SABROE Air Compresser Technical Manual
SABROE Air Compresser Technical Manual
SABROE Air Compresser Technical Manual
Some of these variants are discussed in this instruction manual, even if they are not featured on
your particular unit.
Compressor type
104
SMC
TSMC
106
108
S
E
112
116
Designation
Compressor no.
01 introduction.fm
Refrigerant
Control
R717
Other _________
Compressor
cooling
Thermopump
Water cooled top and side covers
Air cooled top and side covers
Oil cooling
Oil cooling
Drive type
Coupling
V-belts
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1. Introduction
1. Introduction
The purpose of this manual is to provide the operating personnel with a thorough knowledge of the
compressor as well information about:
Service schedules.
curring during the warranty period where this is attributable to incorrect operation.
YORK Refrigeration's manual concept covers six
standard manuals: Engineering, Operating, Service, Installation and Commissioning, Transport
and Spare Parts. Therefore, references may be
made to sections which are not part of this manual.
This manual was produced by:
YORK Refrigeration
Chr. Xs Vej 201
DK-8270 Hoejbjerg
Denmark
Copyright 2003 YORK Refrigeration
This manual 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.
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
3
9
10
11
12
12
14
14
14
15
15
15
16
16
17
17
17
17
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Safety Instructions and Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Personal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Work Area Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tool Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lifting and Carrying Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation and Relocation Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Set-Up and Operation Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Materials Used with this Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
First Aid for Accidents with Ammonia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Basic Rules for First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
First Aid Measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
First Aid for Accidents with HFC/HCFC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Refrigerant no.: R134a - R505A - R507 - R22, etc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Basic Rules for First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Protecting the Operator as well as the Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Furthermore, it can be said about refrigerants: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Purging a Refrigeration Plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubricating Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
19
19
20
20
20
21
21
21
22
23
23
23
23
24
24
24
24
25
26
27
28
28
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Technical Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Areas of Application of the Reciprocating Compressor Unit . . . . . . . . . . . . . . . . . . . . . . . