 4.17 SMC 100 block Pump end

Oil draining valve, pos. 23, for draining and charging of oil. An inner socket at the draining valve ensures that the oil sump is properly drained so that the compressor does not have to be opened when changing oil and filters.

The oil level glass, pos.1B, indicates the pre-scribed oil level in the crankcase. See Section 6, Technical Data - Charging the Compressor with Oil.

Evacuating valve, pos. 42, Fig. 4.18, for evacu-ating the compressor of refrigerant or air after service.

Pos. 10

57231B


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Fig. 4.18 SMC 104 - 108 Short Block

The stop valves, pos. 25-3 and 25-4, are fitted on the compressor discharge and suction flanges for efficient blocking off of the compressor from the refrigeration plant. The stop valves have welding

flanges for connection to ISO and ASME standard pipes. Pipe dimensions are indicated on the di-mension sketches in Section 5, Physical and Con-necting data.

Instrumentation: As standard equipment the compressors are fitted with either an analogous reading and safety system consisting of pressure gauges, pressure switches and thermostat, or with a SABROE microelectronic reading and con-trol system, UNISAB II, as shown in Fig. 4.19. Both systems are described in detail later in this section.

Cooling of compressor and oil: On request the compressor can be delivered with a built-in cool-ing system with either water or refrigerant as de-scribed in the section, Cooling Systems for Com-pressors.

25-44225-3


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Fig. 4.19 Instrumentation

UN

ISA

B II

UN

ISA

B II

D

D

D45

J--

1

45J

--1

45

39

39

4530A

30A

31C

--1

31C

--1

39B

--1

39B

--1

31C

--1

31C

--1

31A

31A

99

99

39A

--1

39A

--1

DA

nal

og

ou

s co

ntr

ol a

nd

sa

fety

sys

tem

An

alo

go

us

con

tro

l an

d

safe

ty s

yste

m

Nam

e p

late

Nam

e p

late


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Two-stage Compressors Type TSMC 100

The TSMC compressors are so-called compound machines in which the refrigerant gas is com-pressed in two stages. The compressor is divided into a low-pressure section, LP, and a high-pres-sure section, HP. The cylinders in the low-pres-sure section compress the gas from evaporating pressure, PE, to intermediate pressure, PI.

During the compression the gas is heated and must consequently be cooled down in the interme-diate cooling system before it reaches the high-pressure stage.

At the high-pressure stage, the gas is compressed from PI to the condensing pressure PC.

The system is described in detail in Cooling of the intermediate discharge gas on TSMC compres-sors later in this section.

The TSMC 100 compressors are available with 8 or 16 cylinders, divided as indicated:

TSMC 100 compressors are connected to instal-lations where the compression ratio (PC/PE) is higher than the permissible compression ratio π for one-stage compressors. This is described in detail in Section 6, Technical Data, Operating Lim-its.

As mentioned previously all compressor types in the SMC 100 and TSMC 100 series - with a few exceptions - are built up of the same components and with the same facilities.

However, the TSMC 100 compressors deviate on the following points:

Compressor BlockThe interior of the compressor block is construct-ed with suction chambers for both low pressure and high pressure stages. The pressure in the crankcase is the same as the suction pressure of the LP stage. TSMC 108:

6 low-pressure (LP) cylinder 2 high-pressure (HP) cylinder

TSMC 116:12 low-pressure (LP) cylinder4 high-pressure (HP) cylinder


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Piston Pin BearingIn the SMC and TSMC low-pressure stages the piston pin bearing consists of slide bearings, pos. 17B, Fig. 4.20. In the connecting rods of the high-pressure stage a needle bearing, pos.17B-2, has been fitted. This is because HP pistons on two-stage compressors - as opposed to single stage and LP pistons - are often subject to uni-di-rectional force.

Fig. 4.20 TSMC 100 Cylinder Liner Complete

Similarly, an O-ring, pos. 19M, is used to seal the intermediate pressure chamber from the crank-case in which there is evaporating pressure.

Fig. 4.21 TSMC cylinder liner

17A17B

17

TSMC LP

TSMC HP17B

19M


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Suction Filters

In the TSMC compressors the two suction filters vary in design. The suction filter for the LP stage is of the same type as the ones for the SMC com-pressors and is characterised by square holes in the shell and openings at both ends.

In the high-pressure stage a suction filter of the same size as the one for the LP stage has been fitted, but this has round holes in the shell and is closed at one end.

Fig. 4.22

Depending on the type of refrigerant and the suc-tion and discharge pressures, a by-pass system is sometimes used to regulate the intermediate pressure PI in order to prevent it from falling below the specified pressure.

The system is either built onto the compressor at the factory or mounted on the refrigeration plant if several two-stage compressors work in parallel.

The by-pass system is described in detail later in this section under Cooling of the Intermediate Dis-charge Gas on TSMC Compressors.

The TSMC 100 compressors can be delivered with one or two oil separators depending on the type of refrigerant and area of application. Other-wise, the terms of delivery are the same as the ones described for one-stage compressors.

B

TSMC 108

LP

HP

HP

Closed end and O-ring sealing

LP

TSMC 116


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Conversion of TSMC Compressors from Two-stage to One-stageIf necessary, it is possible to convert a two-stage compressor into a one-stage compressor.

The following variations are possible:

a. Altering the compressor and using the same refrigerant

b. Altering the compressor and changing the re-frigerant from R717 to HFC/HCFC at the same time

c. Altering the compressor and changing the re-frigerant from HFC/HCFC to R717 at the same time

Generally, the conversion includes the following points:

1. Replacing the suction filter with a normal one-stage suction filter on the HP side.

2. Dismantling the pipe connection on the HP suction side and installing a standard cover, pos. 34 E.

3. Changing the pipe connections on the discharge side. As the built-in channel, which connects the top covers on a one-stage compressor, does not exist between the HP and LP top covers, this connection must be established externally.

4. Changing the HP stage connecting rods to the single stage type (journal bearing in small end). The piston pins must be changed.

5. Ensuring that the correct suction and dis-charge valves are fitted.

6. Installing the correct by-pass valves.

7. Adjusting the safety pressure controls.

Moreover, it is necessary to replace the compres-sor name plate and the name plates on the safety valves.

Please contact YORK Refrigeration’s After Mar-ket Sales Department for further information.


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Oil Separator Type OVUR

The purpose of the oil separator is - under all kinds of operating conditions - to separate the oil which is conveyed with the disharge gas out of the compressor so that it will be led back to the com-pressor crankcase.

The oil separator is mounted on the compressor unit and connected to the discharge gas outlet of the compressor as indicated in the drawing, Fig. 4.23.

On some units the oil separator is not mounted.

Fig. 4.23 Standard Compressor Unit

Mode of OperationThe discharge gas from the compressor flows through the oil separator, Fig. 4.24, from A to B, passing a number of filters in which the oil is sep-arated from the discharge gas. The filters consist of a stainless steel wire mesh which usually needs no cleaning and which is not worn down. Conse-quently, the filters cannot be removed from the oil separator.

Fig. 4.24 Oil Separator

Selecting an Oil SeparatorAs the velocity through the oil separator affects the ability of the oil separator to separate the oil from the discharge gas, a series of oil separators of different sizes has been designed. See Section 6, Technical Data, Selecting an Oil Separator.

Oil Separator

L

B

A

A:B:L:

Discharge gas inletDischarge gas outletOil return to compressor


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Oil Return to the Compressor

The oil separated in the oil separator is usually conveyed directly back to the compressor crank-case by means of the differential pressure be-tween the pressure of the oil separator, PC, and that of the crankcase, PE.

As the return of gas from the discharge side to the suction side will have a negative effect on the plant, it is desirable to lead only the separated oil back to the crankcase. This is controlled by using a thermodynamic liquid trap (TLT) combined with a reliable solenoid valve which blocks the system at standstill. Furthermore, it makes it possible to delay the opening of the oil return after start up and thus allowing condensed refrigerant, if any, in

the oil separator to evaporate and not be led back to the crankcase.

For plants which do not allow solenoid valves, a reliable float valve controlled system can be deliv-ered at an additional price.

A: Solenoid Valve Controlled Oil ReturnAs illustrated in the drawing, Fig. 4.25, the oil from the oil separator is led to the compressor crank-case via valve block A and the TLT.

In the oil separator at position C the pipe is insert-ed 10 mm into the end plate whereby any sedi-ment can settle at the bottom of the oil separator.

Fig. 4.25 Solenoid Valve Controlled Oil Return

Oil separator

C

Compressor

Valve block A Pos. 80A-1

Solenoid valve

Filter TLT valve Pos. 80C-1

stop valve

OrificePos. 80B-1


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In valve block, pos. A, Fig. 4.26, the oil first pass-es a stop valve which is normally completely open. This is not a regulating valve and it is closed only during maintenance work on the com-pressor and during cleaning of the filter in the valve block.

Fig. 4.26 Valve Block, pos. A, Oil Return

From the stop valve the oil passes a wire mesh, which can be removed and cleaned.The filtered oil now passes the solenoid valve, which must be

closed at dead coil whenever the compressor is stopped. When the compressor is operating, the solenoid valve is open, allowing the oil to flow to the compressor.

As stated above it is recommended, however, to keep the solenoid valve closed for 20 to 30 min-utes after start-up by means of a time relay (which may be ordered as an accessory part). Thus the oil is not returned to the compressor before the oil separator is warm and has evaporated any refrig-erant which may have mixed with the oil at the bot-tom of the oil separator.

This time function is built into the UNISAB II sys-tem.

The solenoid valve seat is available with various boring diameters and nozzle sizes. For this pur-pose Ø3.3 mm must be used.

The coil for the solenoid valve can be delivered as a standard part with the following data:

Table 4.1

Wire mesh

Inlet

Outlet

Nozzle

Coil Sizes

220/230 Volt 50/60 Hz 10 Watt

115 Volt 50/60 Hz 10 Watt

240 Volt 50 Hz 10 Watt


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Thermodynamic Liquid Trap (TLT)The purpose of the TLT valve is to ensure that only oil is led back to the compressor as warm dis-charge gas mixed with the oil will cause the com-pressor capacity to decrease.

Fig. 4.27 Thermodynamic Liquid Trap TLT

The TLT valve works in the following way:

A thermodynamic liquid trap uses a disc to control the release of liquid and to trap gas. The trap cy-cles open and close to discharge liquid and closes tightly between discharges. The disc, which is the only moving part, rises and falls in response to dy-namic forces produced by the gas flowing through the trap.

Liquid and/or gas enters the trap through the cen-tral orifice, lifts the disc and is discharged through the outlet orifice. The gas passes along the under-side of the disc at high velocity and collects in the control chamber above. The resulting pressure imbalance forces the disc downward onto the seating surfaces and stops the flow.

The trap remains tightly closed until the loss of heat through the trap body lowers the control chamber pressure, allowing the inlet pressure to raise the disc and repeat the cycle.

One side of the disc (3) is plain with a single scratch towards the outer edge, whereas the oth-er side of the disc has a machined circular groove.

The trap is supplied with the grooved side of the disc towards the seating faces and is suitable for clean operating conditions.

If there are irregularities in the oil return, it may be due to impurities in the oil. The problem can be solved by unscrewing the cap, preferably using a ring spanner, and turning over the disc so that the plain side with a bleed scratch is towards the seat-ing faces.

Replace the cap - no gasket is required but a suit-able high temperature anti-sieze grease without copper should be applied to the threads.

MountingIn principle, the liquid trap can function in all posi-tions but to minimise uneven wear (and thereby achieving maximum life time) mounting it in a hor-izontal line with the cap up or down is recom-mended. See also Fig. 4.25.

The surface of the connection is machined to make a tight sealing using Al gasket.

Fig. 4.28 Principle piping diagram

1 : Housing2 : Cap3 : Disc

6

3

2

4

1

5

4 : Strainer5 : Strainer Cap6 : Gasket

TLT 15 EVRB

245893Reciprocating compressor

Nozzle ø 3.3 mm

Oil separator


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B: Float Valve Controlled Oil ReturnThe float valve is located in a separate float ves-sel, mounted on the side of the base frame and connected to the oil separator and compressor as illustrated on Fig. 4.29.

Fig. 4.29 Float Valve Control Oil Return

The separated oil is drained through stop valves A and filter D to the float vessel C, and here the float valve opens at an increasing oil level and returns the oil to the crankcase.

The pipe connection with valve B acts as a pres-sure equalizer between the two vessels. The float can be dismantled for servicing.

Oil Return in Connection with Parallel OperationIf several compressors are running in parallel on the same refrigeration plant, it is expedient to ad-just their oil level in the crankcase by means of an automatic system. This is particularly necessary in the case of HFC and HCFC plants in which the oil is returned to the compressors with the suction gas as it is not distributed evenly on all the com-pressors.

However, also in modern, automated R717 refrig-eration plants an automatic oil equalizing system can contribute to greater reliability, thus reducing the daily inspection tours.

The following passages A, B and C include a de-scription of the three systems most commonly used.

The following passages describe each of the three systems in general. For more detailed infor-mation, please contact YORK Refrigeration.

B

C

To the compressor

A D


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System A

System A is used where two or more compres-sors are working in parallel and where either HFC, HCFC or R717 is used as the refrigerant. It is a condition, however, that the compressors keep working at the same suction pressure.

Principle diagram, Fig. 4.30, is an example of a plant with two compressors working in parallel on the same suction and discharge line.

Fig. 4.30 Principle Diagram

Table 4.2

2

3

4

1 12

3

47

6

5

9

10

5

7

6

9

8

5

11

12

13

14

1516

14

AlternativeOil seperator with float valvecontrolled oil return

StandardOil seperator with solenoil valvecontrolled oil return

1. Compressor 9. Oil vessel

2. Float valve 10. Non-return valve,1 bar

3. Filter 11. Solenoid valve

4. Stop valvet 12. Nozzle, dia. 3.3 mm

5. Oil separator 13. Filter

6. Solenoid valve incl. nozzle (Fig. 4.30) 14. Heating cartridge

7. Non-return valve 15. Oil charging valve

8. Float valve 16. Oil level glass


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As illustrated in Fig. 4.31 a float valve, pos. 2, is fitted on each of the compressors in front of the oil level glass. This makes the oil level in the float house equal to that in the crankcase. This can be checked visually in the oil level glass. The com-plete float valve can be seen in Fig. 4.31.

Fig. 4.31 Float Valve Housing with Float Valve

The float controls a needle valve which opens at a falling oil level, letting the oil flow from the oil ves-sel, pos. 9, return to the compressor. This ensures a constant oil level in the compressor.

Fig. 4.32 Oil Vessel, pos. 9

The oil vessel, pos. 9, is illustrated by the principle drawing, Fig. 4.32. Its size is calculated so that an extra amount of oil is available to ensure the oil level in the compressor.

The total volume of the vessel should be approx. 50% of the oil volume in all the compressors, and the vessel should not be charged to more than 50%.

This means that the amount of oil in the vessel corresponds to 25% of the total amount of oil in the compressor.

The oil vessel must be equipped with:

- heating rod, 240 W, pos. 14- oil charging valve, pos. 15- oil level glass, pos. 16

From the top of the oil vessel, pos. 9, a pipeline is taken to the suction side of the plant.

A non-return valve, pos. 10, Fig. 4.30, has been inserted in the pipeline, and this valve opens at a differential pressure of 1 bar. This way the pres-sure in the oil vessel will be 1 bar higher than the suction pressure in the plant. This is sufficient in order to squeeze the oil through the float valves, pos. 2, without causing foaming in the float valve houses.

Pipe connection Vent valve

Oil level glasson compressor

16

To common suction line

240 W

To float valves

15

Max. oil level

14


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The Oil Return Systems from the Oil Separa-tors are the same as the ones described in Oil re-turn to the compressor in this section. The only dif-ference is that the oil return system is not connect-ed to the compressor but taken to the common oil vessel, pos. 9.

Solenoid valve, pos. 6, closes whenever the actu-al compressor stops.

In case the oil return system from the oil separa-tors is controlled by a float valve, which is also de-scribed in this section, it will be necessary to mount a pipe connection to the discharge pipe as illustrated in Fig. 4.33.

This ensures a slight gas flow to the oil vessel, pos. 9, and consequently overpressure that presses the oil out to the compressors through

float valves, pos. 2. Solenoid valve, pos. 11, clos-es when the plant stops and all the compressors are stopped.

Fig. 4.33 Oil separator with float valve control-led oil return

9

8

5

11

12

1314


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System B

System B is used where more than two compres-sors are working in parallel but where they do not have any joint suction line. The refrigerant may be HFC, HCFC or R717.

Principle diagram, Fig. 4.34, is an example of a plant with two compressors working in parallel but which do not have the same suction pressure, PE+, PE-.

Fig. 4.34

Table 4.3

A-B Compressor 9. Oil vessel

2a-2b. Level Switch 10. Non-return valve,1 bar

3. Filter 11. Solenoid valve

4. Stop valve 12. Nozzle, dia. 3.3 mm)

5. Oil separator 13. Filter

6a-6b. Solenoid valve incl. nozzle (Fig. 4.34) 14. Heating cartridge

7. Non-return valve 15. Oil charging valve

8. Float valve 16. Oil level glass

ET--

ET+

4

3

2a 2b6b6a

A B

5 5

7

6

7

6

3

4

9

9

8

5

11

12

1314

10

1416

15

To condenser

AlternativeOil seperator with float valvecontrolled oil return


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To be able to press the oil from the oil vessel, pos. 9, to the crankcase on the compressor, pos. A, which is working at the highest suction pressure PE+, the pipeline with the non-return valve (1 bar), pos. 10, is connected to the suction gas line for this compressor.

There is a risk, however, that the differential pres-sure between the oil vessel, pos. 9, and the crank-case on compressor B may become so great that the oil conveyed via the solenoid valve 6a starts foaming. Usually, this foaming does not cause any problems as the oil is supplied to the compressor

above oil level. Any foaming that may occur will soon be dissolved in the crankcase.

The system has one further advantage as the oil does not pass the level switch vessels 2a and 2b. Should foaming occur, this is not going to interfer with the working of the level switch.

In case the oil return system is regulated by means of a float valve as described under System A, the same system as the one shown in Fig. 4.35 should be used.


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System C

System C is a float regulated oil return system which is used when only two compressors are op-erating in parallel with the same condenser. It is not a requirement that the suction pressure is the same on the two compressors. The float valve is of the same type as the one used in system A.

The oil level equalizing system is illustrated in Fig. 4.35.

It works by pressing the oil from one compressor to the next by means of the oil pump pressure (4.5 bar), pos. 3, in each of the compressors.

The oil level in the crankcase is regulated by a float valve, pos. 2a or 2b, which opens at a falling oil level in the compressor.

If e.g. the oil level in compressor A is too low, the float valve, pos. 2a, will open. The oil pump in compressor B will now supply oil through the sole-noid valve (nozzle incl.), pos. 1a, until a normal oil level has been established, whereupon the float valve will close. The solenoid valve pos. 1 is open when the compressor in question is running.

Fig. 4.35

1a - 1b: Solenoid valve2a - 2b: Float valve3a - 3b: Connection to oil pump discharge4a - 4b: Standard oil return system

A

B

4a

4b

3a

1a 2a

2b1b

SN

V8

CD

ø10/8

ø10/8

3b


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Capacity Regulation of CompressorAll compressors have a built-in capacity regulat-ing system which continually adjusts the compres-sor capacity to the cooling requirements of the plant. Even at reduced capacity the compressor works very efficiently. This makes it very well-suit-ed for plants with reduced cooling requirements for lengthy operating periods.

Fig. 4.36 Capacity Regulating Mechanism

The capacity regulating system including the frame, pos. 13, is activated by the compressor oil pressure and controlled by means of solenoid valves fitted on the compressor. At a capacity re-duction two suction valves are forced open at a time. In this case no compression takes place in the relevant cylinders as the sucked in gas in the cylinders is pressed back to the suction chamber through the suction valves.

The above forced opening of the suction valves is also used when starting up the compressor. The system works as follows: At compressor standstill all the suction valves are forced into an open po-

sition and cannot be closed until the compressor is in operation and the oil pump has built up the oil pressure in the lubricating system. With an open suction valve there is no compression resistance in the compressor and this reduces its starting torque considerably. Thus, a motor dimensioned to suit the operating conditions of the compressor can easily start up the compressor also by using the star/delta starting system.

For compressors fitted with extra capacity stages (extended unloading), one cylinder (SMC 104-106-108) or two cylinders (SMC 112-116) will be in operation all the time, also at start up. See extended unloading.

Capacity Regulation and Unloading of Compressor

Capacity RegulationAs mentioned in the introduction to this section all SMC and TSMC compressors are fitted with a hy-draulic capacity regulating system by means of which the compressor capacity can be adjusted to the refrigerating requirements of the plant.

When reducing the compressor capacity, two or more suction valves (on compressors with ex-tended unloading: one or more suction valves) are forced open so that compression does not occur in the cylinders in question.

The suction valve is forced open when the unload-ing ring together with the pins, pos. 19B, are pressed up under the suction valve, thus keeping the valve in open position as shown in Fig. 4.37.

13


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Fig. 4.37 Cylinder Liner Complete

The unloading ring, pos. 19B, is activated by two rocker arms, pos. 15A, Fig. 4.38, one at each side of the cylinder liner. The rocker arms, which are placed in ball sockets, pos. 15B, are moved back and forth by the unloading frame, pos. 13.

The unloading frame, which is controlled by two brackets with guiding pins, does always activate two cylinders at a time. The unloading frame is moving back and forth by means of the unloading cylinder, pos. 12. If oil pressure is put on the cylin-der during operation, the unloading frame will move to the left as shown in Fig. 4.38. Thus the angle of slope of the rocker arms is changed so that the unloading, ring pos. 19F, is able to move freely. Consequently, the cylinder is forced to work.

If the oil pressure to the unloading cylinder closes, the unloading frame, pos. 13, will move to the right, thereby raising the rocker arms. The unload-ing ring with pins, pos. 19B, are pressed up under the ring plate and the suction valve is forced open, thereby unloading the cylinder.

Fig. 4.38 Unloading System

19A

19B

19F

15B

15A

1312


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Start Unloading

As already mentioned the compressor cylinders are unloaded when there is no oil pressure on the unloading cylinders. This means that when the compressor is stopped, i.e. without any oil pres-sure, all the unloading cylinders are unloaded and consequently there is no compression resistance during start-up.

This unloading during start-up reduces the start-ing torque of the compressor considerably.

This can be seen from the starting torque curves, in Section 6, Technical Data.

Solenoid Valves for Capacity RegulationThe unloading cylinders are controlled by sole-noid valves, Fig. 4.39, which receive opening and closing signals from a connected regulator. This could e.g. be a programme device or the YORK electronic control system, UNISAB II, as de-scribed later in this section under Instrumentation.

Fig. 4.39

The solenoid control valve is an electromagnetic three-way valve which, with a dead coil, connects the unloading cylinder, pos. 12, with the crank-case (the passage of the oil flow from pipe 2 to pipe 3 is open), Fig. 4.39

If the coil is energized, the valve will reverse so that the passage of the oil flow from oil discharge

pipe 1 to 2 is open and the connection to pipe 3 is closed.

The solenoid valves are mounted in joint blocks, Fig. 4.40, with one, two, three or four solenoid valves in each block.

3

2

2

2

1

12


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Fig. 4.40 Solenoid Valve Block

In the block there is a common supply of pressure oil from the oil pump (pipe a) to the solenoid valves as well as a common connection to the crankcase (pipe c). Each solenoid valve has its own oil connection to the relevant regulating cylin-der (pipe b).

Regulating SequenceAs described earlier, the compressors are always completely unloaded during start up exept for the compressor with extra capacity stages (ex-tended unload), which will always have one or two cylinders loaded during start up (SMC104-108) and (SMC 112-116).

Standard compressors, however, with 2 cylinders on the SMC 104, 106 or 108 compressors or 4 cyl-inders on SMC 112 and 116 will be set to work when the compressor oil pump has worked up an oil pressure in the lubricating system.

The cylinders mentioned are connected directly to the oil system without any solenoid valve as shown in . This makes it the lowest capacity stage on the compressors.

The standard SMC 100 compressors can be reg-ulated with the following capacity stages, repre-sented by the hatched fields in Table 4.4.

b

c

a


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Schematic Drawings, Standard

SMC/HP 104

%100

50

LY

1

N

2 1

SMC/HP 106

%100

YL

N

1

21

3

26733

SMC 186

SMC/HPC 108SMC 188

%

100

YL

N

1

2

3275

25 4

3

4

SMC 112 TSMC 108TSMC 188

SMC 116 TSMC 116

%

100

83

67

50

33

LY

N

1

3

5

2

4

6

%

1006733

LY

0

HP

1

2

S

S

%

Y

N

L

S

100

83

67

50

33

Y

NL

3

1

75

5

5

6

2

%

100

50 3

12

37

5

S87

63

2

6

1

3

5

S

4S

S

1

3 1

4

8

S

1

2

1

3

2

4

25

1

50

4

2


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The electric regulating system should be made in such a way that, after start-up, addi-tional capacity cannot be loaded until the mo-tor has reached its full torque.

The recommended run up time is 10 sec. The min-imum speed according to the operating limit dia-gram is 5 sec (also applies to variable speed driv-en compressors).

Fig. 4.41 illustrates the regulating system in prin-ciple. The percentages indicate the compressor capacity at every stage. When unloading a com-pressor without extra capacity stages, the sole-noid valves are unloaded in numerical order: 1 -> 2 -> 3 -> 4. When loading, the order is: 4 -> 3 -> 2 -> 1.

Note: On TSMC 116 compressors the solenoid valves nos. 3 and 4 must always be loaded simul-taneously as they control both the LP and the HP cylinders.

Further, the TSMC compressors can, as standard equipment, be totally unloaded as described in the following.

Total UnloadingBesides the standard equipment as described in the previous passage the compressor can be fit-ted with a solenoid valve marked S (optional). Fig. 4.41.

The TSMC compressors, however, are always equipped with this S solenoid valve.

The S solenoid valve makes the total unloading of the compressor possible - i.e. the compressor idles at 0% capacity. The S solenoid valve must never, however, be part of a normal capacity reg-ulation as the compressor will heat up excessively during a lengthy operating period at 0% capacity. The S solenoid valve must therefore only be used as follows:

• When total unloading is required until the motor has reached its maximum torque mo-ment.

• When a refrigeration plant has sudden brief operational stops for a short time and com-pressor stop is not required. In this case the compressor must not be allowed to run for more than 5 minutes at 0% capacity. If the compressor is equipped with a refrigerant cooled oil cooler type OOSI (R717) or OOKH (HFC/HFCF) and liquid refrigerants are available so that the cooling system can operate, idling is allowed for up to 30 min-utes.

The regulating sequence can be seen from the schematic drawings in Fig. 4.41.

Capacity Stages:The SMC 100 compressors can be regulated with the following capacity stages, represented by the hatched fields in Table 4.4.


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Fig. 4.41 Schematic drawings, Additional Equipment

%

100

67

%

SMC/HPC 104

33

10050

0

LY

N

S

1

1S

SMC/HPC 106

1

SMC 186

2

S

1

2

S

LN0

100

%

Y

SMC/HPC 108

1

25

100

0

75

L

50

N

Y

1

22

3

S

3

S

Compressor seen from the shaft end

1

Relief cylinder2

3Oil return

Oil pressure

SMC 112

S

83

67

50

33

0L

Y

N

%

2

4

1

S

3

2

4

S

S

1

3

SMC 188

SMC 116

%

%

75

1

1

7550

025

100

LY

N

2

S

3

2

S 1

3

100

87

63

50

3725

0

LY

N

3 S

5

2

4 6

S

1

3

5

2

4

6

S

S

A

BB

A


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Table 4.4

As illustrated in Table 4.4, the SMC 100 standard compressors can only be capacity regulated in steps of two cylinders, which is sufficient in most cases.

However, it will occasionally be required to feature more stages and for this reason a system called “extended unloading” has been developed to ca-

pacity regulate the compressor in steps of one cyl-inder per stage with the following capacity stages represented by the hatched fields in Table 4.5.

Table 4.6 displays the numbers of the solenoid valves which must be activated to obtain the stat-ed capacity stages (load).

CompressorType

Capacity per Stage in %

25 33 37 50 63 67 75 83 87 100

SMC 104

SMC 106

SMC 108

SMC 112

SMC 116

TSMC 108

TSMC 116


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Table 4.5 Extended unloading

Base: Capacity step by one cylinder. For SMC 112 and SMC 116 min. load two cylinders.TSMC not included.

The system is optional and can be ordered when an order for a new compressor is placed.

Already delivered SMC 100 compressors can be converted for extended or totally unloaded sys-

tems by means of reconstructing kits supplied by YORK Refrigeration's After Market Service De-partment.

LoadType : SMC 100

104 106 108 112 116

12.5%

16.7%

18.8%

25.0%

31.3%

33.3%

37.5%

41.7%

43.8%

50.0%

56.3%

58.3%

62.5%

66.7%

68.8%

75.0%

81.3%

83.3%

87.5%

91.7%

93.8%

100.0%


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Extended unloading, solenoid valve no. according to Fig. 4.41

Table 4.6

LoadType : SMC 100

104 106 108 112 116

12.5% 0 0

16.7% 0 0

18.8% A

25.0% 0 S A AB

31.3% 6A

33.3% S AB

37.5% 3 6AB

41.7% 4A

43.8% 56B

50.0% S 2 3S 4AB 56AB

56.3% 456A

58.3% 34B

62.5% 23 456AB

66.7% 2S 34AB

68.8% 3456B

75.0% 1 23S 234A 3456AB

81.3% 23456A

83.3% 12 234AB

87.5% 123 23456AB

91.7% 1234B

93.8% 123456B

100.0% 1S 12S 123S 1234AB 123456AB


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Extended UnloadingThe additional capacity stages are obtained by changing the unloading of one (SMC 104, 106 and 108) or two (SMC 112 and 116) cylinder pairs in such a way that the relief system only works the one cylinder while the other one is constantly con-nected.

Note: When the mentioned systems are used, the compressor will not start up completely un-loaded but with capacity as shown in Table 4.7.

Table 4.7

The change is obtained by removing the following pos. nos. from the constantly connected cylinder: both systems of rocker arms pos. 15A-1, bearing cup pos. 15B-1, spring retainer pos. 15C-1, spring

pos. 15D-1 and tand washer for bearing cup pos. 15E-1.

The constantly connected cylinder is not mounted with unloading ring pos. 19B, washer pos. 19C-1, spring pos. 19D-1 and spring pos. 19E. It is marked “S” on the guide ring for the discharge valve pos. 19J-1. See the position of the cylinder in Fig. 4.43.

Fig. 4.42 Cylinder Liner with Suction Valve

104 106 108 112 116

25% 16.5% 12.5% 16.5% 12.5%

S

19J


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Fig. 4.43 Position of cylinders in compressor frame

The valve body as for “Total unloading” is used to regulate the capacity stages instead of the stand-ard valve body and the corresponding connecting pipes are mounted.

The increased starting torque must therefore be taken into consideration when choosing motor and start system.

For this purpose, the start up torque curves for R717 compressors and for HFC/HCFC compres-sors might be useful. These figures can be seen in Section 6, Technical Data, Starting torque of the

compressor. Please note that the max rpm is shown in the Operating Limits Diagrams in section 6.

Please note that if the motor is started up by means of a Y/∆ starter, the starting torque of the compressor may exceed the starting torque of the motor at a high differential pressure. In these cas-es the compressor must be equipped with a by-pass system which makes the pressure on the discharge side of the compressor equivalent to the suction pressure as illustrated in Fig. 4.44.

4 2

3 S1

S

4

36

5

S

1

3

48

7

6

5

SMC112 S MC116

12

11

10

9

S

7

S 3

5 2

4 1

13

14

59 1

6S 2

15

16 12 S 4

7 311

SMC 104 SMC 106 SMC 108


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Fig. 4.44

After long operating hours at minimum capacity, the temperature of the compressor block and the oil will exceed the normal operating temperatures. It is therefore recommended to adhere to

YORK Refrigeration's recommendations as to the cooling of the compressor. These recommenda-tions can be found in the Operating Limits dia-grams.

Variable speed drive (VSD)Further, the compressor can be driven by VSD as long as the rpm limits are not exceeded - see Op-erating limits. For the standard and total unloading compressor, UNISAB II is able to control the VSD combined with the mechanical capacity control in the most efficient way taking into consideration both energy consumption and wear.

Solenoidvalve

Nonreturn valve orautomatically controlledstop valve


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Compressor Units

The compressor units can be delivered as stand-ard units with base frames adapted to IEC electric motors. Against additional payment base frames can also be delivered for non-standard electric motors. On the base frame one oil separator can

be mounted for the SMC compressors and two oil separators for the TSMC compressors. Oil return from oil separator to compressor is controlled by a system as described in the section, Oil return to the compressor.

Fig. 4.45

The compressors can be connected to an electric driving motor or a combustion motor. The trans-mission can be either direct through a coupling that is flexible in both radial and longitudinal direc-tion but which is also rigid in its contorsion, there-by stabilising the compressor rotation. The trans-mission can also take place by means of a V-belt drive, which, through the selection of standard belt pulley diameters, is able to provide the com-pressor with the correct number of revolutions and consequently, the desired compressor capacity. For more information, read Section 6, Technical Data.

Please note that the compressor must be modified in order to change the direction of rotation: the oil pump must be changed on Mk4.

Extent of Delivery The compressors can be delivered as blocks only in standard execution or mounted on a base

frame as standard units as illustrated on dimen-sion sketches in Section 6, Technical Data, see also Dimension and Piping diagrams. Further-more, it is possible to have compressors built into non-standard units following a specific agreement with YORK Refrigeration.

A standard compressor is delivered without oil in the crankcase but charged with Nitrogen N2 to 0.2

bar [3 psi] overpressure.

A yellow label, Fig. 4.46, on the compressor indi-cates this Nitrogen charge.

Fig. 4.46

SMC 100 Unit - Direct Couple SMC 100 Unit - V-belt Driven

Påfyldt beskyttelsesgasCharged with inert gasEnthält SchutzgasChargé du gaz protecteurContiene gas protector

N20,2 bar3 PSI

1534-169


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Instrumentation

In the standard version the compressors are avail-able with one of the following two systems:

A: analogue reading and safety system

B: UNISAB II reading, safety and capacity regulating system

The compressors are designed so that either the analogue system or the UNISAB II system can be fitted without changing the compressor. They each have their own characteristics, however, as described in the following:

A: Analogue Reading and Safety SystemThe analogue system only has reading and safety functions and cannot control the com-pressor capacity.

Capacity control is handled by an external system built into the electrical switchboard and connected to the compressor on the mounting site. Some mounting costs must be expected.

The control system can be one of many types and makes. It must, however, be able to send out opening and closing signals to the solenoid valves of the compressor in the prescribed unloading and loading sequence as already described in this section, Capac-ity Regulation and Unloading of Compres-sor.

In special cases a manually operated switch system can be used instead of the automat-ic one. This makes it possible to regulate the compressor capacity by hand.

In its standard execution the analogue sys-tem consists of controls, built onto the com-pressor on delivery, but without electrical connections.

The controls are not factory adjusted and should therefore be adjusted before the ini-tial start-up of the compressor.

As may be seen from the drawing Fig. 4.47 some of the controls have a dual function, i.e. the type designation KP15 indicates that 1 is the low pressure and 5 the high pres-sure cut-out function. KP98 e.g. has two temperature systems incorporated.

The specific controls are mentioned in the following, with reference to the numbers in Fig. 4.47.

Fig. 4.47

6 5 4 3 2 1


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1. High Pressure Cut-out KP15

Adjusted to stop the compressor if the dis-charge pressure rises to a pressure 2 bar [29 psi] lower than the setting pressure of the by-pass valve.

The pressostat has a manual reset function.

2. Low Pressure Cut-out KP15

Adjusted to stop the compressor if the suc-tion pressure drops to a pressure corre-sponding to 5K lower than the lowest evap-orating pressure.

The pressostat has an automatic reset function

and will therefore restart the compressor once the pressure rises again.

3. Intermediate Pressure Cut-out KP5

Used only on TSMC compressors. Stops the compressor if the intermediate pressure has risen to 8 bar [116 psi].

The pressostat has a manualreset function.

4. Oil Differential Cut-out MP55

Adjusted to stop the compressor if the pres-sure in the lubricating system drops below 3.5 bar [51 psi] compared to the pressure in the crankcase.

The pressure cut-out has a built-in time de-lay of 60 sec. which keeps it idle during the start-up of the compressor until the correct oil pressure has been established.

The pressostat has a manual reset function

as well as a yellow indicator lamp which, when illuminated, indicates that the electric circuits are working. Normal oil pressure in the compressor is 4.5 bar [65 psi] which is indicated on the manometer 9 on Fig. 4.48.

5. Discharge Pipe Thermostat KP98

Adjusted to stop the compressor if the discharge gas temperature exceeds:

150 °C [302 °F] for R717

120 °C [248 °F] for HFC/HCFC

This adjustment can, however, be set to 20°C [68 °F] above the normal discharge gas temperature, once this is known from experience. This makes it possible to safe-guard the compressor against excessive temperatures.

The thermostat has a manual reset function.

6. Oil Thermostat KP98

Adjusted to stop the compressor whenever the oil temperature in the crankcase ex-ceeds 80°C [176 °F].

The thermostat has a manual reset function.

7. Oil Filter Differential Pressostat

Indicates when oil filter pos. 9A needs to be replaced. Connections on the pressostat has a transparent housing and will indicate power supply with green LED and filter re-placement with red LED.


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Manometers

For reciprocating compressors the following three types of manometers are available:

Fig. 4.48

8. High Pressure Manometer

High pressure manometer indicating the discharge pressure of the compressor and used in SMC compressors. Fig. 4.48

9. High and Intermediate Pressure Manom-eter

High and intermediate pressure manometer indicating the discharge pressure for the HP and LP stages on TSMC compressors, Fig. 4.48.

This manometer has two manometer works and two arrows, a red one for high pressure and a black one for intermediate pressure.

10. Low Pressure and Oil Pressure Manometer

Low pressure and oil pressure manometer indicating the compressor suction pressure and oil pressure in the lubricating system of the compressor. Used in the SMC and TSMC compressors.

This manometer has two manometer works which are interconnected so that one of the works indicate the suction pressure with an arrow whereas the oil pressure is indicated by means of a dial in the middle of the ma-nometer and turned round by the other works. The figure on the dial right below the arrow indicates the oil pressure. This makes it possible to read the oil pres-sure directly from the manometer.

The manometers can be used with several refrigerants.

• HFC/HCFC manometers for R22, R134a, R404A

• R717 manometers

• R410A, R744 (CO2) manometers

On delivery of compressors using other re-frigerants the manometers are graded for that particular refrigerant. The standard units on the scale is bar/°C but others can be delivered on request.

8-910


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B: UNISAB II Reading, Safety and Capacity Regulating System

UNISAB II is a computerized control and monitoring system which is specially devel-oped to fit all YORK Refrigeration's SABROE reciprocating and screw compres-sors, i.e. the same UNISAB unit is used for both compressor types. It is only necessary to select type of compressor, refrigerant and a few other functions - and the UNISAB will be ready for operation. UNISAB II is based on YORK Refrigeration's extensive experi-ence with design and operation of compu-terized compressor control systems.

Fig. 4.49 Computerized Control and Monitoring

UNISAB II is designed for safe control, mon-itoring and optimization of compressor oper-ation and a minimum of unintended opera-

tion stops. In addition to efficient control and monitoring of single compressors UNISAB II is also designed for advanced control and monitoring of any combination of up to 14 compressors. It is thus possible to centrally control and monitor up to 14 compressors by using a COMSAB or PC COMSAB module.

Multi-lingual SystemUNISAB II is available in 15 different lan-guages, and it is possible to switch to the English version at any time.

Easy to Operate

UNISAB II has a systematic and easily ac-cessible user interface which does not re-quire any special knowledge or education.

Operational data and status appear from the distinct display which features four lines with twenty characters each. The user interface also has arrow keys for menu selection, set key for parameter changing as well as keys for selection of manual/automatic operation, start/stop, manual capacity regulation and resetting.


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Safety Monitoring and ControlUNISAB II provides safe monitoring by means of warning and alarm values/settings for all measuring points. If a set value is ex-ceeded, a red diode will flash slowly in warn-ing situations without stopping the compres-sor, and quickly in alarm situations with compressor shut down. A display text will show the cause of the alarm. In both warn-ing and alarm situations separate relays are activated for connection of a remote lamp, bell or alarm panel.

It is easy to find all the set values and their warning and alarm values through the straightforward menu system.

Besides monitoring the compressor pres-sures and temperatures, the UNISAB II also calculates the suction pressure vapour overheating, monitors the capacity slide po-sition and oil flow, and calculates the oil filter differential pressure on screw compressors.

For correct fault diagnosis in case of a com-pressor shut down, the UNISAB II immedi-ately stores the alarm situations in its mem-ory which can be displayed and analyzed on the display at any time.

InstrumentationDepending on compressor type the UNISAB II is equipped with a number of

pressure and temperature transducers as well as position transmitters on the com-pressor. On one-stage reciprocating com-pressors three pressure and three tempera-ture transducers are mounted while two-stage reciprocating compressors are equipped with four pressure and tempera-ture transducers.

Screw compressors are fitted with four pres-sure and three temperature transducers as well as one or two slide position transmit-ters.

Furthermore, a thermistor input is available for motor protection.

Factory TestEvery UNISAB II is tested during the pro-duction process and when it is mounted on the compressor. A computer test is per-formed including a test certificate before the compressor leaves the factory.

Please note that UNISAB II cannot directly combine the capacity of compressors with extended capacity control; only SMC 104 can be controlled directly by UNISAB II when it is equipped with a simple box (this has to be configured as a HPC 108 or SMC 108).


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Cooling of the Intermediate Discharge Gas on TSMC CompressorsAt two-stage operation it is necessary to cool the discharge gas from the LP stage before it enters the HP stage. This intermediate cooling is carried out with the systems described below, depending on the type of refrigerant used.

Common for these intermediate cooling systems is that they must cool the intermediate pressure gas sufficiently and at the same time ensure that no liquid is admitted into the HP stage since liquid may result in liquid slugging in the HP cylinders and excessive wear on the moving parts. It is therefore important to check the systems as de-scribed below.

Intermediate Cooling System with Intermediate Cooler Type DVEA, R717The two-stage R717 plant may consist of two compressors, one low-pressure compressor (LP) and one high-pressure compressor (HP) as illus-trated in Fig. 4.50 The plant may also consist of one or more two-stage compressors as shown in Fig. 4.51.

In both cases the compressors are connected to an intermediate cooler in which the warm gas from the LP-stage is cooled down before it flows on to the HP-stage.

In the intermediate cooler the liquid level of R717 is regulated by the float valve and the discharge gas from the LP stage is cooled by bubbling up through the refrigerant from the distributor at the bottom of the intermediate cooler.

Fig. 4.50 SMC 100 compressor

Fig. 4.51 TSMC 100 Compressor

In the liquid subcooling spiral the refrigerant flow-ing from the receiver to the evaporator in the re-frigeration plant is cooled. The intermediate cooler is dimensioned so that the cooled gas is free of liq-uid refrigerant before leaving the top of the inter-mediate cooler. It is important to check that the float valve is operating correctly and keeping the liquid level constant. Frosting of the liquid level pipe on the intermediate cooler indicates the liquid level.

Oil separatorOil separator

Equalizing pipe

Mixingchamber

Solenoidvalve

Float valve

Liquid subcoolingspiral

Oil drain off

Intermediatecooler type

DVEA

HP

LP

CT

LP

IP HP

IP

Oil separator Oil separator

Mixing chamber

Equalizing pipe

Solenoid valve

Float valve

Liquid subcoolingspiral

Oil drain off

Intermediatecooler

CT

LP IP HP

LP IP


78/288 0178-931 - ENGRev. 27.10.03


As a matter of precaution a solenoid valve should be used in the liquid line to the float so that it may shut off the liquid flow to the intermediate cooler whenever the system is stopped.

At regular intervals the intermediate cooler must be drained of oil through the oil drain valve.

Intermediate Cooling System with Liquid Injection into the Intermediate Discharge Gas, R22 and R717

Two-stage compressors type TSMC can be equipped with a pipe connection from the LP stage discharge branch to the HP stage suction branch as shown in Fig. 4.52.

In the pipe connection the warm discharge gas from the LP stage is cooled by injection of liquid refrigerant into the intermediate pipe. This can be achieved with the following two systems:

1. Intermediate Cooling with ThermostaticExpansion Valve Type: TEA (R717) or TEX (R22)

Fig. 4.52

In the system in Fig. 4.52 the liquid refrigerant conveyed to the intermediate pipe is regulated by a thermostatic expansion valve type TEA (R717) or TEX (R22) with a sensor placed on the intermediate pipe close to the HP stage.

Connection, pos. B, pipe dimension OD 10 mm, emerges from receiver or priority vessel as de-scribed in Cooling with thermopump - R717 later in this section. The intermediate discharge pipe is built onto the compressor on delivery as a block or a unit. On delivery of a compressor block the liquid system including the expansion valve must be mounted on site.

2. Intermediate Cooling with Thermostatic Injection Valve Type: TEAT (HCFC)

The intermediate cooling system is designed as il-lustrated in Fig. 4.53. Here the intermediate cool-ing is carried out by a thermostatic injection valve of the TEAT type and the subcooling takes place in a HESI heat exchanger.

Fig. 4.53

The sensor of the TEAT valve is placed in a sen-sor pocket at the HP discharge branch of the com-pressor, and a proper thermal contact is obtained by means of the heat conducting compound. The solenoid valve is opened by the KP77 thermostat whenever the temperature of the pressure pipe exceeds 55°C [131°F].

Oil separator

CT

Mixing chamber

Stop valve

FilterSolenoid valve

LP

Opt

TSMC

TEA or TEX

B

T

HPIPIPLP

Oil separator

Mixing chamber

CT

LP

Liquid supply

To evaporatorFrom receiver

LPA

TEAT

KP 77

HESI


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Automatic Regulation of Intermediate Pressure IPIn two-stage plants with reciprocating compres-sors it should be pointed out that the intermediate pressure is not allowed to drop excessively.

A low intermediate pressure reduces the damping effect of the gas on the valve plates in the LP stage discharge valves. The danger is that a breakdown may occur in the form of broken valve plates.

In order to prevent this it may be necessary to mount a by-pass system between the HP side and IP side. Thus a suitable amount of gas is led back to the IP side. The system is illustrated in Fig. 4.54.

The lower limits for IP have been fixed at:

-15°C [5°F] for R717 plants

- 25°C [-13°F] for HFC and HCFC plants.

The by-pass system is additional equipment and is usually mounted by YORK Refrigeration direct-ly on the internal pipe connections on the com-pressor block .

The diagrams, Fig. 4.50 to Fig. 4.53, do only show the principle of the different systems and must not, therefore, be used directly.

Fig. 4.54

Determining the Intermediate Pressure IPThe intermediate discharge temperature of the compressor is dependent on the evaporating tem-perature ET, the condensing temperature CT and of the ratio between the capacity at the LP and HP stages, corres-ponding to the number of cylinders that is working at each stage.

If a TSMC compressor is working at 100% capac-ity, the ratio between the number of cylinders is 3:1 as indicated in the Table 4.8.

When unloading the cylinders, this ratio is changed to 2:1 or 1:1 and the intermediate pres-sure will drop accordingly.

The intermediate discharge pressure is deter-mined by entering the suction tempera-ture ET and the condensing temperature CT into the cal-culation programme COMP 1. The lower limits for the intermediate discharge pressure are the same as stated above:

-15°C [5°F] for R717 plants and

-25°C [-13°F] for HFC and HCFC plants.

To ensure correct operating conditions all partial load possibilities must be calculated. If the result of the calculation shows values below the stated limits, a by-pass must be fitted as described above.

However, it is also possible to connect the capac-ity regulating system in such a way that the com-pressor cannot operate at the capacity stages which produce suction temperatures lower than the limiting value of the refrigerant in question.

As described in the section Capacity regulation the TSMC compressors can be capacity regulated at the following stages:

LPHPIP

LPLP

LP

Opt.

B

TSMCPM main valveCVC pilot valve -0.75 -> 7 bar

Oil separator


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Table 4.8

Compressor Type

Capacity%

Number ofCylindersWorking

Ratios

LP HP

TSMC 108100 66 33

642

222

3:1 2:1 1:1

TSMC 116

100 83 67 5033

1210 8 6 4

44422

3:12.5:1 2:1 3:1 2:1


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Cooling Systems for CompressorsTo preserve the optimum lubricating capacity of the oil it may become necessary to cool during compressor operation. Depending on the operat-ing conditions and the type of refrigerant the plant uses, a number of cooling systems are available. See Section 6, Technical Data, Operating Limits Diagrams.

The following standard cooling systems can be delivered for the compressors, depending on which type of refrigerant the compressor is oper-ating with as well as the compressor type itself.

Standard Cooling Systems for Compressors1. R717

a. SMC only: Air-cooled top and side covers and refrigerant-cooled oil cooler.

b. Water-cooled top and side covers.

c. SMC only: Compressor cooling with thermopump

2. R22-R134a-R404A-R507-R410A-R744

a. Air-cooled top and side covers.

b. Air-cooled top covers and water-cooled side covers.

c. Air-cooled top and side covers and refrigerant-cooled oil cooler.

Description

1a: Air-cooled Top and Side Covers with Refrigerant-cooled Oil Cooler R717

Air-cooled top and side covers are covers without cooling fins, but with a surface large enough to re-

lease any surplus heat in the compressor into the environment, see Fig. 4.55 and Fig. 4.56.

Fig. 4.55 Air-cooled Top Cover

Fig. 4.56 Air-cooled Side Cover

There is therefore no need for forced cooling air flow past the covers.

It is, however, necessary to cool the oil in the com-pressor by means of a built-in oil cooler, which is cooled by the refrigerant in the plant. The cooling system is built onto the compressor. It operates as illustrated in piping diagram, Fig. 4.57, for a nor-mal one-stage compressor and in Fig. 4.58 for a booster compressor.

The cooling system consists of an oil cooler mounted on the oil pipe which connects the oil pump with the shaft seal. The oil cooler is dimen-sioned to maintain the oil temperature at 50-70°C [122 - 158 °F].

The expanding gas is led through pipe, pos. 1, Fig. 4.57, to the compressor suction side. On the outside of the pipe the sensor for the thermostatic expansion valve, type TEA, is fitted.


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The expansion valve, type TEA, is particularly suited for R717. In the liquid line there is also a so-lenoid valve which closes when the compressor is stopped.

Fig. 4.57 Normal One-stage Compressor R717

The filter filters off any dirt particles in the liquid. The filter element can be removed and cleaned. The stop valve can block the cooling system from the refrigeration plant.

A thermostat T is connected to the cooling system and its sensor is placed in the oil of the crankcase. The thermostat is set to open the solenoid valve whenever the oil temperature exceeds 55°C [131 °F]. In this way it is made sure that the oil heats up quickly and separates as much refriger-ant as possible. UNISAB II controls the solenoid valve directly based on the measured oil temper-ature.

Booster Compressor

As illustrated in Fig. 4.57, the pipe pos. 1 is taken to the LP side of the compressor. This means that the compressor must compress the gas coming from the oil cooler which makes up only a very small part of the compressor capacity.

The pipe pos. 1 on the booster and two-stage compressor is led to the IP side as illustrated in Fig. 4.58 and Fig. 4.59. Thus the compressor ca-pacity is not affected by the oil cooling system. The liquid supply is regulated by a thermostatic in-jection valve of the TEAT type whose sensor is placed on the discharge pipe of the compressor. This gives the cooling system two cooling func-tions. One is to cool the oil in the crankcase the other to cool the discharge gas and consequently the discharge side of the compressor.

Fig. 4.58 Booster Compressor R717

Fig. 4.59 Two-stage TSMC Compressor R717

HP

LP

1

LP

T

Oil cooler

Liquid fromreceiver

StopvalveFilter

Solenoid valve

TEA

Oil separator

1

T

Oilseparator

Oil coolerTEAT

Solenoid valve

Stopvalve

Liquid fromreceiver

Filter

LPIP

TEAT

Solenoid valveFilterStop valve

Liquid fromreceiver

IP HP

OilSeparator

OilSeparator

IPLP1

IPLP

HPIP


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The TEAT valve is set to inject liquid into the com-pression chamber of the compressor via the oil cooler in order for the discharge gas to maintain a temperature between +55 and 95°C [131 °F and 203 °F].

The diagrams, Fig. 4.57 to Fig. 4.59, do only show the principle of the different systems and must not be used directly.

1b: Water-cooled Top and Side Covers - R717

The water cooling system must cool the entire compressor block. In principle, it consists of plane covers which are fixed on the top and side covers with a gasket in between as shown in Fig. 4.60 and Fig. 4.61.

A system of canals is thus created between the two covers in which the water is distributed evenly and cools effectively.

As the water covers can be dismantled without re-moving the top covers and depressurizing the compressor, the pipe system and the inner faces of the water cover can easily be cleaned of any impurities.

It is fairly easy to build this water cooling system on an air-cooled compressor. Note, however, that the air-cooled side covers must be replaced with covers with cooling fins on the inside. This may be seen by comparing Fig. 4.56 with Fig. 4.61.

Fig. 4.60 Water-cooled Top Cover

Note: Do not use sea water as cooling water on top covers.

Fig. 4.61 Water-cooled Side Cover

Mounting of Cooling Water HosesOn delivery of the compressor, the cooling water covers are mounted, but they are not connected with water hoses. These are delivered separately to avoid damaging the hoses and connecting branches during transportation and mounting. The cooling water hoses are mounted as shown in the drawing which is delivered with the compres-sor. A copy of this drawing can be seen in Fig. 4.62.


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Fig. 4.62 Mounting of water hoses on top and side covers.

Cooling of top and side coversSMC 104-106-108 and TSMC 108

3

2

4

6

3

1

4

3

5

6

2

3

1

4

3

2

1

5

3

4

SMC 104 3185-230

Pos. No. Hose Type L (mm)

1 C 715

2 C 115

3 C 505

4 C 645

5 A 835

SMC 106 3185-231


1 C 730

2 C 125

3 D 335

4 C 375

5 C 515

6 C 1100

SMC 108 TSMC 108 3185-232


1 C 760

2 C 150

3 C 340

4 E 255

5 C 230

6 A 1090


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Fig. 4.63

3

4

2 1

1

3

3 3

2

3

1

4

Cooling of side covers only

SMC 104-106-108-112-116 and TSMC 108-116 Side covers 3185-235 SMC 104-106-108 and TSMC 108


1 C 715

2 C 175

3 C 230

4 C 765

Side covers SMC 112 3185-246

Pos. No. Hose Type L (mm)SMC 112

1 A 750

2 A 130

3 C 750

4 A 220

Side covers 3185-236 SMC 116 and TSMC 116

Pos. No Hose Type L (mm)SMC 116

TSMC 116

1 A 740

2 A 160

3 C 770

4 B 215


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Fig. 4.64

Cooling of top and side coversSMC 186-188 and TSMC 188

3

2

4

6

3

1

4

5

3

5

6

2

3

1

4

2

3

1

4

SMC 186 3185-242

Pos. no. Hose type L (mm)

1 C 815

2 C 1830

3 C 605

4 C 245

5 C 1165

6 C 595

SMC 188/TSMC 188 3185-243


1 E 335

2 A 1755

3 C 535

4 C 245

5 C 1175

6 C 340

Side covers only 3185-244


1 C 1165

2 C 245

3 C 1315

4 C 410


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Note:

• The direction of the water flow is indicated in Fig. 4.62.

• The hose sections have been shortened to the lengths indicated from factory.

• In the supply pipe to the water system a so-lenoid valve must be fitted which shuts off the water flow in the refrigerating system when the compressor is not in operation. It is recommended, however, to continue the water cooling for approx. 10 minutes after the compressor has been stopped to protect the cooling water hoses against excessive temperatures.

• Dimensions of the inlet and outlet pipes for the cooling water system are indicated in Section 5, Physical and Connection Data - Table of Water Connection.

Necessary Water ConsumptionTo achieve satisfactory distribution of cooling wa-ter and hence proper compressor cooling, the fol-lowing limiting values should be followed.

Min. Water Flow

5.5 litres per hour per kW motor output. On water circulation plants greater water flow is recom-mended. See Fig. 4.65.

Max. permissible inlet temperature:+40°C [104°F]

Min. permissible inlet temperature:+10°C [50°F]

Max. permissible outlet temperature:+55°C [151°F]

Max. permissible temperature rise from inlet to outlet on compressor:

15°C [59°F]

Max. permissible cooling water pressure:

8 bar.


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Pressure Loss in the Cooling System in SMC/TSMC Compressors

Totally for Side and Top Covers

Fig. 4.65 Pressure loss diagram

Water Quality

Water that can be used as cooling water:

– Water from the water works or sea water

– Fresh ground water

– Water from cooling towers or condens-ers

– Closed water systems in which the water is cooled and recirculated

– Salt water (Brine)

Note: Do not use sea water as cooling water on top covers.

Obviously, it is very important that the water does not cause algae to grow or calcareous deposits to develop in the cooling system. This means that when water is recirculated in a closed system, a water treatment plant will usually be required. In such cases YORK Refrigeration recommends that a local dealer in water treatment plants be contacted.

100 500 1000V(l/hour)Volumetric flow

T/SMC116

SMC112

T/SMC188

SMC186

SMC 106 SMC 104

TSMC 108SMC 108Pressure loss

p(mWc)


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1c: Cooling with Thermo Pump - R717The thermo pump is a compressor cooling system which makes the compressor completely inde-pendent of the cooling water. The system is there-fore very applicable in areas where there is a shortage of water resources or where the water quality is poor. The thermo pump system can only be used with R717.

The purpose of the thermo pump is both to cool the oil in the crankcase and to cool the compres-sor discharge gas in order to lower the tempera-ture in the whole compressor.

Fig. 4.66 Short Block with Thermopump

The thermo pump is mounted as a side cover on the compressor and works by pressing the refrig-erant into the canal system on the top covers and into the oil cooler which - depending on the oper-ating conditions - is built into the crankcase.

On TSMC compressors cooling only takes place in the high pressure stage top covers and no oil cooler is used in the crankcase.

The thermo pump works under the influence of heat coming from the oil in the crankcase. In this way it also regulates its own pump capacity. This means that the thermo pump works slowly when the oil is cold, e.g. right after start-up of the com-pressor, but as the oil temperature gradually rises, the pump capacity will increase accordingly.

The thermo pump does not start, however, until the discharge gas temperature exceeds 80°C [176 °F].

The pumping cycle of the thermo pump, i.e. a fill-ing and an evacuation period, lasts between 4 and 8 minutes depending on the number of cylinders of the compressor, its capacity, the oil tempera-ture in the crankcase and the operating pressure and temperatures of the plant. The filling period takes about 45 sec.

The thermo pump has an important advantage, namely that the refrigerant pumped by the thermo pump is led directly into the discharge gas of the compressor. Consequently, this will have no in-fluence on the compressor capacity.


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The Structure of the Thermo PumpThe side cover, see Fig. 4.67 pos. 98A, together with the cooling cover, pos. 98Q, constitute a pump vessel, pos. 98, which is supplied with heat

from the oil bath in the crankcase. The cooling cover is equipped with cooling fins in order to en-sure a proper thermal contact with the oil.

Fig. 4.67 Side Cover with Thermo Pump

As indicated in the principle drawings of the SMC 108,Fig. 4.68, and a TSMC, Fig. 4.69, the thermo pump has the following connections:

• Connection pos. A, which is linked to the compressor suction side and which can be blocked by means of solenoid valve pos. 98G, is used to lower the pressure in the pump vessel, pos. 98. This is partof the pumping cycle.

• Connection pos. B emerges from the plant receiver or the priority tank (will be de-scribed later) and goes right to the valve block pos. 80.

• Connection pos. C is connected to the bot-tom of the pump vessel pos. 98 as well as to the top covers and the oil cooler pos. 98T through a number of nozzles, pos. 98M.

98D B 98B 98A98G

98X

98H

C

A

98Q

98C


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Fig. 4.68 SMC 108

Fig. 4.69 TSMC 108

Filling and evacuation of the pump vessel is con-trolled by two level sensors, pos. 98C, Fig. 4.67. By means of the control box, pos. 98B, the sen-sors control the solenoid valves, pos. 98G and pos. 98H, so that they open and close simultane-ously.

The thermo pump is safeguarded by the following systems as shown in Fig. 4.67, Fig. 4.68 and Fig. 4.69:

a. A thermostat built into the control box pos. 98B with sensors pos. 98X fitted on the com-pressor discharge pipe.

The thermostat is factory set to start up the thermo pump once the discharge gas tem-perature is above 80°C [176 °F].

b. An evacuation system emptying the pump vessel through solenoid valve pos. 98V whenever the thermo pump stops.

Please, note that the pipe connection pos. D to the plant evaporating side must be at a place where there is suction pressure and no risk of the liquid flowing back to the compres-sor through the suction line. Connection should e.g. be made to the liquid separator or the evaporator.

c. A safety circuit with a non-return valve, pos. 98Z, which opens for the flow in the pump vessel at a pressure 3 bar [44 psi] higher than the one in the compressor discharge gas line.

98K

98Y

80

B

D

C

98K

98V

98H

98T

98 98M

98B

98X

98U

4

98M 98M 98M 98Z

98G

HP

LP3

1

2

98M

98G

98Z

98K

98H

98

98Y

80

B

98B

C

D

98X

98K

2

IP

S

1

HP

S

98V


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Description of the Pumping Cycle

Filling the Pump Vessel

As soon as the liquid leaves the bottom level sen-sor, the control box will activate the solenoid valves pos. 98H in valve block pos. 80 and pos. 98G.

Thus solenoid valve, pos. 98G, opens in the pipe connection to the compressor suction side and the pressure in the pump vessel decreases slight-ly. At the same time solenoid valve pos. 98H opens and refrigerant liquid starts flowing to the pump vessel through pipe connection B.

Emptying the Pump VesselWhen the top sensor, pos. 98C, has registered that the liquid has reached the top level, both so-lenoid valves will be closed by the control box.

The pressure in the pump vessel will now rise as a consequence of the heat impact from the com-pressor oil and will - when it exceeds the pressure on the compressor discharge side - make the re-frigerant flow through the pipe connection C to the top covers and the oil cooler.

At the top covers the refrigerant expands through the nozzles, pos. 98M, directly into the hot dis-charge gas, resulting in immediate cooling of the discharge gas.

The oil cooler OOSI (not always required) is a heat exchanger in which the expanding refrigerant

- after cooling of the oil - is taken to the compres-sor discharge side.

Once the liquid in the pump vessel has returned to its lowest level, it is registered by the bottom sen-sor and the control box opens the two solenoid valves for a new pumping cycle.

Capacity Regulation of Thermo PumpWhen reducing the compressor capacity, it will be necessary to reduce the cooling effect of the ther-mo pump as well. This is done as follows:

SMC 104-106-108, TSMC 116

The pipe connection from the pump vessel to the top covers is divided into two pipe lines. In one of these pipe lines a solenoid valve, pos. 98U, is fit-ted.

This solenoid valve is wired to the capacity regu-lating system of the compressor and it closes when the compressor capacity has been reduced as indicated in the following table, Table 4.9.

Table 4.9

On the SMC 112-116 two thermo pumps have been mounted as shown in the principle drawings Fig. 4.70, Fig. 4.71 and Fig. 4.72.

CompressorCapacity

Solenoid Valve pos. 98U

Open Closed

SMC 104SMC 106SMC 108

TSMC 116

100%100 - 67%100 - 75%

100 - 83 - 67%

50%33%

50 - 25%50 - 33%


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Fig. 4.70 SMC 112 Fig. 4.71 SMC 116

Fig. 4.72 TSMC 116

2

4

6

98

98B

98B

98G

1

3

5

98H

80

98D

98H

98K

98K 98K98V98Y

98Z

98M98M98M

LP

LP

98M98M98M

A

B

B

C

98Y

D

X

98V

98K

98Z

98

A

7

B

2

4 6

8

98

98B

98B

98G

98G1

37

5

98H

80

98K

98K

98K 98V98Y

9898T

98Z

98M98M98M

98M

LP

LP

98M

98M98M98M98M

HP

A

B

B

C

D

D

X

98H

98D

98M

98Y98V

98

98B

98U

98K

98G

98K

98H

98M98M

3HP

S 4IP

S

1 5

CB

A

98T

98D


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The total capacity of the thermo pumps is adapted to the compressor capacity by stopping and start-ing the thermo pump marked with an X on the principle drawing.

The stopping and starting is achieved through the wire connection of the thermo pump via terminals 5 and 6/7 or 8 to the capacity regulating system of the compressor. The supply voltage to the thermo pump must be switched off once the compressor capacity has been reduced to the values indicated in the Table 4.10.

Table 4.10

When the compressor is stopped, the current to the thermo pump is cut off, closing the solenoid valves pos. 98H and pos. 98G. At the same time solenoid valve pos. 98V opens and drains the liq-uid in the thermo pump back to the evaporating

side of the plant. See the previously mentioned point b.

Ensuring Liquid to the Thermo PumpThe thermo pump must always be ensured liquid from the plant, irrespective of whether the plant lacks liquid or if some other factor prevails.

Thus, the thermo pump must also be ensured liq-uid during a possible pump down by means of the compressor.

In other words: During operation the compressor must never be short of cooling.

This safety is achieved either by taking the liquid directly from the receiver, pipe connection B, or by building a priority tank into the liquid line of the plant, Fig. 4.73. The liquid volume A of the priority vessel must be minimum 10 litres per thermo pump.

The liquid tube from the priority vessel to the ther-mo pump must be dimensioned to prevent the for-mation of flash gas along the way.

Compr.Capacity

Thermo Pump at CompressorShaft End

Working Not Working

SMC 112SMC 116

100 - 83 - 67%100-87-75-63%

50 - 33%50 - 37 - 25%


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Fig. 4.73

Power ConnectionThe control box is geared for the 3 voltages listed below.

Voltages:110V - 50/60Hz220V - 50/60Hz240V - 50Hz

The control box contains a terminal strip as shown in Fig. 4.74.

Fig. 4.74

1: Refrigerant liquid from condenser/receiver2: Refrigerant liquid to evaporator3: Refrigerant liquid reserve for oil coolingB: Refrigerant liquid for oil cooling

1

3

2B

B

3

2

Receiver

1

K3

Terminal 2

GND

Main voltage selectorVS1

K1

Terminal 4

Terminal 1

Terminal 1

K2 GND

GND

PT100 sensor

Upper level sensor

Lower level sensor

115230

Terminal 1

Terminal 2

M1

N

N

M2

L

N


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2a: Air-Cooled Top and Side Covers R22 - R134a - R404A - R507

Use the same cover mounting as described in par-agraph 1a. As indicated in the Operating Limits Di-agrams in Section 6, Technical Data, there is no need for oil cooling.

2b: Air-Cooled Top Covers and WaterCooled Side Covers R22 - R134a - R404A - R507

If water is available and a need for cooling exists according to the Operating Limits Diagrams, Sec-tion 6, Technical Data, this system is an excellent solution.

The water-cooled side covers are mounted as de-scribed in paragraph 1b, Fig. 4.63.

Fig. 4.75 Cooling of Side Covers only

Table 4.11

2c: Air-Cooled Top and Side Covers and Refrigerant-Cooled Oil CoolerR22 - R134a - R404A - R507

Use the same cover mounting as the one de-scribed in paragraph 1a.

In principle, the oil cooling system is constructed as illustrated in Fig. 4.57 for one-stage compres-sors, in Fig. 4.58 for booster compressors and in Fig. 4.59 for two-stage compressors.

2

3

1

4

Pos No Hose type Length (mm)

1 C 715

2 C 175

3 C 230

4 C 765


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fCompressor AccessoriesFollowing an order, the accessories listed below can be delivered for compressors or units:

• Explosion-proof instrumentation instead of the standard equipment.

• Explosion-proof heating cartridge for oil heating in the crankcase.

• Explosion-proof solenoid valves for capacity regulation.

• Vibration dampers to be inserted between unit and machine floor dimen-sioned to fit the unit in question.

• Normal set of tools, comprising special tools for dismantling and assembling the compressor.

• Extended set of tools. Besides the normal set of tools, this set contains all necessary standard hand tools.

• Spare parts set in various sizes.

When servicing compressor and unit, it is al-ways an advantage if you, as our customer, have some of the most commonly used spare parts at your disposal. This enables you or a summoned YORK Refrigeration service engineer to carry out the necessary service work without having to spend extra time on getting the spare parts required.

Spare parts can be delivered as described in the following. When contacting the local YORK Refrigeration representative, it is possible to receive a list of the spare part sets recommended by YORK Refrigeration.


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Types of Spare Parts Set:

For the different compressor blocks:

• Standard spare parts set: Contains a suit-able selection of O-rings as well as valve ring plates and valve spring.

• Extended spare parts set: In addition to the parts included in the standard spare parts set, the set contains a cylinder liner and discharge valve as well as an extended number and types of gaskets and fittings.

• Certificate spare parts set: In addition to the parts from the extended spare parts set this set contains a major number of components and wearing parts selected by the classification societies.

• Special spare parts set: This is a more comprehensive set than the extended spare parts set as almost all O-rings and gaskets are included and for the most wear-ing parts the number of parts have been ex-tended.

For the Different Compressor Units:• Standard spare parts set: This is a set

consisting mainly of O-rings and gaskets for some of the components included in the unit.

• Certificate spare parts set: In addition to the parts from the standard spare parts set this set contains other components selected in accordance with the requirements of the classification societies.

5. Physical and Connection Data

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5. Physical and Connection DataThe purpose of this document is:

• to describe the physical data of the equip-ment,

• to give complete information concerning the requirements of the surrounding system.

The safety precautions are intended for all user categories.





WDanger!

Risk of injury to personnel and damage to equip-ment! Always read the safety precautions belong-ing to this equipment before start. Failure to com-ply with safety precautions may cause death or in-

jury to personnel. It may also cause damage to or destruction of the equipment.

Safety PrecautionsIn addition to the safety precautions mentioned in Section 3, Safety Precautions, the following apply to the connection of the unit:

The pipe dimensions on the connections made for the unit must fit the dimensions of the connection place. Moreover, the pipes must be of a type and dimension approved for the maximum pressure of the plant.

When planning the pipe layout, make sure that it complies with prevailing standards re-garding pipe bend, flange design, etc.

Electrical connection must be carried out so that it complies with current legislation with-in the area in question.

Electric cables must be dimensioned on the basis of the maximum power consumption of the plant. The cabling must be made so that the cables do not touch any moving parts.

It is recommended to place the cables in ca-ble trays.


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Physical Data

Dimension Sketches

Dimension sketches of all compressor blocks and units are included in a separate binder Dimen-sions and Piping Diagrams.

Connection Data

Refrigerant Suction Side

On the compressor suction side the pipe connec-tion is made to the stop valve pos. 1 - see Dimen-sions and Piping Diagrams. The pipe connection is welded on the connecting branch of the valve, see Table 5.1.

Note: Be aware of the measures which must be taken in order to avoid damaging the valve and other parts of the unit when welding. See Section 7, Installation Instructions.

Refrigerant Discharge Side

On the compressor discharge side the pipe con-nection is made to the stop valve pos. 2 - see Di-mensions and Piping Diagrams. The pipe connec-

tion is welded on the connecting branch of the valve. See Table 5.1

Note: Be aware of the measures which must be taken in order to avoid damaging the valve and other parts of the unit when welding. See Section 7, Installation Instructions.

Connections to the CompressorThe tables in Table 5.1 and Table 5.2 show the pipe connection on standard compressors. On de-livery from YORK Refrigeration the compressors are fitted with standard welding nipples on suction as well as discharge side.

The tables Table 5.3 to Table 5.5 include a list of applicable welding nipples.

The table Table 5.6 show the possible connec-tions of the compressor. In the table some of the connections are marked plugged, which means that the thread hole is closed by means of a plug and a gasket.


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Table 5.1

Table 5.2

Table 5.3

1) Example: Connection type R-KB-32, part no. 2322-095

Compressor

Nominal diameters DN for standard welding connections (in mm)

Suction Discharge Interstage LPD+) Interstage HPS+)Oil

Separator

Conn.SABR.

type

Conn.SABR.

type

Conn.SABR.

type

Conn.SABR.

type

Conn.SABR.

type

SMC 104SMC 106SMC 108TSMC 108

129.5 65808080

80100100100

90.590.590.5 F

65656550

65656550

90.5 65 65 FS 50 50 FP 65656565/50++)

SMC 112SMC 116TSMC 116

154.5 125125125

125125125

129.5129.590.5

10010065

10010065

129.5 100 100 FS 80 80 FP 100100100/65++)

Compressor

Nominal diameters for standard welding connections (in inch.)

Suction Discharge Interstage LPD+) Interstage HPS+)Oil

Separator

Conn.SABR.

type

Conn.SABR.

type

Conn.SABR.

type

Conn.SABR.

type

Conn.SABR.

type

SMC 104SMC 106SMC 108TSMC 108

129.5 2 1/2"3"3"3"

3"4"4"4"

90.590.590.5 F

2 1/2"2 1/2"2 1/2"2"

2 1/2"2 1/2"2 1/2"2"

90.5 2 1/2" 2 1/2" FS 2" 2" FP 2 1/2"2 1/2"2 1/2"2 1/2"/2"++)

SMC 112SMC 116TSMC 116

154.5 5"5"5"

5"5"5"

129.5129.590.5

4"4"2 1/2"

4"4"2 1/2"

129.5 4" 4" FS 3" 3" FP 4"4"4"/2 1/2"++)

Available Welding Connections

Connec.type

Pipe type

Nominal Diameters for Welding Connections, Sabroe part no. 2322-1)

32 40 50 65 80 100 125 150

90.5 R-KBANSI

095122

100124

102126

102127

129.5 R-KBANSI

105129

107131

108132

154.5 R-KBANSI

109133

110134

219.5 R-KBANSI

111135


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+) HPS: High pressure suction sidePD: Low pressure discharge side

++) The first value: connection for the lowpressure Oil Separator.The second value: connection for the high pressure Oil Separator.

F Fixed connection

FS Fixed connection, delivered separately

FP Fixed pipe

R-KB Boiler pipe according to DIN 2448

ANSI Pipe according to ANSI B31.5 schedule 80 and 40 (DN 32 and 40 ~ schedule 40).

Note: In this connection two types of standard welding nipples are available. This should be specified when ordering.


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Standard welding nipples are available from YORK Refrigeration under the designation of R-KB nipples, following the standard of DIN 2448 and with pipe dimensions as indicated in the table in Fig. 5.1 (OD, s, ID1).

The welding nipples are universal as their welded ends have dimensions according to DIN 2448.

– If you wish to connect the welding nip-ples to a pipe with a thicker wall, the nip-ples can be shortened and thus the in-ternal diameter is reduced and the wall thickness increased as illustrated in Fig. 5.1. This makes it possible also to use the welding nipples for pipes in due form according to ANSI B31.5, schedule 80 and 40.

Fig. 5.1 Welding Nipples for R-KB Pipes

Table 5.4

155

305

ID1ODOD1 OD2

S

1ID2

L

A

ID3 ID2 I

Standard welding end for R-KB pipes according to DIN 2448

1)

INCH DN OD s ID1 OD1 OD2 ID 2 ID3 A L Mat.

2" 50 60.3 2.9 54.5 76.0 90.5 52.5 57.0 55 4.0 2

2 1/2" 65 76.1 2.9 70.3 76.1 90.5 62.7 57.0 65 14.0 2

2 1/2" 65 76.1 2.9 70.3 113.5 129.5 62.7 93.0 75 14.0 1

3" 80 88.9 3.2 82.5 113.5 129.5 77.9 93.0 70 9.0 2

4" 100 114.3 3.6 107.1 114.3 129.5 102.3 93.0 65 9.0 2

5" 125 139.7 4.0 131.7 144.0 154.5 128.1 125.0 80 7.0 2

1) Smallest inner diameter = ANSI B31.5

Material:

1: RST 37-2 DIN 171002: SIS 2142/SKF 280


104/288 0178-931 - ENGRev. 27.10.03


– Instead of the welding nipples for R-KB pipes, it is possible to order welding nip-ples solely used for standard pipes in ac-cordance with ANSI B31.5, schedules 80 and 40.

– The welding nipples are shown in Fig. 5.2 and must be specified when or-dering a compressor.

Fig. 5.2 Welding Nipples for ANSI Pipes

Table 5.5

305

ODOD1 OD2

S

1

A

ID2 ID1 ID2ID1

Standard welding end for ANSI B31.5 pipes schedule 80 + 40

INCH. DN OD s OD1 OD2 ID1 ID2 A Mat.

2" 50 60.3 3.9 76.0 90.5 52.5 57.0 51.0 2

2 1/2" 65 76.1 6.7 - 90.5 62.7 57.0 51.0 2

2 1/2" 65 76.1 6.7 113.5 129.5 62.7 93.0 61.0 1

3" 80 88.9 5.5 113.5 129.5 77.9 93.0 61.0 2

4" 100 114.3 6.0 - 129.5 102.2 93.0 56.0 2

5" 125 139.7 5.8 144.0 154.5 128.1 125.0 73.0 2

Material:

1: RST 37-2 DIN 171002: SIS 2142/SKF 280


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Connections on SMC / TSMC Mk4

Fig. 5.3 Standard connections for both SMC / TSMC 10X and 11X

Fig. 5.4 SMC 112-116 Mk4

C

V

AC

Q

EL

O

1

4

G

U

AF

H

P

NT

AD B

AK

AJ

1

4

H

AE

AH

Y

Z

Y

AF

AD

AA


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Fig. 5.5 TSMC 108 Mk4

Fig. 5.6 TSMC 116 Mk4

Fig. 5.7 Top cover Fig. 5.8 Top cover w. flange

AC1

2

H

4

R

3

AF

M

M

AG

AD

Y

H, AL

4

R

Y

3

1

AF

2

AK

S

Z, AL

X, AN


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Fig. 5.9 Pump end

Fig. 5.10 Shaft seal end

BD

BX

BL

BB

BE BT BP BN BJ BS BA BQ

AB

F

AM

K


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Connections for T/SMC104-116

Table 5.6

Numbers at position are referring to 1) SMC10X 3) TSMC108

2) SMC11X 4) TSMC116

PO

S

(CO

MP

. TY

PE

)

TH

RE

AD

(I

SO

228/

1-G

)

PR

ES

SU

RE

OIL

, GA

S

OR

LIQ

UID

AIR

-CO

OL

ED

w

AT

ER

-CO

OL

ED

AIR

-CO

OL

ED

WIT

H

BU

ILT

-IN

OIL

C

OO

LE

R

TE

RM

OP

UM

P

WIT

H B

UIL

T-I

N O

IL

CO

OL

ER

NO

RM

AL

A

PP

LIC

AT

ION

FIG

. NO

.

A 1 1/4 Suction Oil + + + Heating rod Fig. 5.3

B 3/4 Suction Oil + + + Oil charging valve Fig. 5.3

C 1/2 Suction Oil + + + Oil temperature Fig. 5.3

D 1/2 Suction Oil Plugged + Plugged Oil temperature Fig. 5.3

E 1/4 Suction Gas Plugged Plugged Plugged Available Fig. 5.3

F 1/4 Oil Oil + + + Oil pressure to unloading cylinder Fig. 5.10

G (1) 1/2 Suction Gas Plugged + + Return from built-in oil cooler Fig. 5.3

G (3) 1/2 Suction Gas Plugged + Plugged Return from built-in oil cooler Fig. 5.3

G (2+4) 1/2 Suction Gas plugged Plugged Plugged Available Fig. 5.3

H1) 1/4 Discharge Gas + + + High pressure connection Fig. 5.3, Fig. 5.4, Fig. 5.5 and Fig. 5.6

J 1/4 Suction Gas + + + Oil return from solenoid valves Fig. 5.3

K 1/4 Oil Oil + + + Oil pressure to solenoid valves Fig. 5.10

L 1/4 Suction Gas + + + Low pressure connection Fig. 5.3

M1) (3+4) 1/4 Intermediate Gas + + + Intermediate pressure connection Fig. 5.5 and Fig. 5.6

N 1/4 Suction Gas + + + Oil return from oil separator Fig. 5.3

O 1/2 Suction Gas Plugged Plugged Plugged Available Fig. 5.3

P (1+2+3) 1/4 Suction Gas Plugged + Plugged Return from built-in oil cooler Fig. 5.3

Q (1+2+4) 1/4 Discharge Gas Plugged Plugged + Return from oil cooler (thermopump) Fig. 5.3

Q (3) 1/4 Discharge Gas Plugged Plugged Plugged Available Fig. 5.3

R (3+4) 1/4 Suction Gas + + + Suction pressure to unloading cylinder Fig. 5.5 and Fig. 5.6

S 1/4 Discharge Gas Plugged Plugged + Refrigerant cooled top cover Fig. 5.7

T 1/4 Suction Gas Not included Not included + Equalization to suction end of thermo pump Fig. 5.3

U 1/4 Discharge Liquid Not included Not included + Liquid supply to top covers Fig. 5.3

V 1/2 Suction Oil Plugged + + Connection to built-in oil cooler Fig. 5.3

X 1/2 Discharge Gas + + + Discharge gas temperature Fig. 5.8

Y (2+4) 3/4 Suction Gas Plugged Plugged Plugged Plug for fixing intermediate bearing Fig. 5.5 and Fig. 5.6

AN (3) 1/2 Intermediate Gas Plugged Plugged Plugged Available Fig. 5.8

Z (2) 3/4 Discharge Gas + + + Purge valve (discharge pres-sure) Fig. 5.4

Z (4) 1/2 Discharge Gas + + + Purge valve (discharge pres-sure) Fig. 5.8

Z (1+3) 1/2 Discharge Gas + + + Purge valve (discharge pres-sure) Fig. 5.8

AA (2+4) 1 1/4 Suction Oil + + + Heating rod Fig. 5.4 and Fig. 5.6

AB 3/8 Suction Oil Plugged Plugged Plugged Available Fig. 5.10


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1) Positioning on the different block types may vary

AC 1/2 Suction Gas Used in connection with UNISAB Suction temperature (super-heat)

Fig. 5.3, Fig. 5.4, Fig. 5.5 and Fig. 5.6

AD (2+4) 1/4 Suction Gas + + + Return from solenoid valve Fig. 5.4 and Fig. 5.6

AE (2) 1/4 Suction Gas Plugged + + Return from built-in oil cooler Fig. 5.4

AF (1+2) 1/4 Discharge Gas Plugged Plugged + Return from built-in oil cooler Fig. 5.3 and Fig. 5.4

AF (3+4) 1/4 Discharge Gas Plugged + + Return from built-in oil cooler Fig. 5.5 and Fig. 5.6

AG (4) 1/4 Intermediate Gas Plugged Plugged + Equalization from thermopump for intermediate pressure Fig. 5.6

AH (2) 1/4 Suction Gas Not included Not included + Equalization to suction end of thermo pump Fig. 5.4

AJ (2) 1/4 Suction Gas Not included Not included + Liquid supply to top covers Fig. 5.4

AK (2+4) 1/2 Suction Gas Plugged + + Return from built-in oil cooler Fig. 5.4 and Fig. 5.6

AL (3) 1/2 Intermediate Gas + + + Purge valve (intermediate pressure) Fig. 5.8

AL (4) 1/2 Intermediate Gas + + + Purge valve (intermediate pressure) Fig. 5.6

AM 1/4 Suction Oil Plugged Plugged Plugged Available Fig. 5.10

BA 3/8 Oil Oil Plugged Plugged Plugged Not recommended for use Fig. 5.9

BB 1/4 Oil Oil + + + Prelubrication of compressor bearings Fig. 5.9

BD 1/4 Oil Oil Plugged Plugged Plugged Not recommended for use Fig. 5.9

BE 1/2 Suction Oil Plugged Plugged Plugged Not recommended for use Fig. 5.9

BJ 1/8 Oil Oil Plugged Plugged Plugged Not recommended for use Fig. 5.9

BL 1/4 Suction Oil Plugged Plugged Plugged Not recommended for use Fig. 5.9

BN 1/4 See application Oil + + + Oil pressure after oil filter Fig. 5.9

BP 1/8 See application Oil + + + Oil pressure before oil filter Fig. 5.9

BQ 1/4 Oil Oil Plugged Plugged Plugged Not recommended for use Fig. 5.9

BX 1/8 Oil Oil Plugged Plugged Plugged Not recommended for use Fig. 5.9

BS 1/4 Oil Oil + + + Oil pressure Fig. 5.9

BT 1/4 See application Oil Used in connection with UNISAB Q Oil pressure before oil filter Fig. 5.9

1 Low pressure suction stop valve Fig. 5.3, Fig. 5.4, Fig. 5.5 and Fig. 5.6

2 (3+4) Low pressure discharge stop valve Fig. 5.5 and Fig. 5.6

3 (3+4) Connection from intermediate pressure Fig. 5.5 and Fig. 5.6

4 High pressure discharge stop valve Fig. 5.3, Fig. 5.4, Fig. 5.5 and Fig. 5.6

PO

S

(CO

MP

. TY

PE

)

TH

RE

AD

(I

SO

228/

1-G

)

PR

ES

SU

RE

OIL

, GA

S

OR

LIQ

UID

AIR

-CO

OL

ED

w

AT

ER

-CO

OL

ED

AIR

-CO

OL

ED

WIT

H

BU

ILT

-IN

OIL

C

OO

LE

R

TE

RM

OP

UM

P

WIT

H B

UIL

T-I

N O

IL

CO

OL

ER

NO

RM

AL

A

PP

LIC

AT

ION

FIG

. NO

.


110/288 0178-931 - ENGRev. 27.10.03


Electrical Connections

Fig. 5.11

UNISAB II:

Where UNISAB II is supplied with 24 VAC, the connecting terminals supplying the heating ele-ments must be supplied with 115 or 230 VAC, see Installation Manual for UNISAB II.

MOTOR

Supply voltage and motor power appear from the order sheet.

1+2 High and low pressure cut-out KP15 PT1 Suction pressure

3 High pressure cut-out (intermediate pressure) KP5 PT2 Discharge pressure

4 Differential oil pressure cut-out MP55 PT3 Oil pressure

5 Discharge gas thermostat KP98 TT5 Discharge gas temperature

6 Oil thermostat KP98 TT6 Oil temperature

7 Computer control, UNISAB II TT7 Suction gas temperature

8 Heating element

9 Oil filter differential pressure

Electromechanical Control

123456

Computer Control, UNISAB II

7

TT7

PT1

8TT6

PT2TT5

PT3 9

Supply voltage: 115 VAC230 VAC24 VAC

Permissible variation: +10%/-15%Frequency: 45-65 HzPower: 50 VA

Connection data for supply voltage:

VAC

Permissible variation: +10%/-15%Frequency: 45-65 HzPower: kW


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Control of the Unit

The compressors are available with

a. analogue reading and safety system, electro-mechanical control.

b. UNISAB II reading, safety and capacity regu-lating system.

Re a: Wiring connection appears from the wiring diagram included in each delivery. The system requires an external control board for the control of the capacity regula-tion. Control and safety automatics is de-scribed in detail in Section 4, Technical De-scription - Instrumentation.

Re b: UNISAB II is described in detail in a separate Instruction Manual. This manual also includes a description of UNISAB II's general controls. Key diagrams and installa-tion descriptions are included in a separate Commissioning Manual for UNISAB II.

With a Control System not Delivered by YORK Refrigeration

This section describes the instrumentation of the compressor/unit - see data for electrical compo-nents in Section 21, Appendices. The fundamen-tal requirements which must be complied with in order to operate the unit are also described.

If other control systems than the ones prescribed by YORK Refrigeration are used, YORK Refrigeration disclaim the responsibility for the correct control of the unit. Moreover, YORK Refrigeration will not be liable to pay dam-ages for personal injuries or for damage to the unit or the refrigeration plant if caused by malfunction-ing of the control system.

On delivery the compressor is fitted with instru-ments, but not with any other electrical installa-tions.

Note:If UNISAB II is installed as the control system of the unit, the components mentioned below will be standard components. Moreover, the wiring will have been carried out from factory.

1. Pressure Transmitters marked PT1, PT2 and PT3As standard, the product is delivered with pres-sure transmitters of the type: AKS32 and AKS2050 from Danfoss - see data sheet in Sec-tion 21, Appendices.

Connection data: Connect a three-wire cable to the terminals of the plug fitted at the end of the pressure transmitters.

Supply voltage: 5 VDC Output signal: 4-20 mA

Pressure transmitters are used for measuring:

1.1 Suction Pressure, PT1

The measurement is used to protect against too low suction pressure. Low suction pres-sure must stop the compressor. The control system can be adjusted in such a way that the compressor starts automatically at too high suction pressure. The set values must be within the permissible working range for compressors as stated in Section 6, Techni-cal Data.

1.2 Discharge Pressure, PT2

The measurement is used to protect the compressor against too high discharge pressure. Too high discharge pressure must stop the compressor without automatic re-start. The set values must be within the per-


112/288 0178-931 - ENGRev. 27.10.03


missible working range for compressors as stated in Section 6, Technical Data.

1.3 Oil Pressure across Mechanical Oil PumpIs calculated as oil pressure after oil pump PT3 minus suction pressure PT1. Too low oil pressure (< 0.5 bar) must stop the com-pressor without automatic restart. However, this alarm must be delayed 45 sec when starting the compressor.

2. Temperature Sensors marked TT5, TT6 and TT7As standard, the unit is delivered with Pt100 tem-perature sensors of the type P2208. See data sheet in Section 21, Appendices.

Connection data: The sensor is fitted with a plug of the type IEC 947-5-2 with four conductors. The connection is carried out by means of a PG9-screw-joint.

The sensors are used for measuring:

2.1 Suction Gas Temperature,TT7 measuring range: -50°C to +180°C[-60°F to +356°F]

2.2 Discharge Gas Temperature,

TT5 measuring range: -50°C to +180°C[-60°F to +356°F]. The measurement is used to protect the compressor against a too high temperature in the discharge gas pipe. Too high a temperature in the dis-charge gas pipe must stop the compressor without automatic restart. The set values must be within the permissible working range for the compressor as stated in Sec-tion 6, Technical Data.

2.3 Oil Temperature,TT6 measuring range: -50°C to +180°C[-60°F to +356°F]. The measurement is used to protect the compressor against too high an oil temperature. Too high an oil tem-perature must stop the compressor without automatic restart.


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Heating Element for Oil Heating

Fig. 5.12 Dimension Sketch for Heating Element

Table 5.7 Table of Power and Application

* Can be delivered with UL approval. All heating rods are executed in Degree of Protection IP54

Coils for Solenoid Valves1)

The coils form part of solenoid valve for capacity regulation, oil cooler and thermopump.

Marking: Prod. no.WattVoltManu. date

G 1 1/4”

80

Ø30

L2

30

50

L1

NV 50

Heating rods Used for

PowerWatt

VoltageV

L1mm

L2mm

270270270

250230115*

158 175

CMO - TCMO - SMC 100 - TSMC 100

460460460

250230115*

HPO - HPC, SMC 180 - TSMC 180 VMY 347 /447 - 536SAB 110 - 128 - 163 - 202 - 330

220/230 Volt 50/60 Hz 10 Watt

115 Volt 50/60 Hz 10 Watt

240 Volt 50 Hz 10 Watt


114/288 0178-931 - ENGRev. 27.10.03


6. Technical Data

115/2880178-931 - ENGRev. 27.10.03


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6. Technical DataThe purpose of this document is to provide the technical data of the equipment. In this document technical data is defined as:

• Data for compressor

• Data for unit

• Working range

• Handling the compressor

• Area of application

• Laying the foundation

• Noise level data

• Vibration data

• Test pressure for compressors

• Assessing the oil

• Selecting lubricating oil

This document is primarily intended for designers, service engineers, sales personnel and prospective customers.



Copyright 2003 YORK Refrigeration


6. Technical Data

116/288 0178-931 - ENGRev. 27.10.03


Technical Data for the SMC 100 SeriesTable 6.1

1) LP = Low pressure cylinder HP = High pressure cylinder2) Permitted max. speed varies with operation conditions- and refrigerant.

See the Operating Limit Diagrams

Compressor type Number of cylinders

1)

Bore

mm

Stroke Max/min speed

nominal rpm 2)

Swept volume at max speed m3/h

Weight of compressor

block

kg

Weight of compressor

block

lb

Sin

gle

sta

ge

SMC 104S 4 271 580 1279

SMC 106S 6 407 675 1488

SMC108S 8 80 1800/700 542 740 1631

SMC112S 12 815 1250 2756

SMC 116S 16 1086 1350 2976

SMC104L 4 283 580 1279

SMC106L 6 424 675 1488

SMC108L 8 100 565 740 1631

SMC112L 12 848 1250 2756

SMC116L 16 1131 1350 2976

SMC104E 4 100 1500/700 339 600 1323

SMC106E 6 509 700 1543

SMC108E 8 120 679 770 1698

SMC112E 12 1018 1300 2866

SMC116E 16 1357 1400 3086

Tw

o s

tag

e

TSMC108S 6 LP + 2 HP 80 339 775 1709

TSMC116S 12 LP + 4 HP 679 1400 3086

TSMC108L 6 LP + 2 HP 100 424 775 1709

TSMC116L 12 LP + 4 HP 848 1400 3086

TSMC116L 6 LP + 2 HP 120 509 800 1764

TSMC116E 12 LP + 4 HP 1018 1450 3197

6. Technical Data

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Table 6.2 Weight of Compressor Units

Compressor Type Direct driven Belt driven Remarks

Kg lb Kg lb

SMC 104 SMC 106 SMC 108 SMC 112 SMC 116

83092599016601400

18302039218336603086

880970

103018201920

19402138227140124233

TSMC 108 TSMC 108

10601400

23373086

11301410

24913109

Excl. intermediate cooler Incl. in-termediate cooler

TSMC 116 TSMC 116

19002350

41895181

20802530

45865578

Excl. intermediate cooler Incl. in-termediate cooler

The weight is exclusive of electric motor

6. Technical Data

118/288 0178-931 - ENGRev. 27.10.03


Weight of Electric Motors

Sizes MOTOR TYPE

SHORCH LEROY SOMER

IP 23 IP 54 PLS LS FLS

kg lb kg lb kg lb kg lb kg lb

IEC 160L 102 225 80 176 78 172 120 265

IEC 180M 190 419 173 381 98 216 100 220 135 298

IEC 180L 210 462 188 414 128 282 110 243 184 406

IEC 200M 240 529 165 364

IEC 200L 265 584 235 518 190 419 170 375 260 573

IEC 225S 309 681 205 452 290 639

IEC 225M 355 783 340 750 240 529 235 518 388 855

IEC 250S 455 1003 335 739

IEC 250M 480 1058 445 981 360 794 340 750 395 871

IEC 280S 625 1378 570 1257 460 1014 445 981 475 1047

IEC 280M 680 1499 630 1389 515 1135 490 1080 565 1246

IEC 315S 875 1929 900 1984 720 1587 850 1874

IEC 315M 945 2083 940 2072 730 1609 785 1731 1000 2205

IEC 315L 1050 2315 1200 2646 830 1830 1050 2315

IEC 355S 1500 3307

IEC 355M 1790 3946 1600 3527 855 1885

IEC 355L 2095 4619 1750 3858 1510 3329

IEC 355L (LA)1900 (LB)2150

1550 3417

6. Technical Data

119/2880178-931 - ENGRev. 27.10.03


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Compressor CapacityCompressor capacity is calculated by means of the COMP 1 program in the YORK Match Master suite of programs.

Alternatively, contact your local dealer who can help dimensioning the compressor.

6. Technical Data

120/288 0178-931 - ENGRev. 27.10.03


Dimension Sketches of Compressor Block

As standard execution the compressor block can be delivered with either an analog display and safety system, i.e. with pressure gauges, pres-sure sentive and thermostats, or with a UNISAB II system with display and safety facilities as well as capacity regulation of the compressor.

To illustrate the structure of the dimension sketch-es, three examples have been included, Fig. 6.1,

Fig. 6.2 and Fig. 6.3. Moreover, reference is made to Dimension and Piping Diagram, which in-cludes dimension sketches of all compressors and units.

However, during the final planning the latest di-mension sketches from YORK Refrigeration are required.

6. Technical Data

121/2880178-931 - ENGRev. 27.10.03


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Fig. 6.1 SMC 100, V-belt Driven, Anolog System

4833--001_0

SABROE

K

HMAX

900

650

710

275

510

I

25

4XM22HOLES

MIN

250

1100

1500

80

200

G

205

D

C(OVERALLHEIGHT)

200

32

MIN

400

600

E

MIN

620

B

A(OVERALLLENGTH)

1455

F

141

SUCTION

DISCHARGE

FORUNITSWITHUNISAB

987

SMC108

ALL

SMC106

ADD80MM

M76.1x2.9

M88.9x4.85

M114.3x3.6

COMPR

TYPE

SMC104

SMC106

SMC108

200--315M

200--315M

200--315M

IEC

MOTOR

TYPE

MM

A

MM

MAX

B

MM

C

MMD

MM

E

2050

2010

2020

1095

1130

1125

1000

1035

1030

275

275

300

MMF

MM

G

440

395

405

350

395

405

1115

1090

1130

I MM

635

665

MM

635

620

635K

171438

171438

171438

OFUNIT

MOTOR

EXCL.

WEIGHT

315

1335

TYPE

MOTOR

IEC

250

280

200

225

915

1015

1135

1235

HMAX

645

FOUND.

DRWG.

NO.

OFMOTORANDTYPE

FOREXACTLENGTHUSE

VARIESACCORDINGTOMAKE

OVERALLLENGTHANDWIDTH

DIMENSIONHIN

TABEL

880KG

970KG

1030KG

2

FORWITHDRAWINGCRANKSHAFT

R717OILCOOLER(BOOSTER)

COOLINGSYSTEM

43

R22OILCOOLER

5

(COMPR.WITHWATERCOOLINGONLY)

6

SMC104

M76.1x4.5

M88.9x3.2

COMPR.

R717

WELDINGCONNECTIONS

CONNEC.FOR

R717THERMOPUMP.SYSTEM

(H)CFC

FORWITHDRAWINGV--BELT

GUARD

1FOROPERATINGSTOPVALVES

G1/4

G1/4

G1/4

WATERINLETANDOUTLETG3/8

LIQUID

REFRIG.

75

4

8

III

III

2

45

1

6

3

9

6. Technical Data

122/288 0178-931 - ENGRev. 27.10.03


Fig. 6.2 SMC 100, V-belt Driven, UNISAB II System

4833--011_0

HMAX

K

900

650

710

275

510

I

25

4XM22HOLES

MIN

250

1100

1500

80

200

G

205

D

C(OVERALLHEIGHT)

200

32

MIN

400

600

E

BMIN

620

A(OVERALLLENGTH)

1455

F

141

SUCTION

DISCHARGE

87

SMC108

ALL

SMC106

M76.1x2.9

M88.9x4.85

M114.3x3.6

COMPR

TYPE

SMC104

SMC106

SMC108

200--315M

200--315M

200--315M

IEC

MOTOR

TYPE

MM

A

MM

MAX

B

MM

C

MMD

MM

E

2050

2010

2020

1095

1130

1125

1000

1035

1030

275

275

300

MMF

MM

G

440

395

405

350

395

405

1053

1168

1193

I MM

635

665

MM

635

620

635K

171438

171438

171438

OFUNIT

MOTOR

EXCL.

WEIGHT

315

TYPE

MOTOR

IEC

250

280

200

225

HMAX

645

FOUND.

DRWG.

NO.

OFMOTORANDTYPE

FOREXACTLENGTHUSE



DIMENSIONHIN

TABEL

1015

1115

1235

1335

1435

880KG

970KG

1030KG

2



COOLINGSYSTEM

43

R22OILCOOLER

5

(COMPR.WITHWATERCOOLINGONLY)

6

SMC104

M76.1x4.5

M88.9x3.2

COMPR.

R717

WELDINGCONNECTIONS

CONNEC.FOR


(H)CFC

FORWITHDRAWINGV--BELT

GUARD


LIQUID

REFRIG.

WATERINLETANDOUTLETG3/8

G1/4

G1/4

G1/4

47

5

8

III

III

2

45

1

6

3

6. Technical Data

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Fig. 6.3 SMC 100, Direct Driven, UNISAB II System

4843--021_0

MIN400KMIN200

390

OFMOTORANDTYPE

FOREXACTLENGTHUSE

DIMENSIONMIN

TABELBELOW

1250

250

G

510

D

M

L

80

4xM22HOLES

500

560

205

C(OVERALLHEIGHT)



25

32

EF

AAPPROX

620

MIN

555

141

B(OVERALLWIDTH)

H

315

250M

280

108

225--250

SSMC

250

280

315

1005

162

140

114

2250

2350

2450

1125

185

1030

665

204847

171426

875

900

440

443

990KG

200

225--250

S

250M

280

315

180

200

IEC

160--180

225--250

S

250M

280

160--180

MOTOR

TYPE

COMPR

TYPE

MM

A

MM

200

SMC

104

SMC

106

MAX

200

225

180

TYPE

MOTOR

IEC

160

995

995

197

181

209

222M MM

1900

2100

2150

2250

1950

2150

2200

2300

2400

2000

2200

B

MM

1095

1130C

MMD

MM

E

MMF

MM

G

MMH

MM

K

875

1000

160

1035

135

900

MM

635

645

171426

204847

171427

171427

204847

171426

171427

OFUNIT

MOTOR

EXCL.

L

875

440

440

830

FOUND.

DRWG.

NO.

393

418

270

270

270

830KG

925KG

SUCTION

DISCHARGE

87

SMC108

ALL

SMC106

COMPR.

SMC104

R717

WELDINGCONNECTIONS

WEIGHT

M76.1x2.9

M88.9x3.2

M114.3x3.6

M88.9x3.2 M76.1x2.9

(H)CFC

5


COOLINGSYSTEM

4

CONNEC.FOR

R22OILCOOLER

WATERINLETANDOUTLET

6


3

FILTER

FORWITHDRAWINGPISTONSANDSUCTION



LIQUID

REFRIG.

G1/4

G1/4

G3/8

1

I

48

75

2

II

III

45

6

3

6. Technical Data

124/288 0178-931 - ENGRev. 27.10.03


Planning the Machine RoomWhen planning the machine room, make sure that there is enough space around the compressor. The minimum spacing is indicated below, see Fig. 6.4, Fig. 6.5 and Fig. 6.6.

Fig. 6.4

Fig. 6.5 Compressor Block with Analog System

Fig. 6.6 Compressor Block withUNISAB II System

Enough room must be left around the compressor to allow the operating personnel to operate the compressor ➀and carry out service work on the compressor ➁. Space should be considered ➂as

sufficient space to make it possible to take out the crankshaft without dismounting the compressor from the base frame.

Space 1: 500 mm [20”]

Space 2: 400 mm [16”]

Space 3:

SMC 104-106-108, TSMC 108 600 mm [24”]

SMC 112-116, TSMC 116 1100 mm [43”]

2

1

33

6. Technical Data

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Operating Limits DiagramsTo make sure that YORK Refrigeration’s custom-ers experience a satisfactory compressor opera-tion within the specified operating periods be-tween the service intervals, it is essential that the operating conditions are kept within certain per-mitted operating limits.

The operating limits are specified in the following Operating Limits Diagrams. YORK Refrigerationis only liable in so far as the operating limits con-ditions of the compressor are kept within the limi-tation of the curvas. Similary, the recommenda-tion concerning the number of revolutions and cooling of the compressor must be observed.

The limitation curves have been determined on the basis of both constructional and operating conditions.

1. Max Permissible Condensing Pressure:The pressure limit corresponds to the test pressure which is applied to all compressors and as indicated under Test Pressure in this section.

Fig. 6.7

2. Max Permissible Differential Pressure across the Pistons:

Fig. 6.8

3. Permissible Compression Ratios π:The compression ratio is calculated into the diagram with the following values:

Max. value or π for:

Fig. 6.9

3a. Limitation of the Compressor rpm:The limitation has been introduced in order to avoid excessive discharge gas and oil temperatures.

TE

TC

1

- R717 8 (7 for SMC 100 E)

- R134a 12

- R22 10

- R207C 10

- R404A 14

- R507 14

TE

TC

2

TE

TC

3

6. Technical Data

126/288 0178-931 - ENGRev. 27.10.03


Fig. 6.10

4. The Lowest Permissible Suction Pressure:The limit has been fixed at approx 0.5 bar and 5.6 bar for R744 (CO2 triple point).

Fig. 6.11

5. The Lowest Permissible Condensing Pressure:At condensing pressures lower than the ones specified, the dampening effect from the gas on the valve plates against the valve retaining plate is reduced. This increases the risk of valve breakdown.

Fig. 6.12

6. Minimum Difference between Condens-ing and Evaporating Temperature:If there is less difference than specified, the compressor will not get sufficiently warm. Lubrication problems may occur when the refrigerant content in the oil is too high with a subsequent risk of oil foaming in the com-pressor.

It should also be noted that some of the equipment in a refrigeration plant requires a certain pressure difference in order to func-tion properly.

7. The Highest Permissible Evaporating Pressure:In the crankcase there will always be an evaporating pressure. An increase in the evaporating pressure will increase the load on the thrust bearing at the crankshaft as well.

TE

TC

3a

TE

TC

4

TE

TC

5

TE

TC

6

6. Technical Data

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Furthermore, the refrigerant content in the oil is going to increase, primarily refrigerants used with soluble oil, and this may cause lu-brication problems. The HFC and HCFC re-frigerants, which are relatively heavy, will raise the pressure drop through the dis-charge and suction valves and this will im-pede the proper functioning of the valves.

Fig. 6.13

7a. The Highest Permissible EvaporatingPressure:The limitation curves represent the highest permissible suction pressure without reduc-ing the number of revolutions.

Fig. 6.14

The following Operating Limits diagrams include the refrigerants: R717, R134a, R22, R407C, R404a, R410A, R507 and R744.

The cooling systems for compressors which are mentioned in the Operating Limits Diagrams be-low are described in detail in Section 4, Technical Description - Cooling Systems for Compressors.

TE

TC

7

TE

TC

7a

6. Technical Data

128/288 0178-931 - ENGRev. 27.10.03


* SMC 188: 840 - 920 RPM not allowed.

# Included refrigerant cooled oil cooler.

Thermopump: Top and side covers are cooled by injected refrigerant.Oil cooling is included in the system.

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

Discharge temperature must not exceed 150°C (302°F) at full load and at part load.

1) Discharge temperature at part load has to be checked.

TYPE AREA rpm COOLING NOTE

max. min.

CMO201 - 2

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

3 - 4 Thermopump or water-cooled 1)

SMC100S/L1 - 2

1500 700Air cooled top - and side covers # or water-cooled

3 - 4 Thermopump or water cooled 1)

SMC1801 750

450Water-cooled

2 - 3 - 4 1000*

-30

-20

0

10

20

-10

-60 -50

40

50

60

30

Co

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tem

per

atu

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-20-30

3

0

2

-10

4

-40

T0111123_1 VIEW 2

3020 40

1

10

Evaporating temperature

°C

°C

TE°F-40 -22 -4 32 50 86 10468

TC°F

68

86

104

122

140

50

32

14

14

-4

-22

-58-76

R717Operating LimitsOne StageCompressor TypeCMO & SMC

BOOSTER OPERATION

6. Technical Data

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Thermopump: Top and side covers are cooled by injection refrigerant.Oil cooling is included in the system.

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

Discharge temperature must not exceed 150°C (302°F) at full load and at part load.


TYPE AREA rpm COOLING NOTE

max. min.

SMC100E1

1500 700 Thermopump or water cooled2 1)

T0111140_0 view 6

0

10

20

30

-50-60

-30

-20

-10

40

50

60

Co

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-30 0-10

1

-20

2

-40 3020 40

OPERATION

10


TE°F-40 -22 -4 14 32 50 86 10468

TC°F

68

86

104

50

32

14

-4

-22

°C

°C

122

140

-58-76

R717Operating Limits

One StageCompressor Type

SMC100E

6. Technical Data

130/288 0178-931 - ENGRev. 27.10.03


Oil cooling is always necessary.

Thermopump: Only the HP Stage top covers are cooled by a thermo pump. Oil cooling included in the system

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

Part-load operation: 1) Depending on the operating conditions and the pressure on the compressor, a by-pass system may be required.

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

Type Area rpm Cooling Notemax min top and side

TCMO 1-2 1800 900 Thermopump or water-cooledTSMC 100

S-L-E1-2 1500 700 Thermopump or water-cooled 1)

TSMC 1801 750

450 Water-cooled 1)2 1000

0177

128_

0 V

IEW

3,1

TE

TC°C

-30

-20

-10

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

0

10

20

30

40

50

60

70

Co

nd

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tem

per

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re


°C-70-40

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

°F

-22

-4

14

32

50

68

86

104

122

140

158

-40

1

2

R717Operating limits

Two StageCompressors

TCMOTSMC 100 S-L-E

TSMC 180

6. Technical Data

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Top covers: Air-cooled only

1) When required, choose freely between A or B- except SMC180 where only A may be selected.A: Water-cooled side coversB: Built in refrigerant cooled oil cooler with thermostatic expansion valve.


TYPE AREA RPM OIL COOLING REQUIRED1) REMARKS

MAX. MIN.

CMO20

11500

900

No

2 No

31800

At less than 50% capacity

4 Yes

SMC100S

1 1000

700

No

2 1200 No

31800


4 Yes

SMC100L

1 2)

2 1000

700

No

31200

At less than 50% capacity yes

4 Yes

SMC180

1-2 2)

3750 450

At less than 50% capacity yes

4 Yes

-30

-20

-10

0

10

-50 -40

T0111-127_0 view 2

-60

30

40

20

60

70

50

-20 0-10-30 20 30 4010TE

°F-40 -22 -4 14 32 50 86 10468

TC°F

68

86

104

50

32

14

-4

-22°C

°C

-58-76

122

140

158

Co

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1

2

34

R22Operating Limits

One StageCMO & SMC

6. Technical Data

132/288 0178-931 - ENGRev. 27.10.03


Top covers: Air-cooled only.

1) When required, choose freely between A or B- except TSMC180 where only A may be selected.A: Water cooled side coversB: Built in refrigerant cooled oil cooler with thermostatic expansion valve.

2) By-pass equipment required to maintain intermediate temperature at minimun load.(see price list specification).

3) Not applicable.

TYPE AREA RPM OIL COOLING 1) NOTEMAX. MIN.

TCMO1-2 1500

900 No3 1800

TSMC100S1 1000

700 Yes 2)2 12003 1800

TSMC100L1 3)2 1000

700 Yes 2)3 1200

TSMC1801-2 3)3 750 450 Yes 2)

10

20


Co

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tem

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0-60

T0111139_0 view 1

-50 -40 -30 -20 -10 0

40

50

30

60

TE°F-40 -22 -4 14 32

°C

TC°F

68

86

104

122

140

50

°C

32

-58-76

12

3

R22Operating Limits

Two StageCompressor type

TCMO & TSMC

6. Technical Data

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Top and side covers: Air-cooled

1) When required, choose freely between A or BA: Water-cooled side coversB: Built in refrigerant cooled oil cooler with thermostatic expansion valve.

2) Not applicable.

TYPE AREA RPM OIL-COOLING 1) NOTE

MAX. MIN.

CMO

1-21200

900

No

1500At less than 50% capacity

3No

1800 At less than 50% capacity

SMC100S

1 1000

700

No

21200

No

3No


SMC100L

1 2)

21000

700

No

3No


T01

7712

8_ V

8,1

TE

TC°C

-30

-20

-10

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

0

10

20

30

40

50

60

70

Co

nd

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tem

per

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re


°C-70-40

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

°F

-22

-4

14

32

50

68

86

104

122

140

158

-40

80 176

12

3

R134aOperating Limits

One StageCMO & SMC

6. Technical Data

134/288 0178-931 - ENGRev. 27.10.03


1) Oil cooling: Not required.Top- and side covers: Only air-cooled.

2) Part-load operation:By-pass equipment required to maintain intermediate temperature at minimum load.

T01

7712

8_0

V8,

1 TE

TC°C

-30

-20

-10

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

0

10

20

30

40

50

60

70

Co

nd

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tem

per

atu

re


°C-70-40

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

°F

-22

-4

14

32

50

68

86

104

122

140

158

-40

12

3

R134aOperating limits

Two StageCompressors

TCMOTSMC 100 S-L

Type Area rpm Oil-cooling required 1) Notemax min

TCMO 28 1-2 1500

900 1)3 18001 1000

TSMC100 S

2 1200700 1) 2)

3 15001 Not applicable

TSMC 100 L

2 1000700 1) 2)

3 1200

6. Technical Data

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Top covers: Air-cooled design only.

1) When required, choose freely between A or BA: Water-cooled side covers.B: Built-in refrigerant-cooled oil cooler with thermostatic expansion valve.

--30

--20

--10

0

--60 --50

T0111164_2

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

10

20

30

60

40

50

1

�C�F

TC

122

140

104

86

68

50

32

14

--4

--22

--76 --58 --40 --22 --4 --14 32 50 68 86

�C

�FTE

Co

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R404AOperating Limits

CMO & SMCOne Stage


CMO20 11500

900No


SMC100S 11200

700No

1500 At less than 50% capacitySMC100L 1 1200 700 No

6. Technical Data

136/288 0178-931 - ENGRev. 27.10.03


Top and side covers: Air-cooled only.

1) Part-load operation: By-pass equipment required to maintain intermediate temperature at minimum load.

2742

63.3

Rev

. 0

TE

TC°C

0

10

20

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

30

40

50

60

Co

nd

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tem

per

atu

re


°C-70-10

-76 -58 -40 -22 -4 14 32 °F-94

°F

32

50

68

86

104

122

140

14

1

2

R404AOperating Limits

Two StageTCMO & TSMC

TYPE AREA RPM OIL COOLING NOTEMAX. MIN.

TCMO 28 1

1800 900 No21 1200

700 No 1)TSMC100S

2 15001 1000

700 No 1)TSMC 100L 2 1200

6. Technical Data

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Top covers: Air-cooled only.

1) When required, choose freely between A or B

A: Water-cooled side covers.

B: Built-in refrigerant-cooled oil cooler with thermostatic expansion valve.

--30

--20

--10

0

--60 --50

T0111166_2

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

10

20

30

60

40

50

1

�C�F

TC

122

140

104

86

68

50

32

14

--4

--22

--76 --58 --40 --22 --4 --14 32 50 68 86

�C

�FTE

Co

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ensi

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tem

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One StageCMO & SMC


CMO20 11500

900No


SMC100S 11200

700No

1500 At less than 50% capacitySMC100L 1 1200 700 No

6. Technical Data

138/288 0178-931 - ENGRev. 27.10.03


Top- and side covers: Air-cooled only.

1) Part-load operation: By-pass equipment required to maintain intermediate temperature at minimum load.

2742

63.4

Rev

. 0

TE

TC°C

0

10

20

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

30

40

50

60

Co

nd

ensi

ng

tem

per

atu

re


°C-70-10

-76 -58 -40 -22 -4 14 32 °F-94

°F

32

50

68

86

104

122

140

14

1

2


Two StageCompressor

TCMO & TSMC

TYPE AREA RPM OIL COOLING NOTEMAX. MIN.

TCMO28 1

1800 900 No2

TSMC100S 1 1200

700 No 1)2 1500

TSMC100L 1 1000

700 No 1)2 1200

6. Technical Data

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Top covers: Air-cooled design only.

1) When oil cooling is required, choose freely between A or B - however, for SMC 180, only A may be selected.

Type Area rpm Oil-cooling Notemax min required 1)

CMO 1 1500

900no

21800

At less than 50% capacity3 yes1 1200 no

SMC 100 S 2 1500

700At less than 50% capacity

3 1200 yes1 1000 no

SMC 100 L

SMC 100 L SMC

2 1200

700


3 1000 yes

1 NOT APPLICABLE

SMC 1802

750 450At less than 50% capacity

3 yes

Co

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TE

-30

-20

-10

0

10

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

20

40

50

30

TC

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

°F

-22

-4

14

32

50

68

86

104

122

140

T245411_0 view 2

°C-70

60

°C

1

23

R407COperating Limits

One StageCompressor type

CMO & SMC

6. Technical Data

140/288 0178-931 - ENGRev. 27.10.03


Direction of Rotation of the Compressor

The normal direction of rotation for the compres-sors is anti-clockwise when looking at the com-pressor from the shaft end.

Fig. 6.15 Direction of rotation for compressor seen from A

An arrow cast into the bearing cover indicates the direction of rotation as shown in the picture.

Fig. 6.16

At times it may be necessary that the crankshaft rotates in the opposite direction, e.g. if the com-

pressor is connected to a combustion motor with a specified direction of rotation.

In such cases the oil pump must be changed as it is uni-directional.

The direction of rotation for the pump is indicated by a guide pin.

• Counterclockwise compressor rotation:Marking in cover to the right of the logo.

Fig. 6.17

• Clockwise compressor rotation:Marking in cover to the left of the logo.

Fig. 6.18A

Guide pin

Guide pin

6. Technical Data

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Choice of Electric MotorThe IEC electric motors type IP23 or IP54 (55) (IP= Index of Protection) are normally used to drive the compressors, and the base frames are standard design for these motors.

Fig. 6.19 IP23 Drip-proof Motor

When selecting an electric motor, the following factors must be taken into consideration:

Motor DimensionThe size of the motor is determined on the basis of the power demands of the compressor under the current operating conditions calculated by means of the YORK COMP1 PC program.

However, for various reasons, always choose a motor a little bigger. The reason for this is ex-plained in the following:

A. Generally speaking, the calculated power de-mand should be increased by one of the fol-lowing factors in order to ensure that the mo-tor has sufficient driving power, both during start-up, at minor deviations from the worked out operating conditions and with regard to mechanical transmission loss for instance in the V-belt drive:

B. Do consider, however, which type of plant the compressor is going to work on, and then di-mension the motor in accordance with the fol-lowing rules:

a: For plants in which a higher ET may be expected, and consequently also a higher CT in the start-up phase, the motor must be dimensioned to meet the higher operating temperatures. Usually, this does not incor-porate factor 1 and 2.

Likewise, special consideration should be given concerning the booster compressors.

b: Alternatively, the motor can be connected to a system for Ampere limitation which re-duces the compressor capacity until the planned operating temperatures have been reached. This element is found in UNISAB II, which must be linked to the Amp. signal, however. In this case, factor 1 and 2 should also be omitted.

Note: YORK Refrigeration would like to point out that when using a motor with a class F insulation (105K) for operating conditions like for class B (90K), approx. 10% continual overloading of the motor will be acceptable in connection with the nominal effect.

As mentioned previously, all compressors are as standard completely unloaded during the start-up phase. This reduces the power consump-tion of the compressor considerably as may be seen from the starting torque curve, Fig. 6.20.

As standard, the SMC 100 can only be capacity regulated in steps of two cylinders, which is usual-ly satisfactory. If required, extended unloading can be ordered when the order is placed or it can be mounted at a later time.

For more information on this subject, see Section 4, Technical Description - Extended unloading of the Compressor.

1: Air conditioning plant: Factor 1.10

2: Other refrigeration plants: Factor 1.15

3: For V-belt drive: Factor 1.05

6. Technical Data

142/288 0178-931 - ENGRev. 27.10.03


The starting torque for compressors with extend-ed unloading appears from and Fig. 6.22.

Please note that moment of inertia is not included in the diagrams. Further pay attention to the fact that the motor should reach its maximum torque moment before the non-adjustable cylinders are put into operation.

The maximum time for reaching minimum rpm (TSMC 100 : 750 rpm.) is 5 sec. and nominal speed should be reached after max. 10 sec.

For more information on this, see Section 4, Tech-nical Description - Capacity Regulation and Un-loading of the Compressor.

Fig. 6.20

500

450

400

350

300

250

200

150

100

50

00 250 500 750 1000 1250 1500 1750 2000

104S

106S

108S

112S104S

116S

106S

108S

112S

116S

STARTING TORQUE FOR COMPRESSOR SMC/TSMC/HPC100

RPM (/min)

Torque (Nm)

Starting torque at 0% load

Start up torque for L-models: Diagram values x 1.6Start up torque for E-models: Diagram values x 2.6

R717 (TE = +55C)HFC/HCFC (R507 TE = +55C)

6. Technical Data

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Starting Torque of the Compressor

The motor size is usually selected as described in the previous section. With all cylinders unloaded during the starting-up phase the motor generally has sufficient starting power in order to bring the compressor at full speed before the cylinders are loaded. Read more in Section 4, Technical De-scription - Capacity Regulation and Start Unload-ing of the Compressor.

At times, however, it may be a good idea to com-pare the starting torque curve of the compressor

to the starting curve of the motor (this information can be obtained from the motor manufacturer). Especially, when the compressor starts at a plant pressure below normal and when power limiting

systems are used to start up the motor, e.g. a Y/ ∆ starter, it may be necessary to work out a dia-gram as the one shown in Fig. 6.21. The hatched area represents the torque moment available to the motor when speeding up the compressor.

Fig. 6.21 Starting Torque Curve for Electromotors

Kpm[Lb.ft.]

0

Compressor

Motor Y starters

Motor starters

6. Technical Data

144/288 0178-931 - ENGRev. 27.10.03


Start up torque SMC 100 R717 25% load

6. Technical Data

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Fig. 6.22 Start up SMC 100 - HFC/HCFC - 25% load

Dp

6. Technical Data

146/288 0178-931 - ENGRev. 27.10.03


Moment of Intertia

As to the moment of inertia, Table 6.3 and Table 6.4, the SMC/HPC/TSMC 100 compressors have the following values:

Table 6.3 Moment of Inertia (kgm2) for SMC/HPC/TSMC 100 Compressors

Table 6.4 Moment of Inertia (Ib.ft2) for SMC/HPC/TSMC 100 Compressors

Type SMC 100 S (80 mm stroke) SMC 100 L (100 mm stroke) SMC 100 E (120 mm stroke)

No of cylinders: SMC/TSMC 100

4 6 8 12 16 4 6 8 12 16 4 6 8 12 16

HPC 100 4 6 8

Compressor with free shaft end

0.154 0.189 0.218 0.376 0.427 0.196 0.234 0.269 0.464 0.579 0.254 0.321 0.340 0.593 0.705

V-belt driven compressor with shaft pulley

4 1.529 1.564 1.593 1.751 1.802 1.571 1.609 1.644 1.839 1.954 1.629 1.696 1.715 1.968 2.080

No of V-belts 6 1.404 1.439 1.468 1.626 1.677 1.446 1.484 1.519 1.714 1.829 1.504 1.571 1.590 1.843 1.955

Profil SPB 8 1.779 1.814 1.843 2.001 2.052 1.821 1.859 1.894 2.089 2.204 1.879 1.946 1.965 2.218 2.330

Direct driven com-pressor with com-plete AMR coupling

0.262 0.297 0.326 0.559 0.610 0.304 0.342 0.377 0.647 0.762 0.362 0.429 0.448 0.776 0.888

Type SMC 100 S (80 mm stroke) SMC 100 L (100 mm stroke) SMC 100 E (120 mm stroke)

No of cylinders: SMC/TSMC 100

4 6 8 12 16 4 6 8 12 16 4 6 8 12 16

HPC 100 4 6 8

Compressor with free shaft end

3.66 4.49 5.18 8.93 10.14 4.66 5.56 6.39 11.02 13.75 6.03 7.62 8.08 14.09 16.75

V-belt driven compressor with shaft pulley

4 36.31 37.15 37.84 41.59 42.80 37.32 38.22 39.05 43.68 46.41 38.69 40.29 40.74 46.75 49.41

No of V-belts 6 33.35 34.18 34.87 38.62 39.83 34.35 35.25 36.08 40.71 43.44 35.72 37.32 37.77 43.78 46.44

Profil SPB 8 42.26 43.09 43.75 47.53 48.74 43.25 44.16 44.99 49.62 52.35 44.63 46.22 46.67 52.68 55.34

Direct driven com-pressor with com-plete AMR coupling

6.22 7.05 7.74 13.28 14.49 7.22 8.12 8.95 15.37 18.10 8.60 10.19 10.64 18.43 21.09

6. Technical Data

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Direction of Rotation of Electric Motor

Sometimes the motor is equipped with specially designed ventilation wings to reduce the noise level. These motors have a specified direction of rotation which must be considered when con-necting them to a compressor. If the motor is con-nected by means of a coupling, it must rotate clockwise when looking at it from the shaft end, Fig. 6.23.

Fig. 6.23

If the motor is connected by means of a V-belt pul-ley, the direction of rotation should be as follows:

SMC 104-106-108 and TSMC 108Anti-clockwise, Fig. 6.24.

Fig. 6.24

SMC 112-116 and TSMC 116Clockwise, Fig. 6.25.

Fig. 6.25

Note: The driving part of the V-belts must always be closest to the base frame.

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Handling of Compressor and UnitWhen lifting the compressor, only use the lifting eyes M20, Fig. 6.26, which are fitted in the thread-ed holes at the top of the block. The weight of the compressor block is indicated in Table 6.1 in the beginning of this section.

Note: It is only the compressor block which may be lifted in the lifting eye. The same applies to the motor.

Fig. 6.26

The unit is lifted in the lifting eyes, which are weld-ed onto the base frame and clearly marked with red paint. When the unit is lifted, make sure that

the wires do not get stuck and thus damage the pipes or any other components on the unit.

Fig. 6.27

Alternatively, the unit can be lifted with a forklift truck.

It is recommended to make the distance "x" as wide as possible yet still keeping it within the sup-ports as illustrated in the Fig. 6.28. Be careful that the unit does not tip sideways as the point of grav-ity is rather high.

Fig. 6.28

The weight of the unit can be seen in the shipping documents or in Table 6.2.

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Compressor Shaft

All compressors have the same shaft size. On the shaft it is possible to mount either coupling flange or V-belt pulley as described in the following.

The coupling flange or the V-belt pulley is fixed by means of a cone clamping system.

Fig. 6.29

Boring of HubThe coupling flange or the pulley is usually mounted on the compressor shaft on delivery of compressor units.

On delivery of compressor blocks where the cus-tomer prefers to bore the hub himself, the follow-ing procedure should be observed:

It is recommended to use the types of coupling as stated for SABROE compressors. If the neces-sary data is not known on delivery of the compres-sor, the coupling flange for the motor will be deliv-ered pilot bored and the boring must be completed on site.

Coupling TypesAMR 312 for:- SMC 104-106-108 and TSMC 108. - HPC 104-106-108. AMR 350 for: - SMC 112-116 and TSMC 116.

Just like the flange to the compressor, the motor coupling flange has been duly bal-anced from factory. This makes special de-mands on the accuracy of the boring proce-dure.

Boring ProcedureThe coupling flange is fixed in a lathe or a fine boring machine by tightening the outer diameter C of the flange, Fig. 6.30.

Fig. 6.30 AMR Coupling Flange to Motor Shaft

Alignment must be kept within the values stated in Table 6.5.

Max. 0.02 mm

C A

B

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Table 6.5

Boring is carried out to the immediate motor shaft diameter with an H8 tolerance. Please, note that the max. boring diameter is 95 mm and that two key grooves must be engraved in the key of the motor shaft in order to main-tain balance.

The width of the key grooves is made with an H7 tolerance, and the depth must be such as to create a distance between key and hub of 0.2-0.3 mm, Fig. 6.31

Fig. 6.31

As seen in the above drawing, Fig. 6.30, the coupling hub is slit up axially and clamped to the motor shaft with two screws.

Read more about the coupling in the follow-ing section.

Max. axial untruth measured at point A

0.02 mm

Max. radial untruth measured at point B

0.02 mm

H7

H8

+0.2/0.3 mm

Max. dia. 95 mm

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Coupling

An AMR coupling is used for YORK Refrigeration's Sabroe reciprocating com-pressors. This coupling is resistant to torsional stress but radially and axially flexible. Torsional resistance is achieved by a transmission of the ro-tational force of the motor through a number of thin laminated steel sheets (laminas) collected in two "parcels" (disc packs) A and fixed on the flanges with screws, Fig. 6.32.

Fig. 6.32

With the torsionally resistant coupling the oscilla-tory weight of the rotor in the electric motor works as a "flywheel", providing the compressor with a stable and vibration free operation during all kinds of operating conditions and capacity stages.

Radial flexibility is achieved by means of the inter-mediate piece B which, together with the two lam-inas "parcel A", creates a cardanic effect. In this way the two flanges are able to move a little radi-ally in relation to each other, thus equalizing minor lateral movements of motor and compressor.

The compressor unit is delivered with coupling flanges mounted on the compressor and motor,

provided that the motor comes from YORK Refrigeration. Intermediate piece and par-cels with laminas are delivered separately and must be mounted on site. Remember that com-pressor and motor must be aligned as de-scribed in Section 7, Installation Instructions.

Intermediate piece B also makes it possible to re-move the shaft seal of the compressor without having to move motor or compressor. The length C of the intermediate piece (Fig. 6.33) and the lamina parcels cover a distance - after they have been dismantled - that makes it possible to dis-mount the coupling flange and the shaft seal of the compressor.

Fig. 6.33

Table 6.6

A B A

Compressor Distance C mm

HPC/SMC 104 - 106 - 108TSMC 108

102

SMC 112 - 116TSMC 116

113

C B

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The procedure for alignment of compressor and motor is described in Section 7, Installation In-structions.

Balancing must be made before the key groove is engraved.

After boring, the coupling flanges are balanced. This is characterized by one or more holes on the side of the flange. Max. permissible imbalance can be seen from the table, Table 6.7.

Table 6.7

Compressor HPC/SMC 104-106-108 TSMC 108

SMC 112-116 TSMC 116

Balancing Gmm

Coupling hub - motor AMR 312 S AMR 350 S 550

Coupling hub - compressor AMR 312 AMR 350 400

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V-Belt Drive for SMC/TSMC 100Fig. 6.34

By letting the electro motor drive the compressor through a V-belt drive, the speed of the compres-sor can be selected so that the max. capacity cor-responds to the capacity requirements of the plant.

The V-belts are referred to as SPB Red Power. Their cross section dimensions are shown in Fig. 6.35

Fig. 6.35 S = C plus SPB 2650

The V-belts are of an excellent quality. Under nor-mal operating conditions they do not require any service and are shape-permanent, which means that they can be characterised as S = C plus, which is stamped on the outside of the belts, see Fig. 6.36. Moreover, the V-belts are made with

such narrow tolerances that they can be fitted im-mediately, which means that it is no longer neces-sary to check whether the belts match. A V-belt drive which has been set up and adjusted correct-ly will usually have a service life of approx. 20,000 operating hours.

Fig. 6.36

Transmission RatioThe required transmission of speed between mo-tor and compressor is achieved by choosing the right combination of pulley diameters as stated in the Table 6.8. It appears from the table that there is only one pulley diameter for the compressors and that the transmission ratios are achieved by choosing among the standard motor pulleys.

Thus the Compressor Speed for Motor Speed 1460 rpm (50Hz) and 1760 rpm (60 Hz) stated in the table is achieved. The nominal V-belt length is stated in the column Length of V-belt, and the same length is stamped on the outside of the V-belts as in the example shown in Fig. 6.36.

16.3

13

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Table 6.8 Standard Programme for V-Belts and Pulleys for SMC/TSMC 100

* SMC 104 - 108 and TSMC 108 only

Standard V-belt pulley Diameter mm

Compressor speed comparedto Motor speed

Length of V-beltsmm

Compressor Motor 50 Hz 1460 rpm 60 Hz 1760 rpm SMC 104- 106-108TSMC 108

SMC 112- 116TSMC 116

180 792 1900

190 836 2650 1900

200 *730 880 2650 1900

224 817 985 2650 2000

400 250 912 1100 2800 2000

265 976 1166 2800 2000

280 1022 1232 2800 2000

315 1150 1386 2800 2120

335 1273 1474 3000 2120

355 1295 1562 3000 2240

400 1460 1760 3000 2240

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Power TransmissionThe number of V-belts which must be used to transmit the necessary power from the motor to the compressor - which usually corresponds to the nominal capacity of the motor - is stated in the fol-lowing tables, Table 6.9 and Table 6.10.

Note: To obtain a smooth transmission, the number of V-belts must be chosen so that the belt drive loads at its maximum as stated in the table. The motor pulleys are always delivered with the number of grooves corresponding to the number

of V-belts which must be used to transmit the maximum power of the motor to the V-belt drive in question, thus indicating how many V-belts must be fitted.The compressor pulleys, however, are only de-livered with the number of grooves shown below. Thus it may occur that there are more grooves on the compressor pulley than on the motor pulley.

SMC/TSMC 100 The compressor pulleys are always delivered with 4 - 6 or 8 grooves.

Table 6.9 Max. Power Transmission SMC104-106-108 and TSMC108Number of

V-beltsMotor speed 1460 rpm (50 Hz)

730 817 912 976 1022 1150 1295 1460 rpm

2 22 22 30 30 30 37 45 45

kW

3 30 37 45 45 45 55 55 75

4 37 45 55 55 55 75 90 90

5 45 55 75 75 90 110 110

6 55 75 75 90 90 110 132 132

8 75 90 106 110 118 132 150 169

Number of V-belts

Motor speed 1760 rpm (60 Hz)

792 836 880 985 1100 1166 1232 1386 1474 rpm

2 26 36 36 36 44 44

kW

3 26 26 36 44 44 54 54 66 66

4 36 44 44 54 66 66 66 90 90

5 54 54 54 66 90 90 108 108

6 66 66 90 108 108 132 132

8 66 90 90 108 127 132 143 158 171

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Table 6.10 Max. Power Transmission (kW) SMC112, 116 and TSMC116Number of

V-beltsMotor speed 1460 rpm (50 Hz)

730 817 912 976 1022 1150 1295 1460 rpm

3 55 55 55

kW

4 55 55 55 75 75 90

5 55 75 75 90 90 110

6 75 90 110 110 132

8 90 106 110 110 132 150 169

Number of V-belts

Motor speed 1760 rpm (50 Hz)

792 836 880 985 1100 1166 1232 1386 1474 rpm

3 54 66 66

kW

4 54 66 66 66 90

5 54 54 66 90 108 108

6 54 66 90 90 108 132

8 66 66 90 108 108 132 132 158 158

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Construction of V-Belt DriveOn standard units the nominal shaft distance be-tween motor and compressor is 900 mm for SMC/TSMC 104 to 108 as shown in Fig. 6.37, and 500 mm on SMC/TSMC 112 and 116 as shown in Fig. 6.38.

Fig. 6.37 SMC 104-106-108, TSMC 108

Fig. 6.38 SMC 112-116, TSMC 112-116

The driving part of the V-belts must always be closest to the base frame as shown with A in Fig. 6.39.

Fig. 6.39

The compressor pulley is bored with a cylindrical hole and is fitted to the crankshaft with a clamping unit. The end of the crankshaft and the outer face of the clamping unit must be aligned. Thus the belt pulley can be mounted on the crankshaft without previous adjustment. It must be tightened with the nine screws on the clamping unit, see fig. 6.41. The screws are tightened with a torque wrench.

Fig. 6.40

Fig. 6.41

When dismounting the belt pulley, loosen the screws on the clamping unit.

900 mm

Nominal center distance

II

III

I

Nominalcenterdistance500 mm

A

Align these faces

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The motor pulley is tightened to the motor shaft by means of a conical bushing, pos. 1 in Fig. 6.42, which fits the conical boring of the belt pulley. The bushing is bored and equipped with a key, which fits the motor shaft in question. When mounting the pulley, first place the belt pulley and the bush-ing on the motor shaft, then fix the pulley to the bushing by means of two or three screws, pos. 2 in Fig. 6.42. Mount the screws in the holes where the thread faces the belt pulley. Thus the conical bushing is pressed around the motor shaft so that it both holds and centers the belt pulley. Before tightening, the belt pulley is placed on the motor shaft so that it is flush with the compressor belt pulley. Tighten the screws, pos. 2, with the torque moment as indicated in Section 21.

Fig. 6.42

When dismounting the belt pulley, first dismount the two or three screws, pos. 2, and then mount one or two of the screws in the free hole/s where there is only a thread in the side which faces the bushing. By tightening the two screws evenly, it is now possible to press the belt pulley off the bush-ing. The bushing and the belt pulley can now be dismounted manually.

The V-belts must only be mounted and dismount-ed when the motor is placed close to the compres-sor to avoid damage of the belts.

Tightening and Adjusting the V-Belt DriveWhen the necessary number of belts have been mounted - corresponding to the number of grooves on the motor pulley (max. 8) - the V-belt drive is tightened by moving the motor away from the compressor. For this purpose, use two washers which are part of the base frame and mounted at the feet of the motor.

For measuring the correct belt tension, use Ten-sion Gauge II, part no. 1622.003.

Spare Parts

When delivering belt pulleys as spare parts, the compressor pulley is always ready bored and balanced. It can thus be fitted directly on the com-pressor.

The motor pulley is delivered balanced and with a conical bushing, which is ready bored for direct fitting on the motor shaft in question.

ServiceThe V-belt drive has an average service life of ap-prox. 20,000 operating hours during which period it is only necessary to check and perhaps adjust the belt tension. Checking and adjusting the V-belt drive is best carried out by means of the special tool (Tension Gauge) mentioned above, which is available from YORK Refrigeration Af-ter-Market Service Department.

When replacing the V-belts, the grooves in the V-belt pulleys should be checked for wear and tear by means of a Belt and pulley groove gauge, part no. 1622.001, which can also be ob-tained from our After-Market Service Department.

1

2

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Laying the Foundation

When erecting a compressor unit, it is important that the bed plate upon which it is placed is as plane as possible as the rigidity of the base frame depends on whether the base frame is supported correctly under all its "feet".

The base frame should therefore be stress-free and rest evenly on all its "feet" when positioned on the foundation.

In the following paragraphs a distinction is made between stationary plants and marine plants.

Stationary PlantIn stationary refrigeration plants the compressor unit is either mounted directly on a concrete foun-dation or positioned on vibration dampers, Fig. 6.43 and Fig. 6.44.

Fig. 6.43 Unit mounted directly on concrete foundation

Fig. 6.44 Unit mounted on vibration dampers

The most preferred form of mounting today is the one on vibration dampers as the unit can be po-sitioned directly on the machine floor without any clamping and without the laying of a concrete foundation. This reduces the plant costs consider-ably both during the initial installation and later on during a potential rearrangement of the units in the machine room.

Further, the use of vibration dampers is a way to ensure that vibrations from the unit are not propa-gated to the construction itself via the foundation.

In return, this form of mounting requires a plane and horizontal machine floor within narrow limits as specified in the following.

300

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Mounting Directly on Foundation:Mounting directly on the foundation or the floor of the machine room. The base plates of the unit are clamped down by means of foundation bolts, cast into the foundation as shown in the drawing.

Fig. 6.45 Example of Foundation Drawing

Foundation bolts, nuts and foundation plates are delivered together with an order. Following a spe-cific order a foundation drawing will be forwarded and the holes poured into the foundation as indi-cated in this drawing.

As shown in the drawing, Fig. 6.45, the unit is placed on a concrete foundation which is usually 300 mm high. During the concreting the holes are moulded into the concrete as indicated in the for-warded drawing, Fig. 6.46.

Fig. 6.46 Moulding of Foundation Bolts

After the foundation has hardened, the unit is lo-cated, leaving it to rest on wooden blocks in a flush position and without twisting the base frame.

The foundation plates are tightened under the base plates of the base frame by means of steel wire. The foundation bolts are suspended in the holes with the nut screwed down flush with the end of the foundation bolt as illustrated in the drawing.

The concrete poured round the foundation bolts should only contain very little water in order that it may be stamped down properly round the bolts. A low water content does not cause contraction of the setting concrete.

10-14 days should be allowed to pass before the joists are removed and the nuts of the foundation bolts tightened. Remember to remove the steel wire and check that no space is left between base frame and foundation plates. Otherwise, place the liners between the plates before tightening.

300 1250 350

125

500

125

Foundation bolts

Compressor Motor

300

110 x 110

250

10

Foundation plate

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Mounting of Vibration Dampers

By placing the compressor unit on vibration damp-ers, Fig. 6.44, calculated and delivered by YORK Refrigeration, an optimum damping of vi-brations from the unit to the foundation and con-sequently to the construction will be achieved.

As already mentioned, the unit with the vibration dampers is usually placed directly on the floor which must be strong enough to be able to carry the weight of the unit.

The vibration dampers need not be clamped to the floor as the bottom side has a rubber coating, the friction of which prevents them from sliding around on the floor.

This makes it easy and quick to align the units on a plane floor and they are easily moved during a potential later rearrangement of the machine room.

Vibration Dampers:From the table in Fig. 6.48 it is possible to read how much the damping of a vibration damper de-pends on its deflection when loaded. YORK Refrigeration recommends that vibration dampers be selected and loaded to a deflection of

nominally 2 mm. A good and rigid support of the unit is thereby achieved as well as a proper damp-ing coefficient.

The rotating parts in the compressor are com-pletely balanced for forces of the 1st order and consequently, damping is primarily necessary for forces of the 2nd order, which rotates at double speed.

In the table in Fig. 6.47 the normative values for damping can be read in relation to the number of revolutions:

Fig. 6.47 Guide for Selection of Suitable Deflec-tion

In the diagram in Fig. 6.48 the vibration damping with various vibration speeds can be read in de-pendence of the deflection of the vibration dampers:

rpm Suitable de-flection order

Damping of 1st order

vibrations

Damping of 2nd ordervibrations

950115014501750

2.3-3mm1.6-2.4mm1.2-2.0mm0.8-1.4mm

25-50%30-60%40-72%40-74%

87-92%87-92%90-94%89-94%

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Fig. 6.48 Diagram for Damping of Vibrations

Since each part of the unit has its own weight, the whole unit does not rest with the same weight on all supports.

As a consequence, vibration dampers with differ-ent bearing capacity will be used on a unit and these must be placed correctly in accordance with the Mounting Instruction supplied by YORK Refrigeration for that particular unit. Fig. 6.49 is an example of such an instruction.

Damping

500

700

1000

1400

2000

2500

3000

30 20 16 12 10 8 6 5 4 3 2 1.6 1.2 1 0.8 0.6 mm

Naturalfrequency

0%

50%

70%80%

85%

90%

95%

97%

98%

Vib

rati

on

spee

d r

pm

Deflection of vibration dampers

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Fig. 6.49

Vibration dampers can be adjusted in height by means of screw, pos.1, Fig. 6.50 which is finally locked by tightening nut, pos. 2. The height H can now be changed within the limits stated in the ta-ble and are thus able to even out any minor differ-ences in the planeness of the floor.

Fig. 6.50

After this equalizing a further tightening of screws will lead to a deflection of the vibration damper. This reduces the measure h from an unloaded to

a loaded state, corresponding to the deflection re-ferred to in the diagram in Fig. 6.48.

When designing the piping connections to the compressor, care must be taken that these do not influence the push and pull forces of the unit. The length of the pipes changes with the temperature and this makes it necessary to make the pipings flexible as shown in the drawing, Fig. 6.51.

Fig. 6.51

Make sure, however, that the pipes are supported so that they do not start oscillating, thereby affect-ing the unit.

After alignment of the unit as described above, compressor and motor must be aligned in relation to each other.

Vibration absorber type

Pos. A - B - C D

1 LM LM

2 LM LM

3 LM LM

4 LM LM

5 LM

6 LM

1 3 1 3 5

2 4 2 4 6

Compressor

Unit A

Motor Compressor Motor

Unit B

Base-frame

D

H

h

1

2

D h H

LM1 80 30 38

LM3-4T025 120 37 49

LM3-33 120 32 44

21

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Specific Requirements to Vibration DampingIn places where particularly strict requirements are set up in order to prevent vibrations from being propagated to the building construction itself and causing noise nuisance, specific measures should be taken.

This could be in connection with housing and of-fice buildings or e.g. hospitals.

In such cases the best results are achieved by fastening the whole unit on a sufficiently large concrete foundation which is placed on vibration dampers with a large bearing capacity or on a rub-ber mat adapted to the purpose.

At the same time flexible vibration eliminators should be used in the pipe connection to the unit in order to avoid transmission of noise through the piping. Very often it will be necessary to insulate the machine room against noise or to use a noise absorbing lining on the unit, Fig. 6.52, in order to prevent noise from spreading to the environment.

Fig. 6.52 Noise absorbing shielding of com-pressor unit

In case of questions, please contact YORK Refrigeration whose employees are al-ways ready to place their expertise at your dispos-al.

Marine InstallationsUnits in marine refrigeration plants are always placed on vibration dampers as they serve a two-fold purpose in so far as they dampen both the vi-brations of the marine engines as well as those of the compressor.

Fig. 6.53 Vibration dampers for marine installa-tions

Liner plate

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The illustrated type of vibration dampers, Fig. 6.53, which is standard equipment on YORK Refrigeration's Sabroe reciprocating com-pressors, is fixed to the unit feet and foundation. This keeps the unit fixed to the foundation under all kinds of load conditions when the ship is ex-posed to the sea. It is not possible to adjust the height of the vibration dampers. This makes it necessary to machine the steel foundation as evenly as possible (max. deviation approx. 1 mm).

In case of a larger tolerance on the planeness or where vibration dampers of different heights are used due to the fact that the base frame loads dif-ferently on the surfaces of support, this must be compensated with liner plates as shown on the drawing, Fig. 6.53

Vibration dampers are selected by YORK Refrigeration for a particular unit and delivered together with a drawing indicating the position of each damper.

Fig. 6.54

It is very important to observe these positions as the unit does not rest with the same weight on all feet.

The vibration dampers are selected to a deflection of 3 to 5 mm. A damping of the forces of the 2nd order is thereby achieved as indicated in the dia-gram in Fig. 6.54. Read more on this subject in this section under Vibration Dampers.

Vibration absorber type

Pos. Unit A Unit B

1 C C

2 C C

3 C C

4 C C

5 C

6 C

1 3 3 51

2 4 2 4 6

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Noise from Compressors and Units

Noise is inevitable when a compressor or unit is working. However, by taking this into considera-tion during the project phase, it is possible to re-duce noise pollution of the environment consider-ably.

Through the years YORK Refrigeration has been aware of this problem. As a consequence, we have designed the compressors and units with a view to meeting market demands concerning maximum noise levels.

Of course, modern compressor units are loud and must be expected to make noise, and this makes it the more important that the sound data stated for a compressor or unit should be evaluated cor-rectly.

The above issue will be discussed in the following. In this connection YORK Refrigeration would like to point out that at a fairly low cost it is possible to make the machine room a pleasant work place. The use of noise absorbing materials could be one solution to the problem.

1. Sound Power and Sound Pressure

As seen in Table 6.12 sound data is indicated as sound power level LW or sound pressure level LP. It is essential to distinguish between these two

values as they are stated in dB (decibel) and should be read as follows:

1.1. Sound Power Level LW

According to ISO 9614-2 LW is measured directly

at the unit, Fig. 6.55, by installing a measuring grid as close to the unit as possible.

Fig. 6.55 Unit covered with a measuring grid

The measuring grid is divided into fields of max.1 sq. m each. The measuring is carried out by moving the sound level meter in a kind of back and forth movement, as illustrated in Fig. 6.55. The sound level meter now calculates the total sound power level LW for the entire unit.

The sound power level LW is, however, dependent

on the surroundings of the noise source. Conse-quently, it is a somewhat theoretical value. Here, the sound pressure level Lp becomes of inter-est.

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1.2. Sound Pressure Level Lp

It is actually the sound pressure level Lp that is measured by the sound meter. In the sound meter this is then automatically converted to the sound power level LW by means of its built-in calculation

programs.

The sound pressure measuring is, however, de-pendent on the room in which the measuring is carried out. As a consequence, this may yield dif-ferent results from one room to another.

The arrangement of the room as well as building materials have a considerable influence on the re-sults of the measuring.

This is why the measured values of the manufac-turers for sound pressures are based on standard measures according to ISO 3989 which refers sound pressure level LP to a free field above a re-flecting plane at a distance of 1 meter from the measuring grid, as described in pt. 1.1.

Above facts should be taken into consideration during a check measuring on the plant in question as mentioned in points 2.1 and 2.3.

1.3. Frequency

Sound is fundamentally a pressure wave in the air at a given wave length (frequency).

From a compressor unit sound waves are emitted at many different frequencies due to the different movable parts.

The human ear can normally perceive frequen-cies in areas ranging from 20 Hz to 20 k Hz, but it does not perceive all frequencies equally well. Consequently, a sound meter must measure the sound pressure at various frequencies and then filter the measuring corresponding to the percep-tual capacity of the ear (the A-weighting).

To this must be added the purely subjective per-ception of sound as most human beings feel con-siderable unease on hearing the so-called "pure" notes. If a frequency is followed by a sound pres-sure of 3-6 dB above the other frequencies, this feels annoying. In case of screw compressors, it is a fact that 300 and 600 Hz is normally felt to be an-noying whereas reciprocating machines issue a more low-frequency (pleasant) sound.

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2. Assessing the Measured Values

2.1.

As a consequence of the difference between the actually measured sound and the sound that the ear perceives, the measured values are weighted in the sound meter. Usually, the sound meter is set for A-weighted values called dB (A), based on a logarithmic scale.

That is why it is so important to apply the same unit of measure on comparing values from several different machines.

Further, we would like to point out that the sound pressure level LP measured in the machine room

as described under pt. 1.2 will always be above the one indicated in table, Table 6.12

The measured value will normally lie somewhere between the stated LP and LW values.

2.2.

In machine rooms with a number of compressors the total sound pressure level can be calculated by adding ∆ L read on the curve in Fig. 6.56 to the sound pressure value for the unit with the highest sound pressure.

Fig. 6.56 Curve for adding of logarithmic levels

Example 1:

With two compressors in the same room

Compressor 1,LP1= 81 dB (A)

Compressor 2,LP2= 86 dB (A)

Difference 5 dB (A)

Total sound pressure level:

LP = 86 + 1.2 = 87.2 ≅ 87 dB (A)

Example 2:

In case two compressors have the same sound pressure level, e.g. 86 dB (A) the difference will be 0.

total sound pressure level:LP = 86 + 3 = 89 dB (A)

Example 3:With a number of compressors in the same room the sound pressure level is calculated by miner of the curve, Fig. 6.57, as follows:

Difference (L2-L1) dB

3,0

2,5

2,0

1,5

1,0

0,5

0 5,0 10,0 15,0

dB∆ L

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Fig. 6.57

2.3.

It is essential that during a potential check meas-uring to carry out more than one sound pressure measuring, e.g. by measuring in fields as shown in Fig. 6.55 as a few local measures may result in incorrectly high measured values.

2.4.

Likewise, pay attention to the fact that the meas-ured values stated for a certain unit should com-prise a complete unit incl. compressor, motor, oil

separator etc. which have all been covered by the measuring grid.

Thus, on assessing the measure results it is es-sential to know the extent of the measured surface area in the surrounding measuring grid.

2.5.

If the compressor is working at part load, this will generally lead to higher measured values than the ones indicated in the tables.

56 52 61 dB

62,6

48 54 61 62

63 dB

62 58 dB

67,2 67 dB

55,0

57,5

62,0

65,0

66,7

6 compressors

=~

~=

3 compressors

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3. How to Check Sound Data

3.1.

The only correct method is the measuring of sound power LW on the site itself and this requires

the setting up of a measuring grid as well as the use of sound intensive equipment.

3.2.

If using sound pressure Lp meters only, an addi-

tional measuring of the reverberation period of the room will be required. This makes it possible to find a theoretical value of the emitted sound power provided that the background noise is too low to be of any importance!

Noise Data for Reciprocating Compressors

Single-stage

LW and Lp values are measured at the following

conditions:

Heat Pump

Table 6.11

Table 6.12

Two-stage

LW and Lp values are measured at the following

conditions:

Table 6.13

Evaporating temperature ET = 5°C [5°F]

Condensing temperature CT = +35°C [95°F]

Refrigerant = R22/R717

Number of revolutions = 1450 rpm

Evaporating temperature ET = 20°C

Condensing temperature CT = +70°C

Refrigerant = R22/R717


Compressor block LW LP

HPO 24HPO 26HPO 28

919394

767879

HPC 104 SHPC 106 SHPC 108 S

979899

818284

Compressor block LW Lp

SMC 104 SSMC 106 SSMC 108 SSMC 112 SSMC 116 S

95969799100

7980818283

SMC 104 LSMC 106 LSMC 108 LSMC 112 LSMC 116 L

969798100101

8081828384

SMC 104 ESMC 106 ESMC 108 ESMC 112 ESMC 116 E

969798100101

8081828384

Evaporating temperature ET= 35°C [-31°F]

Condensing temperature CT= +35°C [+95°F]

Refrigerant= R22/R717


Compressor block LW LP

TSMC 108 S TSMC 116 S

9597

7981

TSMC 108 LTSMC 116 L

9698

8082

TSMC 108 ETSMC 116 E

9698

8082

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4. Damping Acoustic Noise in a Machine Room

On planning or renovating a machine room, atten-tion should be paid to the acoustic environment as a minor investment is sufficient to change an acoustically hard room to a noise damped room which is pleasant to work in.

This is possible to achieve by choosing a sensible noise absorbing material, fitted on walls and ceil-ing or which is part of the building construction

It is recommended to seek advice from a consult-ing firm experienced in noise damping in order to obtain the solution best suited to your plant.

For this purpose computer calculated frequency analyses can be requested from YORK Refrigeration for the compressor unit in question.

Another and very efficient solution would be to noise insulate the compressor unit itself. YORK Refrigeration is able to deliver pre-fabricat-ed and tested noise baffle boards.

Fig. 6.58

In GeneralThe following paragraphs include a description of the factors that influence the acoustic quality of a machine room.

Reverberation TimeBy a correct application of noise absorbing mate-rials it is possible to change the reverberation time of a machine room which is defined as the time it takes for the sound pressure level Lp to

drop 60 dB once the noise source stops.

The duration of the reverberation time depends on the volume of the room as well as the average ab-sorption coefficient for the noise absorbing mate-rials that are fitted in the room as they should be.

Absorption CoefficientUsually the absorption coefficient α for noise ab-sorbing materials is 0.5 to 0.8. See the following il-lustration, Fig. 6.59.

Fig. 6.59

Incidentsound power

X =

Transmitted sound power

Noise damping material

Absorbedsound power

Reflected sound powerIncident so’und power

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Subjective Perception of Noise DampingWith reference to table, Table 6.14, indicating how the human ear perceives the effect of noise insulation in a machine room, the following should be noted:

• By investing in a sensible noise insulation of the ceiling of the machine room this usually means reducing the reverberation time by

half in the machine room with a subsequent great subjective effect.

• When using a pre-fabricated noise baffle board from YORK Refrigeration, the sound pressure in the machine room will typically be reduced by 20 dB. Naturally, this must be considered a great improvement - subjec-tively perceived.

*The YORK Refrigeration prefabricated Version 2.0 noise baffle board for compressor units

Table 6.14

Reduction of sound pressure by noise insulation of

compressor unit

Reduction of the average sound pressure level by noise insulation

Subjective perception of the improved acoustic quality

of the room

dB dB Relative reverberation time

0 0 1 -

1 0,5 0,9 Insignificant

3 1 0,8 Perceivable

6 2 0,6 Distinct

10 3 0,5 Considerable

20 * 6 0,25 Very considerable

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Vibration Data for Compressors - All Compressor Types

Vibration data for YORK Refrigeration's Sabroe reciprocating compressors comply with: the ISO 10816, standard, Part 6, Annex A, group 4, AB, which fixes max. permissible operating vibrations at 17.8 mm/s.

Vibration data for YORK Refrigeration's Sabroe screw compressors comply with: ISO 10816

standard, part 1, Annex B, Class III, C, which fixes max. permissible operating vibrations at 11.2 mm/s.

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

Fig. 6.60

Pay attention to the following, however:

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

• When placing the unit on the vibration dampers supplied by YORK Refrigeration (additional), the vibrations against the foun-dation are reduced by:

– 85-95% for screw compressor units

– 80% for reciprocating compressor units

• However, higher vibration level may occur if:

– motor and compressor have not been aligned as described in the Instruction Manual.

– the compressor runs at an incorrect Vi

ratio. This applies to screw compres-sors.

– the piping connections have been exe-cuted in a way that makes them force pull or push powers on the compressor unit or transfer vibrations to the unit caused by natural vibrations or connect-ed machinery.

– the vibration dampers have not been fit-ted or loaded correctly as indicated in the foundation drawing accompanying the order.

x x x xCH DHBHAH

AA

AVBV

BACA

DA

CV DV

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Fig. 6.61 Specification of Compressor Materials

The materials to be used for the individual compo-nents of the compressors have been selected in view of a long life, wear resistance as well as re-

sistance to the refrigerants and oils approved for the compressors.

The following table,Table 6.15, lists the most im-portant components.

Table 6.15

Designation Material Form

Compressor frame SMC and TSMC Compressor frame HPC 100Oil pump housing HPC 100, SMC and TSMC100Bearing cover pump end HPC 100, SMC and TSMC100Water covers HPC 100, SMC and TSMC100All other covers SMC and TSMC All other covers HPCCrankshaft HPC108Crankshaft all other compressorsConnecting rodPiston pin bushingHalf section of bearings for Connecting rodBolts for connecting rodPistonPiston rings and oil scraper ringPiston pinCylinder liners

Suction and discharge valve platesSuction valve retaining plateSafety head springMain bearingsShaft seal carbon ringShaft seal steel ringSuction filterOil level glassOil strainerBy-pass valveBuffer springsGasketsO-ring seals

Cast ironDuctile cast ironCast iron

Ductile cast iron

Cast ironCast ironDuctile cast ironDuctile cast ironDuctile cast ironDuctile cast ironPhosphor bronzeWhite metal on a steel base

Cr-Mo steelAluminium alloyCast ironCr-steelCast iron w/special heat treatment

Special steel

Ductile cast ironSteel springWhite metal on a steel baseSpecial carbonSpecial steelStainless steel wire-meshGlass in steel flangeFilter cartridgeVarious steelSpring steelNon-asbestosCR Rubber (standard)

EN-GJL-250, EN 1561EN-GJS-500-7, EN 1563EN-GJL-250, EN 1561

EN-GJS-500-7, EN 1563

EN-GJL-250, EN 1561EN-GJL-250, EN 1561EN-GJS-500-7, EN 1563EN-GJS-800-2, EN 1563EN-GJS-700-2, EN 1563EN-GJS-700-2, EN 1563BS1400, PB1-C

Cl, 12.9, DIN 898BS 1490/LM13BS 1452 (W.CI7)17Cr3, DIN 17210EN-GJL-250, EN 1561

EN-GJS-600-3, EN 156354SiCr6, DIN 17221

A62PAISI 316

AISI 304C75, DIN 17222

Compound 2347

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Test Pressure Levels for Standard Compressors and Components

All components for refrigeration plants which are under the influence of gas pressure must be pres-sure tested to prove their strength and tightness.

The approving authorities determine the test pres-sure levels on the basis of various criteria. How-ever, the test pressure requirements can be sum-marized into a number of standard pressure levels which in practice meet the requirements set up, and which can therefore be approved by all au-thorities involved.

The following table, Table 6.16, shows the stand-ard pressure levels used by YORK Refrigeration. In case of specific applications, the authorities may, however, demand a higher test pressure lev-el. Within certain limits such requirements can be met for SABROE compressors - against an addi-

tional price. Please, contact YORK Refrigeration for further information.

When pressure testing compressors and vessels, components must first prove their strength by re-sisting the test pressure of the strength test. This test is carried out with air. Afterwards, the leak test is carried out, also with air, at the pre-scribed pressure and with the component soaked in a water basin for 30 minutes.

Units consist of components which have been pressure tested as described in the following ta-ble. This means that it is only necessary to leak test the unit. Dwelling time is 20 minutes. Leak testing is carried out with pressurized air at the pressure stated in the table. All weldings and con-nections are covered with a frothing liquid which will start foaming in case of a leak.

Table 6.16

Standard Test Pressure Levels

Compressor Type Compressor SideStrength Testing

Leak Testing withPressurized Air

bar [psi] bar [psi]

CMO High pressure side 42 [609] 25 [363]

SMC 100SMC 180 Low pressure side 27 [392] 14 [203]

High pressure side 42 [609] 25 [363]

TCMOTSMC

Low pressure side 27 [392] 14 [203]

Intermediate pressure side 42 [609] 25 [363]

HPO High pressure side 80 [1160] 40 [580]

HPC Low pressure side 45 [653] 22 [319]

SAB 110SAB 128SAB 163SAB 202

The entirecompressor block

42 [609] 21 [305]

SAB 283L/ESAB 355 L 39 [566] 26 [377]

CompressorUnit

All typesThe entire unit 7 [102]

Vesselsin general

Individual pressure testing in accordance with the local rules and regulations. Consequently, no table can be set up.

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Charging the Compressor with Oil

Usually, the compressor is delivered without any oil in the crankcase. As a principal rule, the amount of oil indicated in the table, Table 6.17, should be charged to the compressor.

Table 6.17 Oil Charging

After some hours of operation the compressor must be recharged with oil, however, as part of the oil has been absorbed by the refrigerant. This is especially the case for HFC and HCFC refriger-ants.

The amount of oil to be recharged depends on the size of the refrigeration plant and the amount of refrigerant. Oil is charged to the middle of the oil level glass and the amount of oil needed in order to increase the oil level 10 mm is indicated in the table, Table 6.18.

Fig. 6.62 Oil level glass

Table 6.18

A manually operated pump connected to the oil charging valve pos. B can be used for the first as well as the following oil charges. See Section 5, Physical and Connection Data.

Note: On HPC 100 compressors with R717, the pressure must be relieved before oil charging.

Fig. 6.63 Manually Operated Oil Pump

Compressor Amount of oil in crankcase

Type Size Liter US gal.

HPC 100SMC 100

TSMC 100 Mk 4 S-L-E

104106108112116

2628304750

6.97.47.912.413.2

Compressor Difference in oil level of 10 mm corresponds to:Type Size

HPC 100SMC 100

TSMC 100 S-L-E

104106108

- 2 litres of oil[0.5 US gal.]

112116

- 6 litres of oil[1.6 US gal.]

T0177162_0

10 mm

-

B

To compressor

Gasket

Optional hand-operated oilpump

Cap T0177131_0V

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Oil Consumption

In refrigeration compressors there will always be a minor oil consumption, which means that a little oil is bound to follow the warm discharge gas out of the compressor.

In order to separate this oil, an oil separator is nor-mally used. The separator is built into the dis-charge pipe, right next to the compressor. The separated oil is returned to the compressor as de-scribed in Section 4, Technical Description - Oil Separator.

A minor part of the oil, however, present in the dis-charge gas as vapour, cannot be separated and

will consequently continue into the plant, in which it is condensed in the condenser.

In HFC and HCFC as well as in compact R717 re-frigeration plants this oil will return to the compres-sor together with the suction gas.

In return, the oil in larger and ramified R717 refrig-eration plants should be drained off and never re-used in the compressor. This amount of oil repre-sents the so-called oil consumption measured in ppm. Ppm is the abbreviation for parts per million and is calculated by using the following formula:

The normal oil consumption is between 20 and 30 ppm for an SMC/HPC 100 compressor.

Selecting Oil SeparatorAs the velocity through the oil separator affects the ability of the oil separator to separate the oil from the discharge gas, an oil separator size has been designed for each compressor. See Table 6.19.

The maximum oil consumption for this oil separa-tor is 35 ppm. Depending on the choice of lubricat-ing oil, the oil consumption is normally much low-er.

Oil consumption kg/h = Circulated amount of refrigerant Q (kg/h) x Oil consumption (ppm)

106

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Table 6.19 Oil Separators

Code no. Part no. Type Refr.

SMC 104S - B301 SMC 104L - B301 SMC 104E - B301 SMC 104S - B302 SMC 104L - B302 SMC 104E - B302

4241.2804241.2804241.2804241.2804241.2804241.280

OVUR 3206D OVUR 3206DOVUR 3206D OVUR 3206D OVUR 3206D OVUR 3206D

SMC 106S - B301 SMC 106L - B301 SMC 106E - B301 SMC 106E - B314 SMC 106S - B302 SMC 106L - B302 SMC 106E - B302 SMC 106E - B315

4241.2804241.2804241.2814241.2804241.2804241.2804241.2814241.280

OVUR 3206D OVUR 3206D OVUR 4107D OVUR 3206D OVUR 3206D OVUR 3206D OVUR 4107D OVUR 3206D


4241.2804241.2804241.2814241.2804241.2804241.2804241.2814241.280

OVUR 3206D OVUR 3206D OVUR 4107D OVUR 3206D OVUR 3206D OVUR 3206D OVUR 4107D OVUR 3206D


4241.2814241.2814241.3424241.2814241.2814241.2814241.3424241.281

OVUR 4107D OVUR 4107D

OVUR 5008 HP OVUR 4107D OVUR 4107D OVUR 4107D

OVUR 5008 HP OVUR 4107D

SMC 116S - B301SMC 116L - B301SMC 116E - B301SMC 116E - B305SMC 116E - B314SMC 116S - B302SMC 116L - B302SMC 116E - B302SMC 116E - B308SMC 116E - B315

4241.2814241.2814241.2824241.3424241.2814241.2814241.2814241.2824241.3424241.281

OVUR 4107D OVUR 4107DOVUR 6006D

OVUR 5008 HPOVUR 4107DOVUR 4107DOVUR 4107DOVUR 6006D

OVUR 5008 HPOVUR 4107D

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For the E - version the following special conditions apply(TE = evaporating temperature):

TSMC 108S-B301TSMC 108L-B301TSMC 108E-B301TSMC 108S-B311TSMC 108L-B311TSMC 108E-B311TSMC 108S-B302TSMC 108L-B302TSMC 108E-B302TSMC 108S-B312TSMC 108L-B312TSMC 108E-B312

4241.2794241.2794241.279

4241.279/4241.2804241.279/4241.2804241.279/4241.280

4241.2794241.2794241.279

4241.279/4241.2804241.279/4241.2804241.279/4241.280

OVUR 2106DOVUR 2106DOVUR 2106D

OVUR 2106D/OVUR 3206DOVUR 2106D/OVUR 3206DOVUR 2106D/OVUR 3206D



TSMC 116S-B301TSMC 116L-B301TSMC 116E-B301TSMC 116S-B311TSMC 116L-B311TSMC 116E-B311TSMC 116S-B302TSMC 116L-B302TSMC 116E-B302TSMC 116S-B312TSMC 116L-B312TSMC 116E-B312

4241.2804241.2804241.280

4241.280/4241.2814241.280/4241.2814241.280/4241.281

4241.2804241.2804241.280

4241.280/4241.2814241.280/4241.2814241.280/4241.281





SMC 104E: OVUR 3206D

SMC 106E: OVUR 3206D (TE<+15°C) [+59°F]

OVUR 4107D (TE>+15°C) [+59°F]

SMC 108E: OVUR 3206D (TE<+5°C) [+41°F]

OVUR 4107D (TE>+5°C) [+41°F]

SMC 112E: OVUR 4107D (TE<+10°C) [+50°F]

OVUR 5008D (TE>+10°C) [+50°F

SMC 112E: OVUR 4107D (TE<0°C) [+32°F]

OVUR 5008D (0°C<TE<+20°C) [+32°F<TE<+68°F]

OVUR 6006D (TE>+20°C) [+68°F]

Code no. Part no. Type Refr.

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Selecting Lubricating Oil for SABROE Reciprocating Compressors

Refrigerant: R717

In a period from 1990 to 1995 YORK Refrigeration experienced a rising number of problems with the use of mineral oils, especially in R717 plants. The problems can be divided into two groups:

c. The oil changes viscosity within a few operat-ing hours.

d. The oil dissolves (becomes very black).

The problems have been observed in connection with several different types of mineral oil and often occur within only a few operating hours. The con-sequences have been severe for both compres-sors and plants.

On the basis of the thorough investigation subse-quently carried out by YORK Refrigeration, it was decided to introduce a series of synthetic oils complying with the requirements of modern refrig-eration plants.

Mineral oils can, however, still be used in refriger-ation plants, provided the lubricating quality is carefully monitored. For modern high-capacity re-frigeration plants where a long service life for both lubricant and moving parts is expected, YORK Refrigeration recommends the use of syn-thetic oils.

Areas of application and specifications for the syn-thetic oils mentioned are described in the follow-ing pages. Supervisors and/or users of plants are at liberty to choose between YORK Refrigeration's own oil brands and alterna-tive oil brands, provided they comply with the specifications required.

General

This recommendation will only deal with the lubri-cation of the compressor. The performance of the lubricant in the plant (receiver, evaporator, etc.) must, however, also be considered.

Lubricating oils with relatively high viscosity must be used to ensure a satisfactory lubrication of re-frigeration compressors.

To achieve the best lubrication, the oil must:

• possess the correct viscosity under all operating conditions.

• possess acceptable viscosity at start-up.

• possess sufficient oxidation stability (the oil must be free of moisture when charged to the system).

• possess sufficient chemical stability when used together with R717.

Moreover, the extent to which different refriger-ants dissolve in the oil must be determined so that the oil return system, etc. can be designed to per-form at its optimum.

StratificationNote that the oil in some plants is layered in refrig-erant receivers and evaporators under certain op-erating conditions and at certain oil concentra-tions.

Plants with Several Different Compressor Types/Makes

In plants where several different compressor types/makes are connected, it is strongly recom-mended to use the same type of oil in all the com-pressors. This is very important where automatic oil return systems are used.

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If you consider changing the type of oil, please read the section Oil Changing on SABROE Com-pressors carefully.

Selecting Lubricating OilThe correct oil is selected by means of the follow-ing diagrams. When the general conditions con-cerning the lubrication of the compressor have been considered, the specific conditions of the plant must be taken into account.

Use the oil recommendation diagrams to select the correct oil code number.

The oil code number consists of letters indicating the oil type and viscosity number.

In the oil recommendation diagrams it is possible to find the code number best suited for the operat-ing conditions in question. With the code number it is possible to select the correct Sabroe oil for the application in question.

Oil Types and Oil Companies

Due to the large number of oil companies offering oil for refrigeration plants, it has not been possible for YORK Refrigeration to test all the different oil brands on the global market.

It is our experience that certain oil brands can change character during use and thus no longer correspond to the specifications stated by the oil companies on delivery. We have thus experi-enced changes in specifications as well as formu-la and performance without having received infor-

mation on this beforehand from the oil company. This makes it extremely difficult for YORK Refrigeration to give a general approval of other oil brands.

In co-operation with a large, respected oil compa-ny YORK Refrigeration has therefore developed a series of three different oils covering most de-mands. Furthermore, a list of the oils which can be supplied through YORK Refrigeration has been prepared. Data for these oils is included in the ta-ble Data for Sabroe Oils. We recommend that you use these oils, which can be delivered in 20 litre pails or 208 litre drums. When ordering, use the part no. stated in List of Part Numbers for Availa-ble Sabroe Oils.

It is of course possible to use similar oils from oth-er oil companies. If this is the case, use the table Data for Sabroe Oils.

Please note that YORK Refrigeration has not test-ed other oils than our own brand. Thus we cannot guarantee the quality, stability or suitability of oth-er oils. The respective oil companies are thus re-sponsible for the quality and suitability of the oil delivered, and if there are any problems with these oils in the compressor or the refrigeration plant, contact the oil supplier directly.

When selecting oils from other oil companies, special attention should be paid to the suitability of the oil in the compressor and the refrigeration plant as a whole.

Please note in particular the following points:

• Oil type

• Compressor type

• Miscibility between refrigerant and oil

• Operating data for the compressor

– Discharge gas temperature

– Oil temperature

Table 6.20

Code design

Oil types

M Mineral oil

A Synthetic oil based on Alkylbenzene

PAO Synthetic oil based on Polyalphaolefin

AP Mixture of A and PAO oils

E Synthetic ester-based lubricants

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– Normal oil temperature in crankcase is 50-60°C

– Max. permitted oil temperature = set point for alarm

– Min. permitted oil temperature = set point for alarm - if there is any

• The viscosity of the oil in the compressor during operation:

– Type of refrigerant and solubility of re-frigerant in the oil

– Operating temperatures

– Vapour pressure in the oil reservoir

– Suction pressure and oil temperature in the crankcase

– Compatibility with neoprene O-rings: The aniline point indicates how the O-ring material reacts to the oil.

– At an aniline point less than approx. 100°C the material has a tendency to swell, and at an aniline point higher than approx. 120°C it has a tendency to shrink

– Thus it cannot be recommended to change the oil type from M to PAO with-out changing the O-rings at the same time as a leak may otherwise easily oc-cur in the compressor or the plant. YORK Refrigeration recommends there-fore the use of the Sabroe AP68 oil since this type of oil in this case reduces con-siderably the risk of leaks. YORK Refrig-eration can supply a list of operating data on request.

• Please note the viscosity limits during oper-ation:

• Optimum viscosity limits = 20 to 50 cSt

• Max. permitted viscosity = 100 cSt

• Min. permitted viscosity = 10 cSt

• Max. permitted viscosity during start-up of the compressor = 500 cSt

• Max. refrigerant concentration in the oil during operation: 25% - also in case the viscosity requirements have been met.

Use of Mineral OilAs described in the introduction, mineral oil in par-ticular causes serious problems especially in R717 plants.

When using mineral oil, it is important to monitor the plant closely. The condition/colour of the oil must therefore be checked on a weekly basis and for each 1,000 to 2,000 operating hours oil sam-ples must be taken for further analysis.

YORK Refrigeration recommends therefore only to use M oil under moderate operating conditions - see the following oil recommen-dation diagrams.

YORK Refrigeration is aware that several custom-ers have used mineral oils for many years without any problems. The customers who wish to contin-ue using mineral oil in existing as well as new compressors can do so, provided that the com-pressor type and the operating conditions are sim-ilar to the existing ones.

YORK Refrigeration has thus decided to market one brand of mineral oil which has been tested and found suitable for most of the general refriger-ation purposes.

In case another brand of mineral oil is used, follow the specifications on the data pages in this recom-mendation as a guideline.

Mineral oil can be used in refrigeration plants, pro-vided the lubricating quality is carefully monitored. YORK Refrigeration recommends, however, that

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you use synthetic oils for modern high-capacity plants where a long service life for both lubricant and moving parts is expected.

The advantage of using synthetic lubricating oils is a much lower oil consumption and longer oil changing intervals. Improved viscosity at low tem-peratures facilitates furthermore drainage at the cold parts of the plants.

How to Use the Diagrams in the Oil Recommendation:

To find the correct code number, select refriger-ant and compressor type in the oil recommenda-tion diagram. Then insert the estimated operating conditions in the diagram.

Example (reciprocating compressors):

Note: Sometimes plants operate under different conditions, e.g. different evaporating tempera-tures due to variations in the plant, or different condensing temperatures as a result of seasonal changes. By inserting TC and TE in the oil recom-mendation diagram, the recommended area is found. In this case it is oil area 1. If the intersection is outside the area, contact YORK Refrigeration for a detailed calculation by means of the calcula-tion program COMP1.

Fig. 6.64

By using the table which is situated next to the oil recommendation diagram, select the recommend-ed code number and thus the recommended oil. In the example above there are thus 3 possibilities: PAO3, AP1 or M1. However, M1 is only recom-mended for moderately loaded compressors.

Table 6.21

Oil Change on Sabroe CompressorsNever change to another oil type without contact-ing the oil supplier. Nor is it advisable to recharge a compressor with another oil type than the one already used for the plant or compressor in ques-tion.

Mixing different oils may result in operating prob-lems in the refrigeration plant or damage to the compressor. Incompatibility between different oil types may reduce the lubricating properties con-siderably and may cause oil residues to form in the compressor, oil separator or plant. Oil resi-

Refrigerant R717

Condensing temperature: TC +35 °C

Evaporating temperature: TE -20 °C

Code no. Area no. 1

PAO3AP1

▲

✩/▲

M1 See note

-60 -50 -40 -30

-30

-20

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6. Technical Data

184/288 0178-931 - ENGRev. 27.10.03


dues may block filters and damage the moving parts of the compressor.

Changing the oil type or brand should only be done following a thorough procedure involving drainage and evacuation of the refrigeration plant. Information on a suitable procedure can be ob-tained from YORK Refrigeration as well as a number of oil companies.

It is extremely important that the new unused oil is taken directly from its original container and that both the brand and the type correspond to the specifications of the plant.

Make sure that the original oil container is sealed properly during storage so that moisture from the air is not absorbed by the oil. Many oils, particular-ly polyolester oils, are extremely hygroscopic. It is therefore recommended only to buy the oil in con-tainers whose size correspond to the amount to be used.

In case all of the oil is not used, make sure that the rest of the oil is sealed in the original container and stored in a warm, dry place. It is recommend-ed to charge nitrogen to keep the water content below 50 ppm.

Ideally, oil containers should be equipped with a barrel tap to ensure an effective, airtight seal.

6. Technical Data

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Oil Changing IntervalsA list of the recommended oil changing intervals is included in the instruction manuals of the com-pressors. This list is for guidance only. The actual oil changing intervals are often determined by a number of operating parameters in the plant.

It is strongly recommended to monitor the quality of the oil by performing oil analyses on a regular basis. This will also give an indication of the con-dition of the plant. This service can be supplied by

YORK Refrigeration or the oil supplier.

Oil recommendation diagram symbols:

▲ In case of a new plant. Very suitable.

✩ 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)

L Zone in which both oils are useable

M Calculation must be performed using COMP1

6. Technical Data

186/288 0178-931 - ENGRev. 27.10.03


Data Sheet for Listed Sabroe Oils

Typical data for lubricating oils for Sabroe compressors

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

Sabroe Viscosity Viscosity Spec. Flash p. Pour p. Anilin Acid no.

code cSt40°C

cSt100°C

Index grav. at15°C

COC°C

°C °Cpoint

mgKOH/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

E3Due to the great difference between polyolester-based lubricants from various suppliers, it is not pos-sible to present any typical data for these oils. When using another oil brand than the one recommend-ed by YORK Refrigeration, please contact the oil supplier to select the correct oil type.

E5

E9

E11

6. Technical Data

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List of Part Numbers for Available Sabroe Oils

1) 18.9 litre pail (5 US gallons)

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

Oil brand Oil code no. Part no.

20 litre pail 208 litre barrel

Mobil Gargoyle Arctic 300 M1 (M68) 1231-264 1231-296

Sabroe Oil A100 A3 (A100) 1231-263 1231-262

Sabroe Oil AP68 AP1 (AP68) 1231-257 1231-260

Sabroe Oil PAO68 PAO3 (P68) 1231-256 1231-259

Mobil Gargoyle Arctic SHC 228 PAO5 (P100) 1231-282 1231-283


Mobil EAL Arctic 68 E3 (E68) 1231-272 1231-273


Mobil EAL Arctic 220 E9 (E220) 1231-279

Sabroe H oil E11 (E370) 3914 1512 954 1) 9415 0008 000

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)

6. Technical Data

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R717one-stagereciprocatingcompressor

Note: YORK Refrigeration recommends that the use of M oil is restricted to moderately loaded compressors and that the oil quality is monitored carefully via regular oil analyses.

j: Very suitable in case of a new plant.

✩: In case you wish to change from mineral oil.


Code no Area no 1

PAO 3 s

AP 1 ✩/▲

M1 See note

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6. Technical Data

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R717two-stagereciprocatingcompressors

-30

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Code no Area no 1

PAO 3 s

AP 1 ✩/▲

M1 See note

Note: YORK Refrigeration recommends that the use of M oil is restricted to moderately loaded compressors and that the oil quality is monitored carefully via regular oil analyses.


✩: In case you wish to change from mineral oil.

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6. Technical Data

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0

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TCR717HPO and HPCreciprocatingcompressors

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


Code no Area no 1

PAO 5 ▲


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6. Technical Data

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List of Major Oil Companies

The oil from the companies listed below are not tested by YORK Refrigeration and are therefore not ap-proved by YORK Refrigeration. The following list includes the information provided by the oil companies. The oil companies are responsible for the information concerning the durability and suitability of their oils for specific purposes. Oils tested and approved by YORK Refrigeration are included in the "List of Part

Numbers for Available Sabroe Oils".

Oil Company Oil Types

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 • •

6. Technical Data

192/288 0178-931 - ENGRev. 27.10.03


Selecting Lubricating Oil for SABROE Reciprocating Compressors

Refrigerant: HFC/HCFC

In a period from 1990 to 1995 YORK Refrigeration experienced a rising number of problems with the use of mineral oils, especially in R717 plants. The problems can be divided into two groups:

e. The oil changes viscosity within a few operat-ing hours.

f. The oil dissolves becomes very black).

The problems have been observed in connection with several different types of mineral oil and often occur within only a few operating hours. The con-sequences have been severe for both compres-sors and plants.

On the basis of the thorough investigation subse-quently carried out by YORK Refrigeration, it was decided to introduce a series of synthetic oils complying with the requirements of modern refrig-eration plants.

Mineral oils can, however, still be used in refriger-ation plants, provided the lubricating quality is carefully monitored. For modern high-capacity re-frigeration plants where a long service life for both lubricant and moving parts is expected, YORK Refrigeration recommends the use of synthetic oils.

Areas of application and specifications for the syn-thetic oils mentioned are described in the follow-ing pages. Supervisors and/or users of plants are at liberty to choose between YORK Refrigera-tion's own oil brands and alternative oil brands, provided they comply with the specifications re-quired.

GeneralThis recommendation will only deal with the lubri-cation of the compressor. The performance of the

lubricant in the plant (receiver, evaporator, etc.) must, however, also be considered.

Lubricating oils with relatively high viscosity must be used to ensure a satisfactory lubrication of re-frigeration compressors.

To achieve the best lubrication, the oil must:

• possess the correct viscosity under all oper-ating conditions.

• possess acceptable viscosity at start-up.

• possess sufficient oxidation stability (the oil must be free of moisture when charged to the system).

• possess sufficient chemical stability when used together with HFC/HCFC.

Moreover, the extent to which different refriger-ants dissolve in the oil must be determined so that the oil return system, etc. can be designed to per-form at its optimum.

Stratification

Note that the oil in some plants is layered in refrig-erant receivers and evaporators under certain op-erating conditions and at certain oil concentra-tions. This applies in particular to HFC/HCFC plants.

The oil recommendation diagrams for SABROE compressors with HFC and HCFC refrigerants in-dicate the limits for Sabroe oils where stratification occurs. The oil concentrations stated in these dia-grams must not be exceeded. This makes it pos-sible to adjust the oil rectification/return systems to the oil consumption of the compressor so that the maximum concentration is not exceeded. For area A in the diagrams, the oil concentration in the liquid phase must not exceed 2%. For the other

6. Technical Data

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areas, the oil concentration must not exceed 5%. For area B, please contact YORK Refrigeration.

Plants with Several Different Compressor Types/Makes

In plants where several different compressor types/makes are connected, it is strongly recom-mended to use the same type of oil in all the com-pressors. This is very important where automatic oil return systems are used.

If you consider changing the type of oil, please read the section Oil Changing on SABROE Com-pressors carefully.

Selecting Lubricating Oil

The correct oil is selected by means of the follow-ing diagrams. When the general conditions con-cerning the lubrication of the compressor have been considered, the specific conditions of the plant must be taken into account.

Use the oil recommendation diagrams to select the correct oil code number.

The oil code number consists of letters indicating the oil type and viscosity number..

In the oil recommendation diagrams it is possible to find the code number best suited for the operat-ing conditions in question. With the code number it is possible to select the correct Sabroe oil for the application in question.

Oil Types and Oil CompaniesDue to the large number of oil companies offering oil for refrigeration plants, it has not been possible for YORK Refrigeration to test all the different oil brands on the global market.

It is our experience that certain oil brands can change character during use and thus no longer correspond to the specifications stated by the oil companies on delivery. We have thus experi-enced changes in specifications as well as formu-la and performance without having received infor-mation on this beforehand from the oil company. This makes it extremely difficult for YORK Refrigeration to give a general approval of other oil brands.

In co-operation with a large, respected oil compa-ny YORK Refrigeration has therefore developed a series of three different oils covering most de-mands. Furthermore, a list of the oils which can be supplied through YORK Refrigeration has been prepared. Data for these oils is included in the ta-ble Data for Sabroe Oils. We recommend that you use these oils, which can be delivered in 20 litre pails or 208 litre drums. When ordering, use the part no. stated in List of Part Numbers for Availa-ble Sabroe Oils.

It is of course possible to use similar oils from oth-er oil companies. If this is the case, use the table Data for Sabroe Oils.

Please note that YORK Refrigeration has not test-ed other oils than our own brand. Thus we cannot guarantee the quality, stability or suitability of oth-er oils. The respective oil companies are thus re-sponsible for the quality and suitability of the oil delivered, and if there are any problems with these oils in the compressor or the refrigeration plant, contact the oil supplier directly.

When selecting oils from other oil companies, special attention should be paid to the suitability of

Table 6.22

Code design

Oil types

M Mineral oil

A Synthetic oil based on Alkylbenzene

PAO Synthetic oil based on Polyalphaolefin

AP Mixture of A and PAO oils

E Synthetic ester-based lubricants

6. Technical Data

194/288 0178-931 - ENGRev. 27.10.03


the oil in the compressor and the refrigeration plant as a whole.

Please note in particular the following points:

• Oil type

• Refrigerant type

• Compressor type

• Miscibility between refrigerant and oil

• Operating data for the compressor

– Discharge gas temperature

– Oil temperature

– Normal temperature in the crank case is 50-60°C

– Max. permitted oil temperature = set point for alarm.

– Min. permitted oil temperature = set point for alarm - if there is any

• The viscosity of the oil in the compressor during operation and under the influence of:

– Type of refrigerant and solubility of re-frigerant in the oil

– Operating temperatures

– Vapour pressure in the oil reservoir

– Suction pressure and oil temperature in the crankcase

– Compatibility with neoprene O-rings: The aniline point indicates how the O-ring material reacts to the oil.

At an aniline point less than approx. 100°C the material has a tendency to swell, and at an aniline point higher than approx. 120°C it has a tendency to shrink.

Thus it cannot be recommended to change the oil type from M to PAO without changing the O-rings at the same time as a leak may otherwise easily occur in the compressor or

the plant. YORK Refrigeration recommends therefore the use of the Sabroe AP68 oil since this type of oil in this case reduces considerably the risk of leaks.

YORK Refrigeration can supply a list of op-erating data on request.

• Please note the viscosity limits during oper-ation:

• Optimum viscosity limits = 20 to 50 cSt

• Max. permitted viscosity = 100 cSt

• Min. permitted viscosity = 10 cSt

• Max. permitted viscosity during start-up of the compressor = 500 cSt

• Max. refrigerant concentration in the oil during operation: 25% - also in case the viscosity requirements have been met.

Use of Mineral Oil

As described in the introduction, mineral oil in par-ticular causes serious problems especially in R717 plants.

When using mineral oil, it is important to monitor the plant closely. The condition/colour of the oil must therefore be checked on a weekly basis and for each 1,000 to 2,000 operating hours oil sam-ples must be taken for further analysis.

YORK Refrigeration recommends therefore only to use M oil under moderate operating conditions - see the following oil recommendation diagrams.YORK Refrigeration is aware that several custom-ers have used mineral oils for many years without any problems. The customers who wish to contin-ue using mineral oil in existing as well as new compressors can do so, provided that the com-pressor type and the operating conditions are sim-ilar to the existing ones.

6. Technical Data

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YORK Refrigeration has thus decided to market one brand of mineral oil which has been tested and found suitable for most of the general refriger-ation purposes.

In case another brand of mineral oil is used, follow the specifications on the data pages in this recom-mendation as a guideline.

Mineral oil can be used in refrigeration plants, pro-vided the lubricating quality is carefully monitored. YORK Refrigeration recommends, however, that you use synthetic oils for modern high-capacity plants where a long service life for both lubricant and moving parts is expected.

The advantage of using synthetic lubricating oils is a much lower oil consumption and longer oil changing intervals. Improved viscosity at low tem-peratures facilitates furthermore drainage at the cold parts of the plants.

How to Use the Diagrams in the Oil Recommendation:To find the correct code number, select refrigerant and compressor type in the oil recommendation diagram. Then insert the estimated operating con-ditions in the diagram.

Example (reciprocating compressors):

Note: Sometimes plants operate under different conditions, e.g. different evaporating tempera-tures due to variations in the plant, or different condensing temperatures as a result of seasonal changes. By inserting TC and TE in the oil recom-mendation diagram, the recommended area is found. In this case it is oil area 1. If TC should change, e.g. from -3°C to +7°C, use oil area 2. As +7°C is within the marked area, oil area 1 can, however, also be used at this TE.

Fig. 6.65

By using the table which is situated next to the oil recommendation diagram, select the recommend-ed code number and thus the recommended oil. In the example above an oil with code number E5 can be used.

Table 6.23

Oil Change on Sabroe CompressorsNever change to another oil type without contact-ing the oil supplier. Nor is it advisable to recharge a compressor with another oil type than the one already used for the plant or compressor in ques-tion.

Mixing different oils may result in operating prob-lems in the refrigeration plant or damage to the compressor. Incompatibility between different oil types may reduce the lubricating properties con-siderably and may cause oil residues to form in

Refrigerant R134a

Condensing temperature: TC +35 °C

Evaporating temperature: TE -3°C

Code no. Area no.

1 2

E5 ▲

E9 ▲


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30

20

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60 50 40 30 20 10 0 10 20 30

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6. Technical Data

196/288 0178-931 - ENGRev. 27.10.03


the compressor, oil separator or plant. Oil resi-dues may block filters and damage the moving parts of the compressor.

Changing the oil type or brand should only be done following a thorough procedure involving drainage and evacuation of the refrigeration plant. Information on a suitable procedure can be ob-tained from YORK Refrigeration as well as a number of oil companies.

It is extremely important that the new unused oil is taken directly from its original container and that both the brand and the type correspond to the specifications of the plant.

Make sure that the original oil container is sealed properly during storage so that moisture from the air is not absorbed by the oil. Many oils, particular-ly polyester oils, are extremely hygroscopic. It is therefore recommended only to buy the oil in con-tainers whose size correspond to the amount to be used.

In case all of the oil is not used, make sure that the rest of the oil is sealed in the original container and stored in a warm, dry place. It is recommend-ed to charge nitrogen to keep the water content below 50 ppm.

Ideally, oil containers should be equipped with a barrel tap to ensure an effective, airtight seal.

6. Technical Data

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Oil Changing IntervalsA list of the recommended oil changing intervals is included in the instruction manuals of the com-pressors. This list is for guidance only. The actual oil changing intervals are often determined by a number of operating parameters in the plant.

It is strongly recommended to monitor the quality of the oil by performing oil analyses on a regular basis. This will also give an indication of the con-dition of the plant. This service can be supplied by

YORK Refrigeration or the oil supplier..

Oil recommendation diagram symbols:

▲ In case of a new plant. Very suitable.

✩ 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)

L Zone in which both oils are useable

M Calculation must be performed using COMP1

6. Technical Data

198/288 0178-931 - ENGRev. 27.10.03


Data Sheet for Listed Sabroe Oils

Typical data for lubricating oils for Sabroe compressors

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

Sabroe Viscosity Viscosity Spec. Flash p. Pour p. Anilin Acid no.

code cSt40°C

cSt100°C

Index grav. at15°C

COC°C

°C °Cpoint

mgKOH/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

E3Due to the great difference between polyolester-based lubricants from various suppliers, it is not pos-sible to present any typical data for these oils. When using another oil brand than the one recommend-ed by YORK Refrigeration, please contact the oil supplier to select the correct oil type.

E5

E9

E11

6. Technical Data

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List of Part Numbers for Available Sabroe Oils

1) 18.9 litre pail (5 US gallons)

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

Oil brand Oil code no. Part no.

20 litre pail 208 litre barrel

Mobil Gargoyle Arctic 300 M1 (M68) 1231-264 1231-296

Sabroe Oil A100 A3 (A100) 1231-263 1231-262

Sabroe Oil AP68 AP1 (AP68) 1231-257 1231-260

Sabroe Oil PAO68 PAO3 (P68) 1231-256 1231-259





Mobil EAL Arctic 220 E9 (E220) 1231-279

Sabroe H oil E11 (E370) 3914 1512 954 1) 9415 0008 000

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)

6. Technical Data

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Code no Area no 1

A 3 ▲

▲: Very suitable in case of a new plant. a: Max oil concentration in liquid phase at TE: 2% W.c: Min suction temperature -50°C. At TE<-50°C superheating must be introduced.

ContactYORK Refrigeration

6. Technical Data

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▲: Very suitable in case of a new plant. a: Max oil concentration in liquid phase at TE: 2% W.c: Min suction temperature -50°C. At TE<-50°C superheating must be introduced.

6. Technical Data

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-30

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Code no Area no

1 2

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▲: Very suitable in case of a new plant. L: Zone in which both oils are applicable.:

6. Technical Data

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Code no Area no

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▲: Very suitable in case of a new plant.

6. Technical Data

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Code no Area no

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E 3 ▲

▲: : Very suitable in case of a new plant.

b: Max oil concentration in liquid phase: contact YORK Refrigerationc: Min suction temperature -50°C. At TE<-50°C superheating must be introduced.

6. Technical Data

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6. Technical Data

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6. Technical Data

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6. Technical Data

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6. Technical Data

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6. Technical Data

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6. Technical Data

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List of Major Oil Companies

The oil from the companies listed below are not tested by YORK Refrigeration and are therefore not ap-proved by YORK Refrigeration. The following list includes the information provided by the oil companies. The oil companies are responsible for the information concerning the durability and suitability of their oils for specific purposes. Oils tested and approved by YORK Refrigeration are included in the "List of Part

Numbers for Available Sabroe Oils".

Oil Company Oil Types

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 • •

6. Technical Data

212/288 0178-931 - ENGRev. 27.10.03


7. Installation Instructions

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7. Installation InstructionsThe purpose of this document is to describe:

• the dangers which may occur when the in-structions and safety precautions pertaining to the installation phase are not followed,

• how to install the equipment in a safe and ef-fective way.

This document is intended primarily for the instal-lation supervisors, installation technicians and electricians. It can also be used in sales activities to inform future customers of the requirements made in connection with the installation of a com-pressor unit.




WDanger!

Risk of injury to personnel and damage to equip-ment! Always read the safety precautions belong-ing to this equipment before starting the installa-tion process. Failure to comply with safety precau-tions may cause death or injury to personnel. It may also cause damage to or destruction of the equipment.

Safety PrecautionsRead Section 3, Safety Precautions, carefully be-fore commencing the installation. If in doubt, please contact YORK Refrigeration.

The safety precautions and instructions pertaining to the individual sections of this document must also be read and followed.

Installation DataThe physical data of the compressor are included in Section 5, Physical and Connection Data. See also Section 6, Technical Data - Noise from com-pressors and units, Laying the foundation.

Installation DrawingsBefore commencing the installation, make sure that drawings showing how to connect the unit are available.

Personnel RequirementsThe personnel which carry out the installation must be well-trained within the area of refrigera-tion technique, possess knowledge of refrigera-tion systems and have experience with pipe as well as wiring installations. Where authorisation is required, the electrician must possess an ap-proved authorisation.

The compressors must only be connected by an authorised refrigeration company.


214/288 0178-931 - ENGRev. 27.10.03


Preparing the InstallationThis section describes the preparations which must be carried out before commencing the instal-lation.

Tools and AccessoriesThe list below shows the tools, accessories and materials which are necessary in order to carry out the installation correctly.

Ordinary Hand ToolsTools for installing pipes, including welding tool

Tools for wiring

Special tools

Small tool set for compressor. See Document no. 0662-061-EN.

Accessories

Lifting eyeShaklesHand-operated oil charging pump, spare part no. 3141-026, see description in Section 6, Technical Data - Charging the compressor with oil.

Safety Equipment

WDanger!


When installing the equipment, use the following safety equipment which must be in good condi-tion:

– Safety shoes

– Gloves

– Eye protectors

– Fire-fighting appliances

– Salt water solution for eye rinsing

– Oxygen equipment

Local RegulationsThe installation must be carried out in accordance with the prevailing rules of the installation site and the regulations of the area in question. When in doubt, contact the local authorities.

Space RequirementsDimensions for all compressor types and units are included in the binder Dimensions and Piping Di-agrams. Note in particular the minimum distanc-es, which must ensure that the compressor can be serviced under all kinds of conditions, e.g. re-placement of crank shaft or filter insert. The piping must be laid in such a way that the access to the top covers is not obstructed.

Preparing the Mounting SiteBefore installing the unit, the following must be carried out:

1. The foundation for the unit must be ready. Check that the foundation is level and has the necessary strength.

2. Check that the access roads are wide enough for the unit to pass through - see the dimension sketches.

3. Block the mounting site.The mounting site must be blocked to pre-vent unauthorised personnel from being in-jured or causing damage.

4. The mounting site must be cleared.


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Lifting Accessories and EquipmentSee Section 14, Transport Instructions.

Preparing LiftsSee Section 14, Transport Instructions.

Lifting and Loading InstructionsSee Section 14, Transport Instructions.

Unpacking and InspectionOn receipt the unit is wrapped in PE plastic film. After unpacking the unit, check for transport dam-age. Check also whether the delivered goods cor-respond to the specification. Check in particular that the control system and valves fitted on the outside of the unit are not damaged. It must also be checked whether the following parts are includ-ed:

– Intermediate piece for coupling, inner and outer screen and perhaps loose coupling hub for motor.

– Cooling water hoses for cooling of top and side covers.

– Vibration dampers as well as drawing in-dicating the position of the dampers.

Disposal of Materials which are not ReusableMaterials from the packing of the unit which can-not be reused must be disposed of according to local regulations.

Moving the Equipment to the Mounting Site after Unloading and UnpackingAfter unloading and unpacking the unit, it must only be lifted in the lifting eyes welded on the frame. If the unit is moved with e.g. a forklift truck, it must be placed on a pallet intended for the pur-pose. Secure the unit so that it does not tip over when starting, turning and braking the forklift truck. Do not lift directly under the unit.


216/288 0178-931 - ENGRev. 27.10.03


Installation Instructions

WDanger!


To ensure the compressor and the motor a long life and a noise and vibration free operation, the compressor unit and coupling need to be aligned with care.

Misalignment of the compressor unit or coupling may result in stresses and vibrations which can be transmitted to the compressor bearings, thus causing major damages.

Vibrations may be caused by the following:

• Distortion between compressor unit and foundation.

• Distortion between compressor and base frame.

• Distortion between motor and base frame.

• Strains from pipe connections between compressor and plant.

• Incorrect alignment of coupling between compressor and motor.

• Compressor or motor shafts are untrue.

• Coupling is untrue.

• Imperfect balancing of coupling.

• Imbalance in compressor and motor.

The supervisor who sets up the unit is responsible for the points up to and including alignment of the coupling. The other points must be checked by the compressor and motor manufacturer before deliv-ery. The following sections will deal with the indi-vidual points concerning the supervisor.

1. Alignment of Unit against FoundationWhen the unit has been moved to the site where it is to be installed, an alignment must be carried out before the piping can be laid.

When mounting the unit on the foundation or the machine floor, it must rest evenly on all its sup-porting surfaces.

The unit can be mounted in the following ways:

• on vibration dampers.

• directly on the foundation with foundation bolts.

With both methods the unit must be set up before the pipes are connected to the plant.

Depending on whether the unit is to be used on land or on a ship, vibration dampers are supplied as shown in the drawing Fig. 7.1.

The purpose of the vibration dampers is to damp-en the vibrations from the unit to the foundation. Moreover, the marine vibration dampers must dampen the vibrations from the foundation to the compressor unit and at the same time secure the unit to the foundation.

It is very important that the vibration dampers are placed correctly as illustrated in the drawing for-warded to the customer or the dealer. This draw-ing applies only to the unit in question.


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Mounting on Vibration DampersFig. 7.1

The vibration dampers supplied are marked with a code, e.g. LM6-60. LM6 indicates the size where-as 60 indicates the rubber hardness and is thus an expression of bearing and damping capacity.

When using vibration dampers, the foundation is assumed to have the necessary bearing strength and to be level enough to enable adjustment of the vibration dampers to be made within the ad-justing measurements stated on the drawing sub-mitted.

In order for the individual vibration damper to dampen properly, a sufficient load must be im-posed: Measure A1 and H (unloaded position) and A2 (loaded position) as shown in drawing Fig. 7.1.

The flexion of a damper is adjusted by increasing or decreasing the load in relation to the other sup-ports. The foot can be raised by lowering the ad-justing rod or inserting more disks between damp-er and foot (marine design), thereby increasing the load and hence also the flexion.

Once the installation has cooled down, check dur-ing operation that the flexion of the dampers is still correct!

T0177040_0

A2

A1

2

H

A1

Hmax

A2

1

Industrial type

1

Marine type

2

Flexion

A1A2

min 1.0

max 2.0

min 3.0max 5.0

Height adjustment

Hmax= H+12 with disks supplied as shown


218/288 0178-931 - ENGRev. 27.10.03


Mounting Directly on FoundationWhen mounting the unit directly on a concrete foundation, the foundation must be cast in accord-ance with the foundation drawing forwarded.

When the foundation has been cast - with the holes shown for the foundation bolts - and has cured, place the unit in a position allowing it to rest on beams levelled at a suitable height so that the foundation plates are recessed slightly into the foundation.

Check that the foundation plates are right next to the base frame. This can be achieved by binding them to the resting surfaces of the base frame by means of steel flex.

The concrete which is cast down around the foun-dation bolts should only have minimal water con-tent to allow it to be rammed well down around the bolts. Low water content does not cause the hard-ening concrete to shrink.

10-14 days should pass before removing the beams and tightening the nuts for the foundation

bolts. 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 before tightening.

2. Alignment of Compressor on Base FrameCheck that the entire footing of the compressor makes full contact against the faces of the base frame.

Perform this check with the bolts loosened. If slip occurs at one or more resting surfaces, shim up before tightening. If unaligned, there is a risk of stresses occurring in the compressor frame, which will damage the bearings.

3. Alignment of Motor on Base FrameCheck the contact faces of the motor against the base frame in the same way as for the compres-sor.


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Fitting and alignment of coupling type AMR

4. Installation and alignmentIn principle, alignment involves manoeuvring the motor to make the shaft form an extension of the crankshaft.

Important!

Before performing any work on the coupling, make sure that the compressor motor cannot start inadvertently.

Fig. 7.2

Table 7.1

* See final installation

CompressorCoupling

size

Distance mm Torque Nm

CNominal*

F A B D

SMC 104-106-108

312 S 102 25 147 55 44

SMC 112-116 350 S 113 27 147 128 44

C

Z

X

F

a

1

2

B A

D


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Preliminary installation

Note: Never tighten the cone screws "D" unless there is a shaft inside the bore. Otherwise it might damage the cone system.

• Degrease the compressor shaft and hub bore surfaces. Any lubricant here will re-duce the transferred torque.

• Place the hub at the compressor side, ob-serving the measurement "F".

• Tighten the screws "D" crosswise in two or three steps of torque. Assembly is complet-ed when no screw can be tightened any fur-ther (one by one) with tightening torque “D”.

• Place the hub at the motor side. Tighten the bolts "A" and the pointed screw loosely.

• Mount the retaining plate from the coupling screen onto the compressor and insert a support ring for the coupling screen over the motor flange.

• Assemble the intermediate piece and the la-mella segments with the 8 screws, applying the prescribed torque. Remember the shaped washers facing the lamellas.

• Insert the coupling intermediate piece. Cre-ate space between the flanges either by shifting the entire motor or just the motor coupling flange.

The intermediate piece should only be secured to the compressor flange. Do not insert the last four bolts in the motor flange until the coupling has been aligned.

As the compressor shaft rotates during the alignment procedure, the motor must turn with it, as the bolts in the intermediate piece engage in the free holes in the motor cou-pling flange.

• Line up the motor so that the free holes in the motor feet are right above the threaded holes in the base frame.

• Shift the motor coupling flange to make up distance "C" in table. See Table 7.1.

• Tighten the two bolts and the pointed screw in the hub.

• Tighten the measuring pin on the coupling flange of the compressor, as shown in the drawing.


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Alignment

Check that the motor with loose bolts is positioned with all four feet on the base frame. Insert any liner plates needed where there is an air gap beneath the feet. Tighten the bolts loosely.

Achieving parallel shafts in horizontal plane

• Turn the coupling so that the alignment gauge is in upper position. See Fig. 7.2.

• Guide the measuring pin (pos. 2) towards the coupling flange, using a 1.0 mm feeler gauge, and fix the pin. Remove the feeler gauge.

• Rotate the coupling 180° and measure the change in distance from the measuring pin to the flange, using feeler gauges. This change is called "x".

• Measure the distance “b” between the motor feet as shown in Fig. 7.3. Measure the dis-tance “a” from the centre of the pin pos. 2 to the centre of the motor as illustrated in Fig. 7.2

• Insert shims of thickness "y" either under both front feet or both rear feet, thereby tilt-ing the motor in the direction required.

• Shim thickness "y" is calculated by using the following formula (see also Fig. 7.3):

Fig. 7.3

• After tightening the motor bolts, repeat the measurement and compare the result with the values in the table below:

Table 7.2

y = Xb

2 x a•

y

b

Compressor Coupling size

Maximum variation (mm) measured with feeler gauge at a 180° turning of the coupling

Pos 1 Pos 2

max.

mm

Horizontal

max. mm

Vertical

min./max. mm

SMC 104-106-108 312 S 0.2 0.1/0.3 0.2

SMC 112-116 350 S 0.2 0.1/0.3 0.2


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Achieving correct centre height

• Turn the coupling so that the alignment gauge faces vertically down.

• Guide the measuring pin (pos. 1) towards the coupling flange, using a 1.0 mm feeler gauge, and fix the pin. Remove the feeler gauge.

• Rotate the coupling 180° and measure the increase in distance "z" from one millimetre using feeler gauges.

• Then lift the motor by placing shims of a thickness equal to half value of "z" under all four feet.

• After securing the motor, repeat the meas-urement and compare the result with the ta-ble values in pos. 1 vertical. Remember that the centreline of the motor shaft must be at least 0.05 mm higher than the centreline of the compressor, corresponding to a mini-mum of 0.1 mm distance less at the top po-sition of the alignment gauge.

Achieving parallel shafts in vertical plane• The motor is now positioned at its correct

height. What remains is to push and turn the motor at the level on which it is already lined up.

• Turn the coupling so that the alignment gauge faces out to one side horizontally.

• Guide both measuring pins towards the cou-pling with a 1.0 mm feeler gauge in be-tween.

• Turn the coupling 180° and by using feeler gauges measure deviations from one milli-metre at both pins.

• Move and turn the motor and repeat this measurement, align the motor in accord-ance with pos. 1 horizontal and pos. 2 in the table. Remember that the motor must be firmly secured during any measurements.

Final installation• Tighten the foundation bolts on the motor

(see torque table).

• Fit four bolts into the motor coupling flange so that thin shims are placed between the flange and the lamellae, with the rounded side facing lamella.

• Tighten the bolts to torque specified in the table.

• Readjust the flange distance "C" so that the lamellae are aligned, by moving the motor flange on the shaft and fastening the motor flange.

• Check the alignment of the coupling in hori-zontal and vertical planes for pos. 1 and pos. 2.

• Dismantle the measuring pin and tighten the screw to the prescribed torque.

• Fit the coupling guard.

• Once normal operating temperature has been achieved, double-check the coupling alignment.


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Preliminary Installation

• Check tightening of coupling flange on com-pressor.

• Tighten 8 coupling bolts securing lamellar segments to intermediate piece to pre-scribed moment stated in table. It is worth-while doing this before placing the interme-diate piece in position.

• Mount retaining plate from coupling screen onto compressor and insert support ring for coupling screen over motor flange.

• Insert coupling intermediate piece. Create space between flanges either by shifting en-tire motor or just motor coupling flange. The intermediate piece should only be secured to the compressor flange. Do not insert the last four bolts in the motor flange until the coupling has been aligned. As the compressor shaft rotates during the alignment procedure, the motor must turn with it, as the bolts in the intermediate piece engage in the free holes in the motor cou-pling flange.

• Line up motor so that free holes in motor feet are right over threaded holes in base frame.

• Shift motor coupling flange to achieve dis-tance "C" in table, Fig. 7.2.

• Tighten two bolts in coupling hub. On CMO-HPO units, the motor flange must be correctly positioned before putting the motor into place.

• Tighten alignment gauge on coupling flange of compressor as shown in drawing.

Alignment Check that the motor with loose bolts stands with all four feet on the base frame. If necessary, insert any liner plates where there is an air gap beneath the feet. Tighten the bolts slightly.

Achieving Parallel Shafts in Horizontal Plane• Turn coupling so that alignment gauge is in

upper position, Fig. 7.2

• Guide measuring pin (Pos. 2) towards cou-pling flange by means of a 1.0 mm feeler gauge and fix pin. Remove feeler gauge.

• Rotate coupling 180° and measure change in distance from measuring pin to flange by means of feeler gauges. This change is called "x".

• Measure the distance b between the feet of the motor as shown in Fig. 7.4. Measure the distance a from the centre of the pin pos. 2 to the centre line of the motor as illustrated in Fig. 7.2

• Insert shims of thickness "y" either under both front feet or both rear feet, thereby tilt-ing motor in direction required. Shim thick-ness "y" is calculated using the following for-mula (see Fig. 7.4):

y = Xb

2 x a•


224/288 0178-931 - ENGRev. 27.10.03


Fig. 7.4

• After tightening motor bolts, repeat meas-urement and compare result with values in table under Pos. 2, Fig. 7.2

Achieving Correct Centre Height • Turn coupling so that alignment gauge fac-

es vertically downwards.

• Guide measuring pin (pos. 1) towards cou-pling flange by means of a 1.0 mm feeler gauge and fix pin. Remove feeler gauge.

• Rotate coupling 180° and measure increase in distance "z" from one millimetre by means of feeler gauges.

• Then lift motor by placing shims of thickness equal to half value of "z" under all four feet.

• After securing motor, repeat measurement and compare result with table values in pos. 1 vertical, Fig. 7.2

1. Remember that the centre line of the motor shaft must be at least 0.05 mm higher than the centre line of the compressor, corre-sponding to a minimum of 0.1 mm distance less at the top position of the alignment gauge.

Achieving Parallel Shafts in Vertical Plane The motor is now positioned at its correct height. What now remains is to push and turn the motor at the level on which it is already lined up.

• Turn coupling so that alignment gauge fac-es out to one side horizontally.

• Guide both measuring pins towards cou-pling with a 1.0 mm feeler gauge in be-tween.

• Turn coupling 180° and measure deviations from one millimetre at both pins by means of feeler gauges.

• By moving and turning motor and by repeating this measurement, align motor in accordance with pos. 1 horizontal and pos. 2, Fig. 7.2.

2. Remember that the motor must be firmly se-cured when measuring.

Final Installation • Tighten foundation bolts on motor (see table

showing the torque for screws and bolts).

• Fit four bolts into motor coupling flange so that thin shims are placed between flange and lamellae with rounded side facing la-mella. There are no thin shims on couplings for CMO and HPO.

• Tighten bolts to torque specified in table.

• Readjust flange distance "C" so that lamel-lae are aligned by moving motor flange on shaft and securing motor flange.

• Check alignment of coupling in horizontal and vertical planes for pos. 1 and pos. 2, Fig. 7.2

• Dismantle alignment gauge and tighten screw to prescribed torque.

• Fit coupling guard.

• Once normal operating temperature has been achieved, double-check coupling alignment.

b

y


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5. Piping Connections

In order to prevent stress from being transmitted from piping connections between unit and plant, pipes must be laid so as not to generate compres-sive stresses or tensile strains in the event of ex-pansions or contractions due to temperature changes. Steel pipes expand approx. 1 mm per metre per 100°C.

We recommend that piping be laid as shown in ex-ample 2 of the sketch, Fig. 7.5. Example 1 demon-strates too rigid pipe laying.

Fig. 7.5

Final alignment of compressor and motor can be performed once all piping has been connected to the unit.

Section 5, Physical and Connection Data includes data concerning dimensions and descriptions of piping connections. The piping connections which must be made are outlined below:

5.1 Refrigerant Connection to Compres-sor

The connecting pipe is to be welded onto a connecting branch on a stop valve. In order to protect the stop valve when welding, re-move the insides of the valve. Do not put the insides back into the valve until the weld has cooled off - see the instructions from the valve manufacturer in Section 21, Appendi-ces.

The welding must be carried out according to the specifications and standards applying to the plant in question.

5.2 Refrigerant Connection to Oil Cooler (OOKH og OSSI)

The connection to the oil cooler is indicated on the compressor with V for water supply and Q for return. See section 5, Physical and Connection Data.

5.3 Connection to Water-Cooled Top and Side Covers

The water cooling hoses are delivered sep-arately and connected to top and side cov-ers according to enclosed mounting instruc-tions. Connect water supply to the inlet of the water system and establish return to drain or the like, e.g. cooling tower for reuse of the water. Connection dimensions are in-cluded in Section 5, Physical and Connec-tion Data. The system is described in detail in Section 4, Technical Description.

T0177057_0

1

> 1.5 m

2


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6. Connecting Electricity Supply

Data for the electrical components of the unit and their supply is included in Section 5, Physical and Connection Data.

WDanger!


Before connecting, make sure that

– there is no power on the cables which are to be connected,

– the power cannot be connected acciden-tally. This can be done by locking the switches or placing a sign indicating that the connection in question must not be connected.

After being connected, all electrical con-nections should be checked by an elec-trician.

6.1 Connecting the Motor

Installation and connection instructions for the chosen motor type is order specific and delivered together with the unit by YORK Refrigeration. These data sheets include descriptions of how to connect the motor. Where another motor type is used, data sheets containing this information must be obtained.

Motor data appear from the name plate on the mo-tor.

Important!Always follow the instructions from the manufac-turer concerning connection.

Remember! Check that the direction of rota-tion is correct - see Section 6, Technical Data - Direction of Rotation of Electric motor.

6.2 Connecting UNISAB

Two manuals are delivered together with UNISAB II: - Starting-up Manual which is placed inside the UNISAB II cabinet on delivery.- Instruction Manual delivered together with other documentation.

Installation

UNISAB II is placed on a bracket on the unit, see dimension sketches in Dimensions and Piping Di-agrams. To gain access to the terminals, open the cabinet by loosening the screws which hold the operating panel. Lift up the panel as shown in Fig. 7.6 and take out the Starting-up Manual. The Starting-up Manual includes key diagrams for UNISAB II. These are included under the section Supplementary Instructions. In this Installation Manual references are made to these key dia-grams.

Fig. 7.6 Opening the Cabinet

Connecting Supply Voltage

The supply voltage 230 VAC, 115 VAC is led through the screwed cable entry and connected to


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the terminals marked L (phase) and N (zero) - see page 010 in diagram 2347-003. Check that the jumper for 220/115 VAC corresponds to the sup-ply voltage used.

As standard UNISAB II is prepared to be supplied by 230/115 VAC, but UNISAB II can also be sup-plied by 24 VAC. If this is the case, another trans-former must be used. Check that the correct trans-former 24/24 VAC (YORK Refrigeration product no. 1556.043) has been fitted. Check, moreover, that the jumper for 220/115 VAC has been removed and that components, e.g. sole-noid valves, are designed for 24 VAC.

Connections to MotorThe control supply of the motor must be connect-ed across terminals 118 and 119 on UNISAB II to which the control system gives start signal to the compressor - see page 021 in the diagram 2347-003.

Connect a potential free digital feedback signal from the motor starter to terminals 41 and 42. This signal informs the control system that the motor is operating. See page 014 in diagram 2347-003.

It is possible to connect a signal to terminals 35 and 36 from the motor starter via a current trans-

former XXX/1 A AC, which reads the motor cur-rent taken up. Terminals 35 and 36 must be supplied with max. 1A - see page 013 in diagram 2347-003.

Other Connections

UNISAB II's alarm output is made in such a way that under normal conditions there is a connection between terminals 107 and 109 whereas in an alarm situation there is a connection between ter-minals 107 and 108. The alarm output is supplied by applying max. 230 V to terminal 107 - see page 020 in diagram 2347-003.

UNISAB II is prepared for connection of thermo-pump. The connection is shown on page 028 in di-agram 2347-003.

6.3 Control without UNISAB IIWhere the unit is to be controlled by a control sys-tem which is not delivered by YORK Refrigeration, the connection must be made as described in the key diagrams pertaining to the control system in question.

Section 21, Appendices includes data sheets for the individual control components with more de-tailed descriptions of how to carry out the connec-tion.


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7. Pressure TestingAfter installing the unit, it must be pressure tested and pumped down.

7.1 Pressure Testing of the Refrigera-tion Plant

Before charging the plant with refrigerant, it must be pressure tested and pumped down.

Pressure test the plant with one of the fol-lowing:

– dry air - pressurized cylinders contain-ing dry atmospheric air may be used - but never oxygen cylinders;

– air compressor for high pressure;

Important!

The plant compressors must not be used to pressurize the plant. Water and other fluids must not be used for pressure testing.

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

During pressure testing, it is important to en-sure that pressure transducers and other control equipment are not exposed to the testing pressure. The compressor stop valves must also be closed during pressure testing.

Plant safety valves must normally be blanked off during pressure testing, as their opening pressure is lower than the testing pressure. Shut-off valve pos. 4K-1 must be closed during pressure testing.

Important!

During this pressure testing no person should be allowed to be present in rooms housing plant parts or in the vicinity of the plant outside the rooms.

• The entire plant must be pressure tested in accordance with the local regulations for pressure testing.

• The test pressure must never exceed the pressure for which the unit was de-signed.

• If it is required that the compressor should be pressure tested together with the unit or with the plant, the testing pressure must not exceed:

– For reciprocating compressors: - HT side 24 bar- LT side 17.5 bar

• Please observe that manometers, pres-sure controls, pressure transmitters and other control equipment are not ex-posed to testing pressure.

• Afterwards, reduce pressure to 10 bar for a period of 24 hours - as an initial tightness test - as a tightly sealed plant will maintain this pressure throughout the period.

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

• By way of a second tightness test, ex-amine all welds, flange joints etc. for leakage by applying soapy water while maintaining the pressure of 10 bar.

When pressure testing, prepare a pressure test report containing the following points:

• date of pressure testing,

• person carrying out the test,

• comments.

7.2 Pumping Down the Refrigeration PlantFollowing pressure testing, the refrigeration plant must be evacuated in order to elimi-nate atmospheric air and moisture. Evacua-


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tion must be carried out on all types of plants, regardless of the type of refrigerant with which the plant is to be charged.

Note that HCFC and HFC refrigerants mix only minimally with water and it is, therefore, necessary to effect evacuation of such sys-tems with particular care.

The boiling point of a fluid is defined as the temperature at which the steam pressure equals atmospheric pressure. For water the boiling point is 100°C. If the pressure is low-ered, the boiling point of the water will also be lowered.

The table sets out the boiling point of water at very low pressures:

Table 7.3

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

The vacuum pump must be able to lower the pressure to approx. 0.1 mm Hg (mercury column) and must be fitted with a gas ballast valve. This valve should be used wherever possible to prevent water vapour condens-ing in the vacuum pump.

Important!

Never use the refrigeration compressor to evacuate the plant.

For an evacuation to be performed satisfac-torily, the final pressure must be lower than 5 mm Hg. Please note that water left in the refrigeration plant may freeze if ambient temperatures are lower than 10°C. In such cases it will be necessary to supply heat to the component surroundings, as ice evapo-rates with difficulty.

It is recommended to carry out evacuation as follows:

• Evacuate to a pressure lower than 5 mm Hg.

• Blow dry air or nitrogen into the system to a pressure corresponding to atmos-pheric pressure. Never use OXYGEN cylinders.

• Repeat evacuation to reduce pressure to less than 5 mm Hg.

• Shut off the vacuum pump from the refrigeration plant and check that the pressure does not rise for the next cou-ple of hours. If the system still contains water, this will evaporate and cause the pressure to rise, thereby indicating un-satisfactory evacuation, which means that the above procedure must be re-peated.

Boiling point of water °C

At pressuremm HG

bar

5 6.63 0.0088

10 9.14 0.0122

15 12.73 0.0170

20 17.80 0.0237


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8. Oil ChargingSince the compressor is usually delivered without any oil in the crank case, oil must be charged in

accordance with the oil recommendation before start-up.


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Final Check of the InstallationAfter the installation has been completed, go through the following check list.

WWarning!

It is of vital importance that all security systems and their functions are checked before start-up. Failure to comply with safety precautions may cause death, personal injury or damage to the equipment.

Table 7.4

Check list for the installation OK

1 Level foundation Measure whether the foundation is level

2 Position of vibration dampers Measure flexion

3 Position of motor on foundation Check that the motor rests on all four supporting surfaces

4 Position of compressor on foundation Check that the compressor rests on all four support-ing surfaces

5 Tightness of pipe connection Pressure testing: After putting the unit under pressure, paint with soapy water around welds, thread connections and union nuts.

6 Coupling between motor and compressor Check that the alignment is in order - must be checked again after 5 hours of operation while the coupling is warm.

7 Torque Check that all bolts are tightened to the torque indi-cated.

8 Electrical connection Check all electrical connections e.g. by measuring.

9 Oil charging Check that the oil in the crankcase goes up to the middle of the sight glass.


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8. Components

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8. ComponentsThe purpose of this document is to describe the components which form part of the product as well as the variety of accessories which can be mount-ed.

This document is primarily intended for construct-ing engineers, service technicians, future custom-ers, sales personnel and personnel in the process of training.





GeneralSMC 100 and TSMC 100 compressor blocks and units are available in different versions with differ-ent components.

Regulating Systems• Electromechanical control (analogue

reading and safety system).

• Computerized reading, safety and capacity regulating system.

• Variable speed drive (VSD) in connec-tion with computerized capacity regulat-ing system.

Valves• Suction valve

• Discharge valve

• Oil charging valve

• Purge valve

• Thermostatic expansion valve for inter-mediate cooling (TSMC)

• Thermostatic expansion valve for oil cooling

• Solenoid valves for oil cooling and inter-mediate cooling

• Solenoid valve block for capacity regula-tion

Equipment• Oil separator

• Oil cooler

• Float valve for oil return

• Intermediate cooler (TSMC)

• Heat exchanger for intermediate cooling (TSMC)

• Heating element

For further information regarding dimensions and location, please see the binder Dimensions and Piping Diagrams as well as Section 5, Physical and Connection Data.

8. Components

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MotorsThe standard SMC 100 and TSMC 100 units are available with motors in different sizes, with differ-ent enclosures, power and supply voltage.

• Makes: Schorch and Leroy-Somer

• Supply voltage: 3x380V 50 Hz or 3x440V 60 Hz

• Enclosure class: IP 22/23 or IP 54/55

• Size: IEC 160 - 355

The necessary motor power depends on the oper-ating conditions of the unit. The motor size can be determined on the basis of the calculations in the calculation program COMP1.

Transmission SystemsSMC 104-106-108 and TSMC 108 are available either directly driven or belt driven.

Directly DrivenThe power transmission between motor and com-pressor takes place by means of a coupling. Type of coupling AMR 312 is used for SMC 104-106-108 and TSMC 108 and type AMR 350 for SMC 112-116 as well as TSMC 116. A cou-pling hub with bushing is mounted on the com-pressor. A hub adjusted to the chosen motor size is mounted on the motor. Moreover, the coupling consists of an outer and inner screen and a cou-pling intermediate piece. These parts are not mounted when the compressor is delivered. They are, however, included in the delivery. In cases where the unit is delivered without motor, coupling hub for motor is also included.

Belt DrivenThe power transmission takes place by means of V-belts. The compressor is always delivered with

a belt pulley diameter of 400 mm. The required transmission of speed between motor and com-pressor is achieved by choosing the right standard belt pulley for the motor.

See, moreover, Section 6, Technical Data where both systems are described in detail.

Oil SeparatorsSection 6, Technical Data - Oil separators in-cludes a complete list of application areas for the individual oil separators.

The function and mode of operation of the oil sep-arator are described in detail in Section 4, Techni-cal Description.

Oil CoolersSee Section 4, Technical Description - Cooling Systems for Compressors where the oil cooling principles are described in detail.

The table below shows which oil cooler (depend-ing on the type of refrigerant) forms part of the units.

Table 8.1 Refrigerant-Cooled Oil Cooler

Table 8.2

Oil Cooler Model Refrigerant

OSSI R 717

OOKH HFC/HCFC

Combinations

Water-cooled top and side covers

Chosen on the basis of

operating limits

Air-cooled top covers and water-cooled side covers

Air-cooled top and side covers, refrigerant-cooled oil cooler

Thermo pump

8. Components

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Regulating Components

Electromechanical ControlThe following components form part of the electro-mechanical control:

KP15 High and low pressure cut-out

KP5 Intermediate cut-out

MP55 Oil difference cut-out

KP98 Discharge pipe thermostat

KP98 Oil thermostat

KZD4/M3 Oil filter differential pressostat

Moreover, the compressor is equipped with ma-nometers for visual control of the pressure condi-tions.

High pressure manometer:

Indicating discharge pressure.

High and intermediate pressure:

Indicating discharge pressure for HP and LP Stages (TSMC).

Low pressure and oil pressure:

Indicating suction pressure and oil pressure.

8. Components

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UNISAB IIThe UNISAB II control receives its impulses from pressure transducers and temperature sensors.

Pressure Transducers, marked PT1, PT2, PT3 For plants with UNISAB II control the unit is deliv-ered with pressure transducers from Danfoss of the type:

PT1: AKS32R and PT2 and PT3: AKS2050 - see data sheet in Section 21, Appendices.

For plants with another control the unit is delivered with pressure transducers from Danfoss of the type:

PT1: AKS3000 and PT2 and PT3: AKS3050 - see data sheet in Section 21, Appendices.

Temperature Sensors, marked TT5, TT6 and TT7As standard the unit is delivered with Pt100 tem-perature sensors of the type: P2208 G¼"B L80.

This type has a replaceable sensor insert placed in a protective pocket made of stainless steel, which makes it possible to replace the insert while the unit is under pressure, see data sheet in Sec-tion 21, Appendices.

The regulating systems are described more close-ly in Section 4, Technical Description - Instrumen-tation.

Heating ElementThe compressor is equipped with a heating ele-ment in the crankcase for decocting of refrigerant in the oil. See Section 4, Technical Data - One-Stage Compressors and Section 5, Physical and Connection Data which include descriptions and data.

AccessoriesIf the compressor is to be installed in rooms where explosive gases may occur, special explo-sion-proof components can be delivered, see Section 4, Technical Description - Compressor Accessories.

9. Settings

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9. SettingsThe purpose of this document is to provide infor-mation about the factory settings of the safety and control equipment, how to change the settings and the effect of a change.

This document is primarily intended for installation and service engineers.




This document must not be copied without a writ-ten permission from YORK Refrigeration and the contents hereof must not be imparted to a third party, nor be used for any unauthorised purpose. Contravention will be prosecuted.

Safety Precautions

WDanger!

Risk of injury to personnel and damage to equip-ment! In addition to the safety precautions in this document, always read the safety precautions be-longing to this equipment before changing the set-tings. Failure to comply with safety precautions may cause death or injury to personnel. It may also cause damage to or destruction of the equip-ment.

Qualification RequirementsChanges in the factory settings must only be car-ried out by an authorised refrigeration company. Moreover, it is required that the personnel is able to follow a detailed description in English.

Factory settings for analogous control and safety system appear from Table 9.1. In connection with fault-finding in case of irregularities in the opera-tion, the table should include own settings to make it easier for the supervisor to identify the error in question. The same applies to UNISAB II control. Table 9.2 and Table 9.3 show the set values for UNISAB II.

9. Settings

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Table 9.1 Pressure and Temperature Settings for Compressor Type SMC/TSMCAnalogous control and safety system

Refrigerant

R22

R 1

34

R 4

04A

R 5

07

R 7

17

Min. setting (own setting)

Max. set-ting (own setting)

S a

f e

t y E

q u

i p

m e

n t

Safety valve on compressor

HTX X X X X 24 bar (standard)

X X X X X 22 bar (special)

MT X X X X X 12 bar

High and intermediate-pressure cut-out

KP5 (KP15) X X X X X

Set so that the compressor stops at a pressure 2 bar lower than the safety valve setting.

Low-pressure cut-out KP1(KP15) X X X X X

Set to a pressure with saturation temp. 5° K lower than the lowest evaporating temperature.

Oil pressure cut-out MP55 X X X X X 3.5 bar

Discharge pipe ther-mostat KP98

X X X * 120° C

X * 150° C

Oil thermostat KP98 X X X X X 80° C

C o

n t

r o

l E q

u i

p m

e n

t

Thermostat for com-pressor cooling KP77 X X X X X 55° C

Thermo valve for com-pressor cooling

T (E) XT (E) NT (E) S

X X X X Normally set at 4° C su- perheatChange to min. 10° C superheat

Injection valve for in-termediate cooling

TEATX X X Factory setting 45° C. See NB

X X Factory setting 75° C. See NB

T (E) XTEA

X Set at min.10° C superheat

X Set at min.10° C superheat

By-pass valve PMC+ CVCX X X -25° C

X -15° C

Oil filter differential pressure KZD4/M3 X X X X X 2,0 bar

Oil pressure regulat-ing valve X X X X X 4.5 bar

* Factory setting - can be adjusted, if required, to a breaking point 20° C higher than the highest normal discharge pipe temperature.

** Adjust the TEAT valves so that the expected discharge pipe temperature (-5° C/+10° C) is achieved at 100% compressor capacity. Increase the opening temperature 10° C by turning the spindle 5 turns clockwise. NB: Factory setting must always be increased by min. 10° C. Ad-justment of the TEAT valve must be carried out with the thermopump out of operation. For detailed descriptions concerning setting and adjustment of automatics, see Section 21, Appendices.

9. Settings

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UNISAB II Reading, Safety and Capacity Regulating System

Table 9.2 Measured and Calculated Pressure Levels

Table 9.3 Measured and Calculated temp. - Reciprocating Compressors

Mesuaring Min. Max. Factory Setting

Note

Suction pressure[bar]

High alarm High warning Low warning Low alarm

-1,5-1,0-1,0

-9,06,06,0

-5,02,51,5

3+4+53+4+53+4+5

Discharge pressure[bar]


4,03,0 -

-1.0

24,022,0

--1.0

16,015,0

--1.0

1+61+6

1+5

Intermediate pressure [bar]For two-stage compressors only

High alarm High warningLow warning Low alarm

4,03,0-1,0-1,0

24,022,010,010,0

7,06,0-1,0-1,0

1+61+6

1+6+161+6+16

Oil pressure[bar]

Calculated value

High alarm High warningLow warning Low alarm

5,05,00,50,5

7,07,05,05,0

6,05,54,03,5

2+5+162+5

2+5+142+5+14

Measuring Min. Max. FactorySetting

Note

Discharge temperature[°C]

High alarmHigh warning Low warning Low alarm

60,050,0-65,0

-

155,0155,0-65,0

-

125,0120,0-65,0

-

1+61+6

Oil temperature[°C]


40,030,00,00,0

105,0105,050,040,0

80,075,030,025,0

222+72+7

Brine temperature[°C]


-60,0-60,0-100,0-100,0

100,0100,0100,0100,0

60,050,04,02,0

1+61+61+61+6

Intermediate gastemperature [°C]For two-stage compressors only

High alarm High warningLow warningLow alarm

50,050,0-20,0-20,0

155,0120,050,050,0

100,095,04,02,0

2+72+72+72+7

Suction gas superheat[°C]

Calculated value


6,05,00,00,0

120,0120,040,040,0

110,0100,0

4,02,0

2+72+72+7+132+7+13

Disch. gas superheat[°C]Calculated value

High alarm High warning

5,00,0

40,040,0

10,00,0

2+7+102+7+10

9. Settings

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4-20 mA Auxiliary input Signal

Notes:Note 1 The alarm cannot be switched off un-

til the problem has been solved.

Note 2 The alarm can be switched off imme-diately (RESET key).

Note 3 The alarm is switched off automati-cally.

Note 4 The safety limits can be entered in bar or °C/R at your choice.

Note 5 Alarm monitoring active when digital output "compressor starting signal" has been chosen.

Note 6 Alarm monitoring always active - ex-cept when "BLOCKED" has been se-lected in the picture COMPRESSOR CTRL MODE.

Note 7 Alarm monitoring 300 sec delayed after compressor start.

Note 8 Alarm monitoring 180 sec delayed after compressor start.

Note 9 Alarm monitoring 45 sec delayed af-ter compressor start.

Note 10 A setting of 0.0 impedes monitoring.

Note 11 Delay of 300 sec, regardless of when the limits are exceeded.

Note 12 The compressor must have been above 5% capacity. Below 5% ca-pacity monitoring is impeded.


Note 14 Delay of 60 sec, regardless of when the limits are exceeded.

Note 15 Only applies to HPO and HPC com-pressors.


Note 17 For VMY Mk 2-2.5, calculate the fol-lowing below: Oil pressure = Oil pressure 3 (after oil filter) - Dis-charge pressure 2. For all other compressor types (except for SAB 80, see Note 20), calculate the fol-lowing: Oil pressure = Oil pressure 3 (after oil filter) - Suction pressure 1 .

Note 18 The limits are not active until AUX. INPUT SIGNAL has been selected in the CALIBRATION 4-20 mA menu.

Note 19 For SAB 80 the differential pressure across the oil filter is calculated as follows below: Oil filter diff. pressure = Discharge pressure 2 - Oil pres-sure 4 (after oil filter).

The shown oil filter pressure will thus be 0.1 to 0.7 bar higher than the ac-tual pressure loss across the filter due to the pressure loss across the oil separator and the oil cooler.

Measuring Min. Max. Factory Note

Auxiliary input(4-20 mA)

High alarm -999,9 999,9 0,0 3+18

High warning -999,9 999,9 0,0 3+18

Low warning -999,9 999,9 0,0 3+18

Low alarm -999,9 999,9 0,0 3+18

9. Settings

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The maximum allowed pressure drop across the oil filter is 1.2 bar. Consequently, the warning limit should be set between 0.8 and 1.4 bar or lower. The alarm limit should be set between 1.1 and 1.7 bar or lower.

Note 20: Set points 1 and 2 are used for alarm monitoring of the mechanical oil pump. Cf. the description of the alarm under "Oil pump error" in the section Other Alarms. For SAB 80, the oil pressure is calculated as fol-lows below: Oil pressure = Oil pres-

sure 3 (after pump) - Suction pres-sure 1 .

Note 21: The set points are used to control the oil pump. When the pressure falls below set point 1, the oil pump will start. When the pressure exceeds set point 2 for 60 seconds, the oil pump will stop.

Note 22: The set points are used to control the full flow pump. When the pressure falls below set point 1, the full flow pump will start. When the pressure exceeds set point 2 for 60 seconds, the full flow pump will stop.

Table 9.4 Oil Cooling

Change af factory settings, see Instruction Manu-al, UNISAB II Control.

Fig. 9.1 - Expected Discharge Gas Temperatures - shows the values recommended when setting operational and safety functions.

No. Regulator Type Min. Max. FactorySetting

Unit

2Set point 1/ oil temp.DifferenceOil cooling

+35 +75 +555(fixed) °C

Set point 2/ oil temp.DifferenceOil heating

0 +75 +355(fixed) °C

Set point 1/ discharge pipetemp. DifferenceWater cooling

-20 +150 +1005(fixed) °C

Set point 2/ discharge pipetemp. DifferenceIntermediate pressureliquid injection

-20 +150 +1005(fixed)

°C

9. Settings

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Fig. 9.1 Expected Discharge GasTemperatures

Suction gas superheat ° C

Condensing temp. ° C

HF

C H

CF

C

bar

bar

bar

10 20 30

20 25 30 35 40 45

8.8

10.1

11.5

5.7

6.6

7.7

8.8

10.1

11.5

5.7

6.6

7.7

8.8

10.1

11.5

20 25 30 35 40 45 20 25 30 35 40 45

38 44 49 53 57 61 48 54 63 67 71 58 64 69 73 81

41 45 50 54 59 63 51 55 60 64 69 73 61 65 70 74 79 83

43 48 53 58 63 67 53 58 63 68 73 77 63 68 73 78 83 87

48 52 58 64 69 74 58 62 68 74 79 84 68 72 78 84 89 94

55 59 66 74 79 82 65 69 76 84 89 92 75 79 86 94 99

8.2

9.5

11.1

14.5

16.5

8.2

9.5

11.1

12.7

14.5

16.5

8.2

9.5

11.1

12.7

14.5

16.5

37 47 55 68 72 81 48 57 65 73 82 90 59 69 75 84 92 99

48 57 65 74 82 90 59 68 76 84 92 98 70 78 86 95 101

108

61 69 77 85 94 100

72 80 88 96 103

109

83 91 98 106

111

117

76 84 92 99 106

112

88 95 102

109

115

121

97 105

111

118

123

128

91 101

108

115

120

126

103

110

117

123

128

133

113

120

125

131

135

139

5371

9111

013

1

10.7

12.6

14.6

16.9

10.7

12.6

14.6

16.9

10.7

12.6

14.6

16.9

65 77 89 101

110 65 77 89 100

111

121 78 90 102

112

123

132

83 95 106

117

126 83 95 106

116

127

136 96 106

118

128

138

148

102

113

123

133

143

103

114

125

134

144

154

115

126

136

146

155

165

121

133

141

151

161

122

132

142

152

162

171

134

144

154

163 -

-

142

151

160

170 -

143

153

162 -

-

-

153

163 -

-

-

-

+10

010

2030

+10

0

1020

300

10

2030

40+

100

10

2030

°CD

isch

arg

e g

as t

emp

.°C

Dis

char

ge

gas

tem

p.

° C

° C

Condensing pressure

10 20

40 45

5.7

6.6

7.7

20 35 40 45 20 25 40

8 9 11.

12.7

14 8 9 11 12 14 16 8 9 11 12 14 16

47 55 68 72 81 48 57 65 73 59 69 75 84 92 99

48 57 65 84 92 98 108

61 69 77 85 94 100

72 80 98 106

111

117

76 84 92 106

109

123

91 101

108

115

120

126

103

110

117

7.6

5371

9111

013

1

9.1

7.6

9.1

7.6

9.1

65 77 89 101

110 65 77 89 78

106

127

106

118

128

138

148

102

113

123

133

143

103

114

125

134

144

154

115

126

136

146

155

165

121

133

141

151

161

122

171

-

143

-

+10

010

2030

+10

0

1020

0

+10

0

1020

30

R13

4aR

22R

404A

/R50

7R

717

°C

°Co

rin

term

edia

te t

emp

erat

ure

°Co

rin

term

edia

te t

emp

erat

ure

Eva

po

rati

ng

tem

per

atu

re

7759

102

16.2

18.2

20.5

11.0

12.5

14.3

16.2

18.2

20.5

11.0

12.5

14.3

16.2

18.2

20.5

40 44 49 54 59 65 50 54 64 69 75 60 64 69 74 85

42 47 52 57 62 67 52 57 62 67 72 77 62 67 72 76 82 87

46 51 56 61 66 71 56 61 66 71 76 81 66 71 76 81 86 91

53 58 63 67 72 77 63 68 73 77 82 87 73 78 83 87 92 97

62 67 71 75 79 83 72 77 81 85 89 93 82 87 91 95 99

11.0

12.5

14.3

7959

103

Condensing pressure

Condensing pressure

Eva

po

rati

ng

tem

per

atu

re

barCondensing pressure

°Co

r

Eva

po

rati

ng

tem

per

atu

re

inte

rmed

iate

tem

per

atu

re

°Co

r

Eva

po

rati

ng

tem

per

atu

re

inte

rmed

iate

tem

per

atu

re

Dis

char

ge

gas

tem

p.°

CD

isch

arg

e g

as t

emp

. °C

10. Operating Instructions

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10. Operating InstructionsThe purpose of this document is to describe:

• Dangers resulting from failure to comply with safety precautions when operating the equipment.

• How to start, operate and stop this equip-ment in a safe way.

• How to act when problems occur during op-eration.

This document is primarily intended for operators and service engineers.





WDanger!


Safety Precautions

WDanger!

A number of safety considerations which must be read before operating the unit in question are pre-sented in the following. General safety instruc-tions/regulations must be studied carefully. Fail-ure to do so may result in personal injury or even death. Moreover, the equipment may be damaged or destroyed.

VentilationBefore operating the unit, always check to see that the ventilation system used in the area where the compressor unit is located (machine room) is functional and operating at full capacity.

The safety instructions explain the risks associat-ed with using the refrigerant and oil. Pay close at-tention to the fact that large amounts of escaping (or released) refrigerant entail risk of suffocation.

The safety instructions also explain the risks gen-erally associated with refrigerants. Body contact with leaking liquid refrigerant entails high risk for injuries caused by intense cold.

PressureA compressor unit comprises a pressurized sys-tem. Never loosen threaded joints (such as a union nut) while the system is under pressure and never open pressurized parts of the system.


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Hot and Cold SurfacesA compressor unit contains both hot and cold sys-tem parts. Always wear and use the re-commend-ed safety items.

Never use your hands or other parts of the body to search for leaks.

Qualification RequirementsBefore carrying out the measures set forth in this document, all personnel must have carefully stud-ied the instructions issued for the compressor unit.

The personnel must also fulfil all national require-ments for authorization.


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Compressor Control and Alarm FunctionsThe reciprocating compressors can be equipped with either analogue reading and regulating sys-tem or UNISAB II reading, safety and regulating system.

Alarms and Warnings

Analogue SystemThe system is described in detail in Section 4, Technical Description - Instrumentation, which is why this section only contains a short description of the system.

Analogue reading and regulating system always require an external control board for the regulation of the capacity. The board can be equipped with alarms.

The safety system consists of the following com-ponents:

• KP 15: High and low pressure cut-out Stops the compressor at too high or too low pressure in the refrigeration system.

• KP 5: Intermediate pressure cut-out (only on TSMC compressors)Stops the compressor at too high intermedi-ate pressure.

• MP 55: Oil differential cut-outStops the compressor at too low oil pres-sure in the lubricating system.

• KZD4/M3 Oil differential cut out Oil differential pressure across oil filter. A warning is given if the pressure drop through the external oil filter is too high.

• KP 98: Discharge pipe thermostatStops the compressor at too high discharge gas temperature.

• KP 98: Oil thermostatStops the compressor at too high oil temper-ature.

The safety equipment stops the compressor if the max. or min. values are exceeded. If this happens, correct the error before restarting the plant. To prevent accidents the plant cannot be started be-fore the function of the safety cut-out has been ac-tivated.

Cut-outs and thermostats are not factory set on delivery. The set values are included in Section 9, Settings - Analoque Control and Safety Function. However, always check the set values before starting the plant.

As regards adjustment and setting of the equip-ment, see Section 21, Appendices, which in-cludes instructions for the individual components.

UNISAB II Reading, Safety and Capacity Regulating SystemUNISAB II is a Computerized Control System, the purpose of which is to monitor and control the compressor.

The signals to the control and safety automatics come from the pressure transmitters and temper-ature sensors mounted on the compressor. It is possible to connect UNISAB II to a superior mon-itoring device- MULTISAB.

On delivery UNISAB II is preset with a number of factory values, e.g. safety and alarm functions. A battery backup makes sure that preset values are not lost in case of power failure.

All control operations for the reciprocating com-pressor unit are carried out from the operator's panel and its keys. The following page in this doc-ument gives a brief explanation of what the keys on the operator's panel are used for.


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A detailed description of the control system, its

functions and its use is included in the Instruction

Manual for UNISAB II Control.

The following are for normal daily operation of the reciprocating compressor unit.

1. The emergency stop button on the side of the control cabinet can always be used to stop the compressor unit quickly.

2. When voltage is applied to UNISAB II, the following main picture will appear on the display, and UNISAB II is ready for opera-tion.

Values for warning limits, alarm limits and set points, etc. are programmed into UNISAB II. This makes it possible to start the compressor immediately.

However, some of the values must always be adapted for the actual operating situation. For this purpose use the table Quick Reference, see Fig. 10.6, Fig. 10.7, Fig. 10.8 and Fig. 10.9.

Carefully read the Instruction Manual UNISAB II Control to get a thorough knowledge of how to op-erate the control system.

UNISAB II is operated exclusively by means of the keys as shown in Fig. 10.2. Reading of operating conditions as well as changing limit values and set points is done via the display, which contains a number of pictures.

The control panel is normally closed and locked with a screw at each end of the panel.

By turning the screws half a turn the control panel is loosened and can be lifted to an open position. Here it is fastened to the cabinet as shown in Fig. 10.1.

Fig. 10.1 Opening the Cabinet

SUCT. PRESS. 0.0 BAR

DISCH. PRESS. 0.0 BAR

MOTOR CURR. 0 A

STOPPED 0% UNISAB II

UNISAB II


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DisplayPos. 1 Has a constant background illumina-

tion and displays 4 lines, each with 20 characters. The contrast has been factory set, but can be adjusted if required. See subsection Contrast (display) in the section Languages in the UNISAB instruction manual.

In the display pressure levels, tem-peratures as well as all set points, warning and alarm limits can be read.

Front PanelThe UNISAB II front panel is divided into two sections:

• the control section, pos. 2-10, by means of which the compressor is controlled.

• the recording section, pos. 11-15, by means of which menu pictures are selected and values changed.

Control SectionPos. 2 Green lamp indicating whether the

compressor is running. At start-up this lamp will flash until UNISAB II has received feedback from the mo-tor starter. At the same time the text

"STARTING" (lamp flashes) and "OPERATING" (lamp light steady ) can be seen in the bottom line of an operating picture.

Pos. 3 Yellow lamp indicating whether the state of operation is automatic or manual. Yellow light = manual operation.

Pos. 4 Red lamp indicating warning or alarm. Slow flashes = warningQuick flashes = alarm

Pos. 5 A Compressor start at manual oper-ation by pressing the key once. Works only if yellow lamp pos. 3 is lit.

Pos. 6 B Compressor stop at manual oper-ation by pressing the key once.Works only if yellow lamp pos. 3 is lit.

Pos. 7 C A change between manual (yellow lamp on) and automatic (yellow lamp off) takes place by pressing the key once.Please note that if manual was se-lected from the CONTROL menu, it is not possible to change to automat-ic. See section Control Mode in the UNISAB instruction manual.

Pos. 8 D Key used to acknowledge alarms.


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Fig. 10.2 Front Panel of UNISAB II

Pos. 9 E Loading of capacity duringmanual operation. By pressing the E key once one capacity level is loaded on a recipro-cating compressor with fixed rpm. On variable speed drive (VSD) com-pressors, the capacity is increased continuously by pressing the key.

Pos. 10 F Unloading of capacity duringmanual operation. By pressing the F key once one capacity level is unloaded on a recip-rocating compressor with fixed rpm. On variable speed drive (VSD) com-pressors, the capacity is decreased continuously by pressing the key.

Recording SectionPos. 11 G This key has several functions.

– When pressing the G key, a change will take place between Bar (PSI) and °C/R (°F/R) for saturated vapours when the display shows a suction or discharge pressure.

– Changing the set values can only be car-ried out by using the password shown on page 1 in the UNISAB instruction manual. As to the encoding of a pass-word, see section Changing Set Values in the UNISAB instruction manual.

Pos. 12 H Used for moving left in the menu system. Used for selecting pictures or a digit when changing a value.

Pos. 13 I Used for moving right in the menu system. Used for selecting pictures or a digit when changing a value.

UNISAB II

R O

I SetSuct.temp. -25°CDish.temp. 38°COil press. 4,3 barReady 0%

10 3 4789 2 5 6 1 11 1213 14 15


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Pos. 14 J Used for moving upwards in a pic-ture in order to point at a certain val-ue, or when changing to a higher val-ue.

Pos. 15 K Used for moving downwards in a picture in order to point at a certain value, or when changing to a lower value.

Menu StructureThe UNISAB II features a number of different pic-tures on compressor operation, set values, configuration, etc. and these pictures are built up in a menu system in which a certain picture can be selected by means of the arrow keys. See Instruc-tion Manual for UNISAB II


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Preparations for Starting

Check the following points before starting the compressor for the first time after the installation.

1. Check that the oil goes up to the middle of the sight glass. If this is not the case, re-charge with oil.

2. Check that the safety equipment is set cor-rectly. All safety functions are factory set.

This is the case for both analogue control and UNISAB II control.

3. The heating element in the crankcase must be energized 6-8 hours before starting-up the compressor.

4. Check that the valves are open according to Table 10.1.

Table 10.1 Position during Operation

Fig. 10.3 Principle Drawing - Position during Operation

5. Switch on the pilot voltage. Check that the emergency stop button, see Fig. 10.4, is in ON-position (the button must be in its outer-

most position). If the plant does not start, check that the fuses are intact. See Fig. 10.5.

Pos no Qty Designation In operation position Remarks

1 1 Suction stop valve Open Must be opened by only a couple of turns.

2 1 Discharge stop valve Open

3 1 Air purge valve Closed

4 1 Oil charge valve Closed

5 1 Stop valve - after oil seperator Open

6 1 Stop valve - receiver Open

7 1 Stop valve - liquid line Open To be opened after start-up

Note!

Other valves may occur. SeeDimensions and Piping Diagram

Receiver

From Condenser

To Conderser

Open

Closed

To Evaporator

3

1 2

5

6

7

4


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Fig. 10.4 Operator's Panel

Fig. 10.5 Drawing of Fuses and their Position

StartingBefore starting up the plant, carefully read the section Preparations for Starting. Reset any alarms.

When the plant is to be started for the first time, it is recommended to choose a manual starting-up procedure.

• Open the suction stop valve a couple of turns. Open all other valves except from the main shut-off valve in the liquid line.

• Start condenser cooling, brine pumps, ven-tilators at air coolers and maybe compres-sor cooling.

• Put the capacity regulation on minimum ca-pacity. TSMC ia allowed to operate in a to-tally unloaded position for a maximum of 5 minutes. The operating temperature will oth-erwise be too high.

• Start the compressor on the control board or by means of A on UNISAB II (on compres-sors with analogue/digital control the start button is often mounted as an ON/OFF service cut-out on the compressor).

• Check suction and oil pressure. For com-pressors with variable speed drive (VSD), the oil pressure has to be adjusted at min. rpm and checked at max. rpm.

• Check if the oil is foaming in the sight glass.

• Check that the time relay keeps the solenoid valve in the oil return line shut for 20-30 min-utes after the compressor has been started. Solenoid valve controlled oil return only.

• Open the suction stop valve slowly until it is completely open.

• Open the main shut-off valve in the liquid line.

• The compressor is now operating. Gradual-ly increase the capacity to 100%.

• Do not leave the plant unattended the first 15 minutes after start-up.

After start up, carry out the final regulation of the plant and set the plant to automatic operation.

Operating Mode UNISAB IIThe compressor can be adjusted to different forms of operation. These are found in SETUP H CONTROL I.

Emergencystop button

U N IS AB II

1 2 33 Amp


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When selecting this picture, the cursor will be in the top line. Press G and the cursor moves to the second line.

It is now possible to select the desired form of op-eration with the keys J K.

The possibilities are:

• STOPPED

• MANUAL

• AUTO

• REMOTE

STOPPED means that the compressor is blocked and thus cannot start.

MANUAL means that the compressor only oper-ates manually, i.e. you cannot change to another form on UNISAB II by means of the key C.

However, the compressor can be started withA and stopped with the B key and capacity in-creased/decreased with the keys E F.

AUTO means that the compressor runs in local automatic operation according to the form of reg-ulation chosen (suction pressure, brine, etc). It is possible to change to MANUAL with the key C.

REMOTE means that the compressor runs in re-mote regulation. It is chosen when a number of compressors are working together in a common MULTISAB regulating system.

RegulatorsIn UNISAB II it is possible to regulate the com-pressor according to different pressures and

temperatures. These forms of regulation are found in CONFIG CONTROL ON.

If you place the cursor on CONTROL ON and press G until the cursor moves to the right side of the picture, you can now select different types of regulation with the keysJ K.

Among the following:

• SUCTION SIDE

• BRINE

• DISCH. SIDE

• HOT WATER

• EXT. COOL

• EXT. HEAT

These regulators have three set values in com-mon: Set point (Sp), Neutral zone (Nz) and Pro-portional band (Pb).

Set point Sp is the pressure or the temperature desired in the plant.

Neutral zone Nz indicates how much the pres-sure or the temperature is allowed to fluctuate in relation to the Sp without the compressor chang-ing its capacity. The set value of Nz positioned symmetrically around the set point (Sp+/- ½ Nz).

Proportional band Pb indicates how powerful the regulating signal to the compressor capacity regulation is going to be, depending on the differ-ence between the desired value (Sp) and the ac-tual value.

In case the measured value is just outside the Nz, the regulating impulses will be very brief, whereas the regulating impulses will be very long if the measured value is outside the P-band. The P-band is positioned symmetrically around Sp out-side the Nz.

COMPRESSOR CTRL. MODE

STOPPED


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Fig. 10.6

1 MAIN PICTURE

Press H until the picture remains unchanged and this is your MAIN PICTURE.

Factory-setting

2 SELECT THE "CONFIGURATION" MENU

Main picture - I suction - K setup - I control - K config. - - - - - - - - - - - - - - - - - - i Check whether UNISAB II is set correctly for the compressor. Press H until the Main picture appears.

3 SELECT THE "TIMER SETUP" MENU

Main picture - I suction - K setup - I control- Ktimers - I timers - K timer setup - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - iCheck the set times in Timer setupPress H until the Main picture appears in the display.

4 READ SUCTION PRESSURE OR DISCHARGE PRESSURE IN BAR OR °C/R.

Place cursor on suct. press or disch. pres and press "SET" (once).

5 SELECT THE MENU FOR SUCTION PRESSURE REGULATION

Main picture - I suction - I suct. press - press "SET" for changing to °C/R - - - - - - - - - - - - - - - - - - iPress H until the Main picture appears.

6 CHANGING THE SET VALUES

In order to be able to change a set value, a password must be encoded as described:Press "SET" for 2 seconds [Standard code number 1234].Find the right password in the instruction manualWith H I and J K the correct password is encodedPress "SET" and the password is kept open for 60 mins.

7 SETTING OF VALUES, f. inst. SUCTION PRESSURE (LOW ALARM)

Main picture - I suction - I suct. press - I high alarm -- K low alarmEncode password (see pt. 6) - JK and HI changing of set values - ”SET” for confirmation.

8 SELECT FUNCTION, f.inst. REGULATOR MODE

Main picture - I suction - K setup - I control - K config. - I type - K control onEncode password (see pt. 6) - JK for selection of regulator - ”SET” for confirmation.

9 SELECT COMPRESSOR CONTROL MODE

Main picture - I suction - K setup - I control - I compressor control mode - "SET" (the cursor is now in line 2)- JK for selection of control type (manual / auto / remote / stopped) - "SET" for confirmation.

10 CHANGING BETWEEN MANUAL- AND AUTOMATIC / REMOTE CONTROL MODE

Press -g to switch between manual - auto/remoteThe light diode above g lights up at manual control mode.It is always possible to change between manual and auto/remote - also during operation.


"QUICK REFERENCE"LEAFLET FOR

UNISAB II - One-stageReciprocating Compressor

2001.07.01 Tel.: +45 8736 7000Fax: +45 8736 7705

SUCT.PRESS XXXXDISCH.PRESMOTOR CURR

XXXXXX

XREADY

CONTROL ON XXXXAUTO START YESAUTO STOP

XXXXXXXCOLD STORE

k

START START XXX

STOP START XXX

START DELAY XXX

XXXSTOP DELAYk

HIGH ALARM XXX

HIGH WARNING XXX

LOW WARNING XXX

XXXLOW ALARM

SETPOINT 1 XXX

SETPOINT 2 XXX

NEUTRAL ZONE XXX

XXXPROP. BAND

k


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11 MANUAL START (THE I-KEY):

By READY in the main picture or in any other monitoring picture: Press "I" to start the compressor.The ready-line changes to Prelubrication or Starting or Operating. (Text depending on compressor type)During the Starting period the green light diode flashes above the I-key.After feedback from the motor starter, the light diode changes to a steady light.

12 MANUAL STOP (THE 0-KEY)

By pressing the "0"-key during operation, the compressor is stopped immediately.

13 MANUAL LOADING/UNLOADING OF CAPACITY (the E F keys)

E regulates the compressor capacity upwards - F regulates the compressor capacity downwards.The immediate compressor capacity can be seen in the main picture or in any of the other monitoring pictures.

14 CONFIRMATION OF ALARMS (THE R-KEY)

Slow flashes from the red light diode = The warning limit has been exceeded.Quick flashes from the red light diode = Alarm and compressor will stop.The alarm may be confirmed by means of the R-key, and the quick flashes will stop once the situation is back to normal.


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Fig. 10.7

°C/R°C/R

A

100%

UNISAB II - Menu TreeOne-stage Reciprocating Compressor

SUCT.PRES.DISCH.PRES.MOTOR CURRRUNNING

Main picture Main menu

SUCTIONDISCHARGEOILMOTOR

BRINEALARMWARNINGSETUP

BrineBRINE TEMP.SUCT.PRESEXT.INPUTRUNNING

°C°C/R

100%

AlarmsNO ALARMS

WarningsNO WARNINGS

Setup

CONTROLMULTISABTIMERSDIAGNOSIS

CALIBRATE

CONFIGLANGUAGE

MotorMOTOR CURRCAPACITYNOT USEDRUNNING

A%%

100%

OilSUCT.PRES.OIL PRES.OIL TEMP.RUNNING

BARBAR

°C100%

DischargeDISCH.PRES.DISCH.TEMP.DISC.SUPERH.RUNNING

°C/R°C°C

100%

Suction

I PARAMETER SETTING

Control

COMPR. CTRL. MODE

MANUAL

Multisab

MULTISAB STATEALL COMPRESSORSPARALLEL CONTR.

MULTISAB

TimersTIMERS

TIMERSTIMER SETUPSERVICE TIMERS

DiagnosisDIAGNOSIS

INSPECT OLD ALARMSMISC.FUNCTIONSSOFTWARE VERSION

Calibrate

CALIBRATEPRESS TRANSDUCERBRINE TEMP.CAPACITY

Config.

REFRIGERANTCONTROL ONVOLUME RATIO

TYPE

Language

CONTRASTLANGUAGE GB

H

Auxiliary output

AUXILIARY OUTPUTACTIVE WHENAT MAX.CAP

4-20 MA input4 MA20 MA

CAPACITY SETPOINT

Analog. inputPRES. INP 1PT 100 INP 1

EXT.

Dig. outputD.OUTPUTD.OUTPUTD.OUTPUTD.OUTPUT

Dig. inputD.INPUTD.INPUTD.INPUTD.INPUT

Date-timeHOURMINSECDAY

Service-timers

ON TIMESINCE START

HOUR

TimersSTART STARTSTOP STARTSTART DELAYSTOP DELAY

SECSECSECSEC

All compressors

COMPR. # 01 MANUALSYSTEM # 01START # 01RUNNING 100%

Multisab stateSTART NO.SYSTEM NO.SYS.CONTROLLER

HIGH ALARM °C/RHIGH WARN. °C/RLOW WARN. °C/RLOW ALARM °C/RACTUAL SP. °C/RSETPOINT 1 °C/RSETPOINT 2 °C/RNEUTRALZONE °C/RPROP.BAND °C/R

J

K

SUCT.PRES.SUCT.TEMP.SUCT.SUPERH.RUNNING

°C/R°C°C

100%


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Fig. 10.8

1 MAIN PICTURE

Press H until the picture remains unchanged and this is your MAIN PICTURE.

Factory-setting

2 SELECT THE "CONFIGURATION" MENU

Main picture - I suction - K setup - I control - K config. - - - - - - - - - - - - - - - - - - i Check whether UNISAB II is set correctly for the compressor. Press H until the Main picture appears.

3 SELECT THE "TIMER SETUP" MENU

Main picture - I suction - K setup - I control- Ktimers - I timers - K timer setup - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - iCheck the set times in Timer setupPress H until the Main picture appears in the display.

4 READ SUCTION PRESSURE OR DISCHARGE PRESSURE IN BAR OR °C/R.

Place cursor on suct. press or disch. pres and press "SET" (once).

5 SELECT THE MENU FOR SUCTION PRESSURE REGULATION

Main picture - I suction - I suct. press - press "SET" for changing to °C/R - - - - - - - - - - - - - - - - - - iPress H until the Main picture appears.

6 CHANGING THE SET VALUES

In order to be able to change a set value, a password must be encoded as described:Press "SET" for 2 seconds [Standard code number 1234].Find the right password in the instruction manualWith H I and J K the correct password is encodedPress "SET" and the password is kept open for 60 mins.

7 SETTING OF VALUES, f. inst. SUCTION PRESSURE (LOW ALARM)

Main picture - I suction - I suct. press - I high alarm -- K low alarmEncode password (see pt. 6) - JK and HI changing of set values - ”SET” for confirmation.

8 SELECT FUNCTION, f.inst. REGULATOR MODE

Main picture - I suction side- K setup - I control - K config. - I type - K control onEncode password (see pt. 6) - JK for selection of regulator - ”SET” for confirmation.

9 SELECT COMPRESSOR CONTROL MODE

Main picture - I suction - K setup - I control - I compressor control mode - "SET" (the cursor is now in line 2)- JK for selection of control type (manual / auto / remote / stopped) - "SET" for confirmation.

10 CHANGING BETWEEN MANUAL- AND AUTOMATIC / REMOTE CONTROL MODE

Press - g to switch between manual - auto/remoteThe light diode above g lights up at manual control mode.It is always possible to change between manual and auto/remote - also during operation.


"QUICK REFERENCE"LEAFLET FOR

UNISAB II - Two-stageReciprocating Compressor

2001.07.01 Tel.: +45 8736 7000Fax: +45 8736 7705

SUCT.PRESS XXXXDISCH.PRESMOTOR CURR

XXXXXX

XREADY

TYPE XXXXREFRIGERANTCONTROL ON

XXXXXXXVOLUME RATIO

k

START START XXX

STOP START XXX

START DELAY XXX

XXXSTOP DELAY

k

HIGH ALARM XXX

HIGH WARNING XXX

LOW WARNING XXX

XXXLOW ALARM

SETPOINT 1 XXX

SETPOINT 2 XXX

NEUTRAL ZONE XXX

XXXPROP. BAND

k


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11 MANUAL START (THE I-KEY):

By READY in the main picture or in any other monitoring picture: Press "I" to start the compressor.The ready-line changes to Starting or Operating. )During the Starting period the green light diode flashes above the I-key.After feedback from the motor starter, the light diode changes to a steady light.

12 MANUAL STOP (THE 0-KEY)

By pressing the "0"-key during operation, the compressor is stopped immediately.

13 MANUAL LOADING/UNLOADING OF CAPACITY (the E F keys)

E regulates the compressor capacity upwards - F regulates the compressor capacity downwards.The immediate compressor capacity can be seen in the main picture or in any of the other monitoring pictures.

14 CONFIRMATION OF ALARMS (THE R-KEY)

Slow flashes from the red light diode = The warning limit has been exceeded.Quick flashes from the red light diode = Alarm and compressor will stop.The alarm may be confirmed by means of the R-key, and the quick flashes will stop once the situation is back to normal.


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Fig. 10.9

°C/R°C/R

A

100%

UNISAB II - Menu TreeTwo-stage Reciprocating Compressor

SUCT.PRES.DISCH.PRES.MOTOR CURRRUNNING

Main picture Main menu

SUCTIONDISCHARGEOILMOTOR

BRINEALARMWARNINGSETUP

Intermed.INTERM.PRESINTERM.TEMPEXT.INPUTRUNNING

°C/R°C/R

100%

AlarmsNO ALARMS

WarningsNO WARNINGS

Setup

CONTROLMULTISABTIMERSDIAGNOSIS

CALIBRATE

CONFIGLANGUAGE

MotorMOTOR CURRCAPACITYNOT USEDRUNNING

A%%

100%

OilSUCT.PRES.OIL PRES.OIL TEMP.RUNNING

BARBAR

°C100%

DischargeDISCH.PRES.DISCH.TEMP.DISC.SUPERH.RUNNING

°C/R°C°C

100%

Suction

I PARAMETER SETTING

Control

COMPR. CTRL. MODE

MANUAL

Multisab

MULTISAB STATEALL COMPRESSORSPARALLEL CONTR.

MULTISAB

TimersTIMERS

TIMERSTIMER SETUPSERVICE TIMERS

DiagnosisDIAGNOSIS

INSPECT OLD ALARMSMISC.FUNCTIONSSOFTWARE VERSION

Calibrate

CALIBRATEPRESS TRANSDUCERBRINE TEMP.CAPACITY

Config.

REFRIGERANTCONTROL ONVOLUME RATIO

TYPE

Language

CONTRASTLANGUAGE GB

H

Auxiliary output

AUXILIARY OUTPUTACTIVE WHENAT MAX.CAP

4-20 MA input4 MA20 MA

SUCT.PRES

Analog. inputPRES. INP 1PT 100 INP 1

EXT.

Dig. outputD.OUTPUTD.OUTPUTD.OUTPUTD.OUTPUT

Dig. inputD.INPUTD.INPUTD.INPUTD.INPUT

Date-timeHOURMINSECDAY

Service-timers

ON TIMESINCE START

HOUR

TimersSTART STARTSTOP STARTSTART DELAYSTOP DELAY

SECSECSECSEC

All compressors

COMPR. # 01 MANUALSYSTEM # 01START # 01RUNNING 100%

Multisab stateSTART NO.SYSTEM NO.SYS.CONTROLLER

HIGH ALARM °C/RHIGH WARN. °C/RLOW WARN. °C/RLOW ALARM °C/RACTUAL SP. °C/RSETPOINT 1 °C/RSETPOINT 2 °C/RNEUTRALZONE °C/RPROP.BAND °C/R

J

K

SUCT.PRES.SUCT.TEMP.SUCT.SUPERH.RUNNING

°C/R°C°C

100%


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Checks during Operation

When the plant has been set for normal operating conditions, an inspection of the plant must be car-ried out. Check for leaks and vibrations in the sys-tem, noise from valves, etc. Particularly variable speed drive (VSD) compressors must be checked

for vibrations due to natural frequency. Rpm re-sulting in vibrations must be locked out in the VSD controller. Check that oil pressure, suction and condensing pressure is within the permissible working range for the compressor.


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14. Transport Instructions

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14. Transport InstructionsThe purpose of this document is to describe:

• The dangers which may occur when the transport instructions and safety precau-tions are not observed.

• How to assemble and transport this equipment in a safe way.

This document is primarily intended for transport supervisors, authorities and personnel who are in-volved in loading, unloading and transporting the equipment.



Copyright © 2003 YORK RefrigerationThis document must not be copied without the written permission of YORK Refrigeration and the contents hereof must not be imparted to a third

party nor be used for any unauthorised purpose. Contravention will be prosecuted.

WDanger!


Safety Precautions

WDanger!

Risk of injury to personnel and damage to equip-ment! In addition to the safety precautions in this document, always read the safety precautions be-longing to this equipment before transport. Failure to comply with safety precautions may cause death or injury to personnel. It may also cause damage to or destruction of the equipment.


262/288 0178-931 - ENGRev. 27.10.03


Transport Data

Weight and Dimensions

When dispatched, the unit is placed on a wooden frame and covered by plastic film. The wooden frame, which is adjusted to the size of the unit, is made so that the unit can be lifted with a forklift truck.

Table 14.1

The weight is exclusive electric motor

Table 14.2 Weight of Compressor Units

Compressor Type

Weight

Kg lb

SMC 104S-L 580 1279

SMC 106S-L 675 1488

SMC 108S-L 740 1631

SMC 112S-L 1250 2756

SMC 116S-L 1350 2976

SMC 104E 600 1323

SMC 106E 700 1543

SMC 108E 770 1698

SMC 112E 1300 2866

SMC 116E 1400 3086

TSMC 108S-L 775 1709

TSMC 116S-L 1400 3086

TSMC 108S-L 800 1764

TSMC 116S-L 1450 3197

Compressor type

Direct driven Belt driven Remarks

Kg lb Kg lb

SMC 104 830 1830 880 1940

SMC 106 925 2039 970 2138

SMC 108 990 2183 1030 2271

SMC 112 1660 3660 1820 4012

SMC 116 1400 3086 1920 4233

TSMC 108 1060 2337 1130 2491 Excl. intermediate cooler

TSMC 108 1400 3086 1410 3109 Incl. intermediate cooler

TSMC 116 1900 4189 2080 4586 Excl. intermediate cooler

TSMC 116 2350 5181 2530 5578 Incl. intermediate cooler


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Table 14.3 Weight of Electric Motors

Personnel RequirementsThe personnel who are to handle the unit during loading, transport and unloading must have taken the necessary courses in the operation of cranes and forklift trucks.

Loading InstructionsLift the packed unit with a forklift truck. As a mini-mum the lifting capacity of the truck must corre-spond to the weight of the unit + the weight of the electric motor + an extra 100 kg for packing.

If unpacked, the unit can be lifted with a crane. The unit must be lifted in the lifting eyes on the unit. Never lift in the lifting eyes of the compressor or the motor separately.

Fig. 14.1

As a minimum the lifting capacity of the crane and the loading capacity of the chains, straps, lifting eyes and shackles must correspond to the weight of the unit + the weight of the electric motor + an extra 100 kg for packing.

Sizes

Motor Type

Schorch Leroy Somer

IP 23 IP 54 PLS LS FLS

kg lb kg lb kg lb kg lb kg lb

IEC 160LIEC 180MIEC 180LIEC 200MIEC 200LIEC 225SIEC 225MIEC 250SIEC 250MIEC 280SIEC 280MIEC 315SIEC 315MIEC 315LIEC 355SIEC 355MIEC 355LIEC 355L

190210240265

3554554806256808759451050

17902095

419462529584

7831003105813781499192920832315

39464619

102173188

235309340

4455706309009401200150016001750

(LA)1900(LB)2150

225381414

518681750

98112571389198420722646330735273858

(LA)1900(LB)2150

8098

128165190

240335360460515

730830

176216282364419

52973979410141135

16091830

78100110

170205235

340445490720785

855

172220243

375452518

750981108015871731

1885

120135184

260290388

39547556585010001050

15101550

265298406

573639855

87110471246187422052315

33293417


264/288 0178-931 - ENGRev. 27.10.03


Preparations before LiftingBefore lifting the unit, make sure that straps/chains are properly secured to lifting eyes/shackles and that the lifting equipment is in good condition.

LoadingTake great care when loading the unit so that it is not damaged. Note in particular that the instru-mentation of the unit is very vulnerable to impacts.

Transport Instructions

WDanger!

Risk of injury to personnel and damage to equip-ment! YORK Refrigeration does not assume re-sponsibility for injury to personnel or damage to equipment caused by the use of transport meth-ods which are not recommended in this document or stated in a separate agreement between a transport company and YORK Refrigeration.

Transport RegulationsIt is the transport company's responsibility that all regulations pertaining to the transport are ob-served.

It is moreover the transport company's responsi-bility that the unit or parts of the unit are properly secured and that they do not shift during the trans-port and thus get damaged.

Unloading InstructionsThe same rules apply as when loading the unit. See therefore Loading Instructions.

Unpacking and Inspecting the UnitSee Section 7, Installation Instructions.

Moving the Equipment to Mounting Site after Unloading

See Section 7, Installation Instructions.

StorageOn delivery the compressor units are charged with a protective gas (N2) with an overpressure of 0.2

bar to prevent moisture from entering the com-pressor. If the equipment is to be stored for a long time, the compressor should be equipped with a service manometer on the evacuation valve so that the pressure can be checked. If the pressure falls below 0.1 bar, recharge with nitrogen (N2).

Place the unit on a level foundation and cover it so that it is protected against dust and dirt. The unit must not be stored with other objects which give off acidic vapours or the like as this can have a corrosive effect on the unit. It is moreover required that the store room is dry and frost-free.

When stored, the unit must be inspected at regu-lar intervals. Every two weeks the compressor and motor must be rotated 8-10 turns to prevent the oil in the bearings from drying. As far as the motor is concerned, check the lubricating nipples and lu-bricate them if necessary.

15. Commissioning Instructions

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15. Commissioning InstructionsThe purpose of this document is to describe:

• The dangers which may occur when the commissioning instructions and safety pre-cautions are not observed.

• How to start-up this equipment in a safe way.

• How to prepare a safe and effective start-up.

This document is primarily intended for inspectors and supervisors.




This document must not be copied without the written permission of YORK Refrigeration and the contents hereof must not be imparted to a third

party nor be used for any unauthorised purpose. Contravention will be prosecuted.

WDanger!


Safety Precautions

WDanger!

Risk of injury to personnel and damage to equip-ment! In addition to the safety precautions in this document, always read the safety precautions be-longing to this equipment before start. Failure to comply with safety precautions may cause death or injury to personnel. It may also cause damage to or destruction of the equipment.


266/288 0178-931 - ENGRev. 27.10.03


Preparations for Commissioning

Final Check of InstallationBefore the plant is put into operation, the installa-tion must be checked one last time, see Section 7, Installation Instructions - Final Check of the Instal-lation.

Personnel RequirementsThe personnel who are going to start up the plant must be well-qualified and have a thorough know-ledge of refrigeration technique. It is moreover necessary that the personnel know the refrigera-tion plant and its construction and mode of opera-tion. The instructions in this manual must be read before start-up.

YORK Refrigeration offers courses which deal with operation of and service on the unit in ques-tion. It is recommended that both the supervisor and the operator take these courses.

TrainingIt must be made sure that all personnel have been trained so that the requirements listed under Per-sonnel Requirements above are complied with.

DocumentationBesides this manual the personnel should be in possession of the following documentation mate-rial before putting the plant into operation:

• Operating Manual

• Starting-up Manual and Instruction Manual for UNISAB II

• Certificates regarding the reciprocating compressor unit

• Installation drawings and functional descrip-tions for the plant

Preparations on the Mounting Site

Final Check of the PlantThe check includes an examination of all parts of the plant and all the connections to the compressor.

Check in particular that

• the piping connections are made as indicat-ed in the installation drawings.

• all electrical connections have been checked.

• the unit and the plant have been pressure tested.

• the coupling between motor and compres-sor are set up as indicated in Section 7, In-stallation Instructions.

• the insulation has been carried out correctly.

• the paint is in order, the screens have been mounted correctly, etc.

Commissioning Instructions

Preparations before the First Start-upBefore start-up, go through the following points:

• Section 10, Operating Instructions -Preparations for Starting.

• UNISAB II's Starting-up Manual - Before Connecting the Voltage.

Go through the following point by point:

Press the Emergency Stop button and connect voltage.

Carry out configuration and setting as well as set-ting of alarms and warnings as described in Be-fore Connecting Voltage in the Starting-up Manual for UNISAB II. Check that set values and alarm values correspond to the operating conditions of


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the plant. However, the values must not exceed the limits in the table of set/alarm values, see Section 9, Settings.

Carry out calibration of pressure transducers as described in Calibration in the Starting-up Manual for UNISAB II. Pressure transducers must be cal-ibrated at atmospheric pressure. The easiest way to do this is to dismount the transducers.

WDanger!

Inadequate or erroneous setting of pressure transducers may result in compressor breakdown or personal injury.

Evacuation and Charging of RefrigerantCheck that the plant is evacuated to a pressure lower than 5 mm Hg. Pressure testing and evacu-ation of the plant is described in detail in Section 7, Installation Instructions.

Check that the prescribed refrigerant corresponds to the specification on the compressor name plate. Charge the prescribed refrigerant. After charging the refrigerant, check all connections and valves for leaks by means of a leak detector.

Start-upThe plant can now be put into operation, SeeSection 10, Operating Instructions - Starting.

After five hours of operation the alignment be-tween motor and compressor must be checked again while the compressor is still warm. If the compressor is belt driven, check the belt ten-sion. Before letting the plant start to work, activate the emergency stop and dismount the main fuses to ensure that the motor does not start uninten-tionally.

Important! Note the procedures for reducing the evaporating pressure.


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Checks to be Performed after Start-up

Check List ✓

Are settings and configuration correct?

Have alarm and warning limits been set correctly?

Have pressure transducers been calibrated?

Is the direction of rotation of the motor correct?

Has the coupling been aligned correctly?

Have the safety valves been adjusted correctly?

Has the plant been evacuated and dried before charging of refrigerant?

Does the plant contain enough oil?

Have valves been set correctly?

Is the capacity regulation correct?

Free passage for cooling water/refrigerant to e.g. oil cooler?

Is the plant leak-proof?

16. Compliance Instructions

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16. Compliance InstructionsThe purpose of this document is to describe:

• The norms and standards which this equip-ment complies with.

• How this equipment complies with the norms and standards.

This document is primarily intended for commis-sioning engineers, inspecting bodies and authori-ties.




This document must not be copied without the written permission of YORK Refrigeration and the

contents hereof must not be imparted to a third party nor be used for any unauthorised purpose. Contravention will be prosecuted.

Conformity with EU RegulationsAccording to current EU regulations, the manufac-turer is under an obligation to document that the product complies with the EU Directive for Ma-chines. This is done by completing a Declaration of Manufacturer, which contains the principal in-formation about the product in question.

The Directive for Machines does not apply to countries outside the EU.

Example of a Declaration of Manufacturer, see Fig. 16.1.

16. Compliance Instructions

270/288 0178-931 - ENGRev. 27.10.03


Fig. 16.1

Declaration of Manufacturer

With reference to EEC's Directive for machines 89/392 EEC as amended by 91/368/EEC - 93/44/EEC. Annex II B for machines to be incorporated.

hereby declare that the below-mentioned product:

is constructed and manufactured in conformity with the above-mentioned EEC Directive.

The product, which is covered by this declaration, may only be used when assembled with or incorporated into another machine/unit and thus in conformity with all relevant provisions.

The following harmonised standards have been applied:

Besides in case of machines with electric equipment:

Operational instruction will be supplied.

Complete technical documentation has been prepared

Agent/dealer stamp

Manufacturer: YORK RefrigerationOperations EuropeChr. X's Vej 201DK-8270 HoejbjergTel.: +45 87367000 - Fax: +45 87367005

Type:_____________________________ Compressor No:____________________

YORK Serial No:____________________ Year:_____________________________

Customer No:______________________

DS/EN 292 Machine safety - Fundamental concepts

DS/EN 294 Machine safety - Dangerous areas and safety distances

DS/EN 418 Machine safety - Emergency functions

EN 60 439-1 Low-voltage switch gear and control gear assemblies - Type-tested and partially type-tested assemblies.

EN 60 204-1 Electrical equipment of industrial machines.

Place and Date: ____________________________

Name and signature ____________________________

17. Certificates

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17. CertificatesThe purpose of this document is to give an overall view of all certificates belonging to screw com-pressors.

This document is mainly intended for inspecting bodies and authorities.





The compressors are made according to the basic specifications for the individual compressor type.

The products comply with current legislation with regard to pressure and material testing.

If the product is to be delivered with certificate, the certificate must be ordered when placing the or-

der. It will not be possible to make a separate cer-tificate for the compressor at a later time.

Approvals• Compressor Units

Are designed to comply with common legis-lation in the EC-countries and former EFTA member states.

• The technical design complies with the re-quirements in the directives, most impor-tantly the "Pressure Equipment Directive" (PED).

Can also be delivered in a design according with the rules of the following classification societies:

Lloyd's Register of Shipping

Det Norske Veritas

Germanischer Lloyd

On request, compressor units can be de-signed to fulfil the standards of other coun-tries and classification societies than the ones mentioned above

17. Certificates

272/288 0178-931 - ENGRev. 27.10.03


20. Final Disposal

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20. Final DisposalThe purpose of this document is to describe how to safely dispose of this equipment or part of it.

This document is primarily intended for the de-commissioning engineers and authorities.





General

Safety Precautions

WDanger!

Before dismantling the plant, read Section 3, Safety Precautions carefully. Failure to do so may result in personal injury or even death.

Dismantling of a cooling unit which is to be scrapped must be carried out in a safe way.

Authorized refrigeration personnel must partici-pate in the first part of the dismantling process as fundamental knowledge of refrigerating systems and the risks involved is required.

Before dismantling the plant, refrigerant and oil must be drained into containers intended for the purpose. Disconnect all electrical connections to the unit. Remove fuses in the main switchboard.

During the dismantling process, the individual ma-chine parts and components must be sorted so that disposal can take place in an efficient way.

WDanger!

Take great care if using cutting tools, e.g. angle grinder or flame cutter, during the dismantling process as pipes or the like will contain oil residue which may ignite. Refrigerant residue does also involve a great risk as HFC and HCFC refrigerants will develop toxic gasses when heated. Make sure that there are no air traps as heating will result in a pressure rise.

Disposal of Machine PartsWhen dismantling the plant, it is important to sort the parts to be disposed of. Compressor, frame, containers, etc. belonging to the category of iron and metal scrap must be delivered to an approved scrap dealer complying with the prevailing rules and regulations of the individual country.

Disposal of Oil and RefrigerantOil and refrigerant must be delivered for destruc-tion or regeneration at a receiving station for haz-ardous waste, including used oil filters. The re-ceiving station must comply with the prevailing rules and regulations of the individual country.

20. Final Disposal

274/288 0178-931 - ENGRev. 27.10.03


Disposal of Electrical ComponentsElectrical and electronic products, e.g. wiring, panels, hardware, etc., must be delivered to a re-ceiving station approved to handle electronic waste. The receiving station must comply with the prevailing rules and regulations of the individual country.

Disposal of BatteriesUsed batteries from e.g. the backup of the compu-ter control must be delivered for destruction at a receiving station. The receiving station must com-ply with the prevailing rules and regulations of the individual country.

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Appendix - SMC/TSMC 100This section includes data sheets and instructions concerning the components and the tables of torque moments.

1. List of torque moments, 4 pages.

2. Danfoss pressure transducer type AKS, 9 pages.

3. Tempress temperature sensor P2208, 3 pages.

4. Valves

Danvalve installation instructions SCV 40-200, 2 pages.PM valves, 10 pagesPilot valve, 3 pages

5. Solenoid valve for oil return

Instruction EVRB-NC, 1 page

6. Danfoss automaticPressure cut-outs type KP, 4 pagesPressure cut-outs type MP, 7 pagesThermostats type KP, 5 pagesThermostatic expansion valves, 9 pagesThermostatic injection valves, 5 pages

276/288 0178-931 - ENGRev. 27.10.03


Fig. 21.1

Table 21.1

Compressor AMR type of

coupling

NominalDistance

Torque moment Max. variation measured with a feeler gauge at a 180° turning of the coupling

C F A B D Pos. 1 Pos. 2

max. mmmm mm Nm Nm Nm

Horizon-tal max.

mm

Vertical min./max.

mm

HPC/SMC104-108

312 S 103,5 25 147 55 44 0,2 0,1/0,3 0,2

SMC112-116

350 S 114,5 27 147 128 44 0,2 0,1/0,3 0,2

CZ

X

F

a

1

2

B A

D

A

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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

Metric thread (ISO 12.9)

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

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

Nm 20 43 167

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Sundry Clearances and Check Dimensions

Bearing clearance

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

Crankshaft end-play

The end-play can be adjusted by means of the gasket under the bearing cover.The gasket is available in the following thicknesses: 0.3, 0.5, 0.75, 1.0, 1.3, 1.5, 1.75 and 2.0 mm.

Piston ring gap

The piston ring gap must be measured with the ring placed in the cylinder liner.

Dimensions of crankshaft bearing journal

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

CMO 1CMP 1

TCMO 1CMO 4

CMO 2TCMO 2

HPO

SMC 65TSMC 65

SMC 100TSMC 1004-10 cyl.

HPC

SMC 100TSMC 10012-16 cyl.

SMC 180TSMC 180

Mk 1 & Mk 2

Main bearings manufacturedmax.

0.080.20

0.080.20

0.080.20

0.080.20

0.080.20

0.140.35

Connecting rodbearings

manufacturedmax.

0.080.15

0.080.15

0.080.15

0.100.20

0.100.20

0.140.30

Piston pinbearings

manufacturedmax.

0.040.10

0.040.10

0.040.10

0.040.10

0.040.10

0.090.20

Pis

ton

Parallel topiston pin

manufacturedmax.

0.18-

0.18-

0.20-

0.20-

0.20-

0.25-

Al right anglesto piston pin

manufacturedmax.

0.110.30

0.110.30

0.110.30

0.150.40

0.150.40

0.350.90

min. 0.30 0.30 0.40 0.40 0.75 0.95

max. 0.55 0.55 0.55 0.64 1.00 1.20

min. 0.25 0.25 0.25 0.33 0.33 0.66

max. 1.00 1.00 1.00 1.30 1.30 1.50

New

Main bearing journals 55 -0.06-0.09 60 -0.06

-0.09 55 -0.06-0.09 80 -0.07

-0.09 80 -0.07-0.09 135 -0.11

-0.14

Connecting rodbearing journals 50 -0.025

-0.040 55 -0.030-0.049 55 0

-0.02 80 0-0.02 80 0

-0.02 135 -0.015-0.040

Intermediate journals 80 -0.010-0.029

Gro

und

dow

n

Main bearing journals 54.5 -0.06-0.09 59.5 -0.06

-0.09 54.5 -0.06-0.09 79.5 -0.07

-0.09 79.5 -0.07-0.09 134 -0.11

-0.14

Connecting rod bearing journals 49.5 -0.025

-0.040 54.5 -0.025-0.040 54.5 0

-0.02 79.5 0-0.02 79.5 0

-0.02 134 -0.015-0.040

Intermediate journals 79.5 -0.010-0.029


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Index

A Accidents with Ammonia .......................................................................................23Accidents with HFC/HCFC .................................................................................... 24Achieving Parallel Shafts in Horizontal Plane ..................................................................................................223Air-Cooled Top and Side Covers ...........................................................................96Air-Cooled Top and Side Covers and Refrigerant-Cooled Oil Cooler ...................96Air-Cooled Top Covers and Water Cooled Side Covers .......................................96Alignment of

Compressor on Base Frame ..........................................................................218Motor on Base Frame ....................................................................................218

Alignment of Unit against Foundation ..................................................................216AMR .....................................................................................................................151Analogue Reading .................................................................................................72anti-clockwise ......................................................................................................140Area of Application ................................................................................................33Areas of Application ...............................................................................................29

B Boring of Hub ....................................................................................................... 149Brine ......................................................................................................................28By-pass system .....................................................................................................45By-pass Valve

SMC .................................................................................................................35

C Capacity Regulation .............................................................................................. 58Capacity Regulation of Thermo Pump ...................................................................92Capacity Stages ....................................................................................................63Caution

Texts Marked with Caution ..............................................................................17Charging of oil .....................................................................................................230Charging the Compressor with Oil ....................................................................... 176Check of the Installation ......................................................................................231Checks during Operation .....................................................................................259Checks to be Performed after Start-up ................................................................268Choice of Electric Motor ......................................................................................141Coils for Solenoid Valves .....................................................................................113Commissioning

Checks to be Performed after Start-up ..........................................................268Preparations ...................................................................................................266Preparations before the First Start-Up ...........................................................266

Commissioning Instructions .................................................................................265Compliance Instructions ......................................................................................269Components ........................................................................................................233Compressor Accessories .......................................................................................97


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Compressor BlockTSMC ...............................................................................................................43

Compressor Name Plate .......................................................................................12Compressor Shaft ................................................................................................149Compressor Units ..................................................................................................71Connecting Rod

SMC .................................................................................................................34Connection Data ..................................................................................................100Connections on SMC

Long block ......................................................................................................105Control Section ....................................................................................................247Conversion of TSMC Mk2 to SMC ........................................................................46Cooling Media ........................................................................................................28Cooling of Compressor and Oil

SMC .................................................................................................................41Cooling system

Booster Compressor ........................................................................................82Pressure Loss ..................................................................................................88R22 ..................................................................................................................81R717 ................................................................................................................81Thermo pump .............................................................................................89, 90Water flow ........................................................................................................87Water pressure ................................................................................................87Water temp. .....................................................................................................87

Cooling Systems ....................................................................................................81Cooling with Thermo Pump ...................................................................................89Correct Centre .....................................................................................................224Coupling

AMR ...............................................................................................................151Coupling Types ....................................................................................................149Crankshaft

SMC .................................................................................................................36

D DangerTexts Marked with Danger ...............................................................................17

Description .............................................................................................................78Additional unloading .........................................................................................64Analogue Reading ...........................................................................................72By-pass system ................................................................................................45Capacity Regulation .........................................................................................58

Solenoid Valves ..........................................................................................60Capacity Stages ...............................................................................................63Conversion of TSMC Mk2 to SMC ...................................................................46Cooling of the Intermediate Gas ......................................................................45Cooling system

R22 .............................................................................................................81R717 ...........................................................................................................81

Determining the Intermediate Pressure IP .......................................................79


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Discharge Pipe Thermostat KP98 ....................................................................73DVEA ...............................................................................................................77High Pressure Cut-out KP15 ............................................................................73Intermediate Cooling

TEAT ..........................................................................................................78TEA-TEX ....................................................................................................78

Intermediate Gas .............................................................................................77Intermediate Pressure Cut-out KP5 .................................................................73Low Pressure Cut-out KP15 ............................................................................73Oil Differential Cut-out MP55 ...........................................................................73Oil Thermostat KP98 ........................................................................................73Regulation of Intermediate Pressure IP ...........................................................79SMC

By-pass Valve ............................................................................................35Connecting Rod ..........................................................................................34Cooling of Compressor and Oil ..................................................................41Crankshaft ..................................................................................................36Cylinder liners .............................................................................................33Discharge Valve .........................................................................................34Draining valve .............................................................................................40Evacuating Valve ........................................................................................40Filter bag ....................................................................................................34Heating Rod ...............................................................................................40Instrumentation ...........................................................................................41Oil Filter ......................................................................................................37Oil Level Glass ...........................................................................................40Oil Pressure Regulating Valve ...................................................................37Oil Pump .....................................................................................................37Pistons ........................................................................................................33Safety spring .............................................................................................. 34Shaft Seal ...................................................................................................38Stop Valves ................................................................................................41Suction Filter .............................................................................................. 34Suction Valve .............................................................................................34

Special unloading 104 ......................................................................................65Standard unloading ..........................................................................................62Start Unloading ................................................................................................60Suction Filters ..................................................................................................45TEA ..................................................................................................................78TEAT ................................................................................................................78Total Unloading ................................................................................................63TSMC

Compressor Block ......................................................................................43Intermediate pressure ................................................................................44Needle bearing ...........................................................................................44Piston Pin Bearing ......................................................................................44

Water Quality ...................................................................................................88Description of Compressor Types ......................................................................... 31Description of Pumping Cycle ...............................................................................92


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Determining the Intermediate Pressure IP ............................................................79Dimension Sketches ....................................................................................100, 120Direction of Rotation ............................................................................................140

Electric Motor .................................................................................................147Direction of Rotation of Electric Motor .................................................................147Discharge GasTemperatures ..............................................................................242Discharge Pipe Thermostat KP98 .........................................................................73Discharge Pressure,PT2 .....................................................................................111Discharge Valve ....................................................................................................34Display .................................................................................................................247

Unisab II .........................................................................................................247DVEA .....................................................................................................................77

E Electric Motor .......................................................................................................141Direction of Rotation ......................................................................................147

Electrical Connections .........................................................................................110Electricity Supply .................................................................................................226Emergency Stop ....................................................................................................16Ensuring Liquid to the Thermo Pump ....................................................................94Evacuating Valve

SMC .................................................................................................................40Explosion-proof ......................................................................................................97Explosion-proof heating .........................................................................................97Explosion-proof solenoid valves ............................................................................97Extended set of tools .............................................................................................97

F Filter bagSMC .................................................................................................................34

Final Check of the Installation .............................................................................231Final Disposal ......................................................................................................273First aid

Accidents with Ammonia ..................................................................................23Accidents with HFC/HCFC ...............................................................................24

Foundation ...........................................................................................................159Mounting Directly on Foundation ...................................................................160

Front Panel ..........................................................................................................247Front Panel of UNISAB II .....................................................................................248Fuses ...................................................................................................................251

H Handling of Compressor and Unit .......................................................................148Heating Element ..................................................................................................113Heating Rod

SMC .................................................................................................................40High voltage ...........................................................................................................22Hot and Cold Surfaces ........................................................................................244


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HubBoring of Hub .................................................................................................149

I Installation and Relocation Safety ......................................................................... 21Installation Instructions

.......................................................................................................................213Instrumentation ......................................................................................................72

SMC .................................................................................................................41Intermediate Cooler Type DVEA ...........................................................................77Intermediate Cooling

Liquid Injection .................................................................................................78TEAT ................................................................................................................78TEA-TEX ..........................................................................................................78

Intermediate Gas .............................................................................................45, 77Intermediate pressure

TSMC ...............................................................................................................44Intermediate Pressure Cut-out KP5 .......................................................................73

K KP 15 ...................................................................................................................245KP 5 .....................................................................................................................245KP 98 ...................................................................................................................245KP15 ......................................................................................................................73KP5 ........................................................................................................................73KP98 ......................................................................................................................73

L Laying the Foundation .........................................................................................159Lifting and Carrying Safety .................................................................................... 20Lifting the compressor Block ...............................................................................148Lifting the compressor Unit .................................................................................. 148Liquid Injection .......................................................................................................78Loading Instructions ............................................................................................ 263Long block .............................................................................................................31

M Machine RoomPlanning .........................................................................................................124

Maintenance Safety ...............................................................................................21Manometers

DescriptionManometers ...............................................................................................74

Marine Installations ..............................................................................................164Max. Power Transmission ...................................................................................155Measured and Calculated temp. ..........................................................................239Menu Tree

SMC ...............................................................................................................255TSMC .............................................................................................................258


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Moment of Inertia .................................................................................................146Motor Dimension .................................................................................................141Motor weight ........................................................................................................118Mounting Directly on Foundation .........................................................................160Mounting Directly on the Foundation ...................................................................218Mounting of Vibration Dampers ...........................................................................161Mounting on Vibration Dampers ..........................................................................217MP 55 ..................................................................................................................245MP55 .....................................................................................................................73

N Needle bearingTSMC ...............................................................................................................44

Nitrogen charge .....................................................................................................71Noise ...................................................................................................................166

Damping Acoustic Noise ................................................................................171Reverberation Time .......................................................................................171

Normal set of tools .................................................................................................97Nozzle size ............................................................................................................49

O Oil Charging .................................................................................................176, 230Oil Consumption ..................................................................................................177Oil Cooling

Settings ..........................................................................................................241Oil Differential Cut-out MP55 .................................................................................73Oil Draining Valve

SMC .................................................................................................................40Oil Filter

SMC .................................................................................................................37Oil Level Glass

SMC .................................................................................................................40Oil Pressure .........................................................................................................112Oil Pressure Regulating Valve

SMC .................................................................................................................37Oil Pump

SMC .................................................................................................................37Oil Return ..............................................................................................................48

Coil for the solenoid valve ................................................................................49Float Valve Controlled ......................................................................................51Parallel Operation ............................................................................................51

Different Et ..................................................................................................55Float valve ..................................................................................................53Same Ct ......................................................................................................57Same Et ......................................................................................................52

Oil returnNozzle size .......................................................................................................49Solenoid Valve Controlled ................................................................................48

Oil Separators ......................................................................................................178


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Oil Thermostat KP98 .............................................................................................73One-stage ..............................................................................................................32Opening the Cabinet ............................................................................................ 246Operating Instructions .........................................................................................243Operating Limits Diagrams .................................................................................. 125

P Parallel Operation ..................................................................................................51Parallel Shafts .....................................................................................................223Personal Safety .....................................................................................................19Physical and Connection Data ..............................................................................99Piping Connections ..............................................................................................225Piston Pin Bearing

TSMC ...............................................................................................................44Pistons

SMC .................................................................................................................33Planning the Machine Room ...............................................................................124Power Transmission ............................................................................................ 155Preliminary Installation ........................................................................................223Preparations for Starting ......................................................................................250Pressure ..............................................................................................................243Pressure and Temperature Setting .....................................................................238Pressure levels ....................................................................................................175Pressure Loss ........................................................................................................88Pressure Testing .................................................................................................228Pressure transmiters

Discharge Pressure,PT2 ................................................................................111Oil Pressure ...................................................................................................112Suctiaton Pressure,PT1 .................................................................................111

Pressure TransmittersAKS32-AKS2050 ...........................................................................................111

PT1 ......................................................................................................................111PT2 ......................................................................................................................111PT3-PT1 ..............................................................................................................112Purging a Refrigeration Plant ................................................................................27

Q Quick ReferenceOne Stage ......................................................................................................253SMC ...............................................................................................................253TSMC .............................................................................................................256

R Refrigerants .....................................................................................................27, 28Regulation of Intermediate Pressure IP .................................................................79

S Safety at Servicing .................................................................................................16Safety Instructions


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High voltage .....................................................................................................22Installation and Relocation ...............................................................................21Lifting and Carrying Safety ...............................................................................20Maintenance Safety .........................................................................................21Personal Safety ................................................................................................19Set-Up and Operation ......................................................................................21Tool Safety .......................................................................................................20Work Area Safety .............................................................................................20

Safety Precautions ................................................................................................19Settings ................................................................................................................237

Oil Cooling .....................................................................................................241Unisab II .........................................................................................................239

Set-Up and Operation Safety ................................................................................21Shaft Seal

SMC .................................................................................................................38Short blocks ...........................................................................................................31Sign

CAUTION .........................................................................................................14Cold surfaces ...................................................................................................15Dangerous noise level .....................................................................................15Hazardous substance ......................................................................................15High Voltage ....................................................................................................14Internal overpressure .......................................................................................15Internal Protection ............................................................................................15Temperature of Tangible Surfaces ..................................................................15

Signs and Warnings ................................................................................................9Signs in Instructions ..............................................................................................14SMC

Cylinder liners ..................................................................................................33Designation ......................................................................................................31Safety spring ....................................................................................................34Type E ..............................................................................................................31Type L ..............................................................................................................31Type S ..............................................................................................................31

SMC/HPC 104 Special Unloading .........................................................................65Sound Data

How to check .................................................................................................170Spare parts set ......................................................................................................97Special unloading 104 ...........................................................................................65Specification of Materials .....................................................................................174Start Unloading ......................................................................................................60Start up

SMC/HPC 100 - HFC/HCFC - 25% load ........................................................145Start up torque SMC/HPC 100 R717 25% load ...................................................144Starting ........................................................................................................250, 251Starting Torque ....................................................................................................143Stop Valves

SMC .................................................................................................................41Structure of the Thermo Pump ..............................................................................90


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Suctiaton Pressure,PT1 .......................................................................................111Suction Filter

SMC .................................................................................................................34Suction Filters ........................................................................................................45

Round holes .....................................................................................................45Square holes ....................................................................................................45

Suction ValveSMC .................................................................................................................34

T TEA ........................................................................................................................78Technical Data .....................................................................................................116Technical Description ............................................................................................29Temperature Sensors ..........................................................................................112

Discharge Gas TT5 ........................................................................................112Oil TT6 ...........................................................................................................112Suction Gas TT7 ............................................................................................ 112

Test Pressure ......................................................................................................175Test pressure ....................................................................................................... 228Test Pressure Levels ...........................................................................................175TEX ........................................................................................................................78The compressor must NOT be used .....................................................................30Thermo Pump

Capacity Regulation .........................................................................................92Thermo pump ........................................................................................................89

Description of the Pumping Cycle ....................................................................92Ensuring Liquid ................................................................................................94Power Connection ............................................................................................95Structure ..........................................................................................................90

Thermodynamic Liquid Trap ..................................................................................50TLT Thermodynamic Liquid Trap ..........................................................................50Tool Safety ............................................................................................................20Total Unloading .....................................................................................................63Transport

Data ...............................................................................................................262Instructions .....................................................................................................261

TT5 ......................................................................................................................112TT6 ......................................................................................................................112TT7 ......................................................................................................................112TWA-Werte ............................................................................................................25Two-stage ..............................................................................................................32Two-stage Compressors

TSMC ...............................................................................................................43Type

E .......................................................................................................................31L .......................................................................................................................31S .......................................................................................................................31

Types of Spare Parts Set ......................................................................................98


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U UNISAB II ..............................................................................................................75Operating Mode .............................................................................................251Settings ..........................................................................................................239

Unisab II ..............................................................................................................246Control Section ..............................................................................................247Display ...........................................................................................................247Front Panel ............................................................................................247, 248Fuses .............................................................................................................251Menu Tree SMC .............................................................................................255Menu Tree TSMC ..........................................................................................258Quick Reference ............................................................................................253Quick Reference SMC ...................................................................................253Quick Reference TSMC .................................................................................256Starting ...........................................................................................................251

Unit Pipe System Name Plate ...............................................................................11

V Valve Position during Operation ..........................................................................250V-Belt Drive .........................................................................................................153

Construction ...................................................................................................157Motor pulley ...................................................................................................158

V-Belts and Pulleys .............................................................................................154Ventilation ............................................................................................................243Vessel Name Plate ................................................................................................12Vibration Dampers

Mounting ........................................................................................................161Vibration dampers .................................................................................................97Vibration Data ......................................................................................................173

W WarningTexts Marked with Warning .............................................................................17

Warnings in Instructions ........................................................................................17Water flow ..............................................................................................................87Water pressure ......................................................................................................87Water Quality .........................................................................................................88Water temp. ...........................................................................................................87Weight of Electric Motors .............................................................................118, 263Welding Nipples for ANSI ....................................................................................104Welding Nipples for R-KB ....................................................................................103Work Area Safety ..................................................................................................20

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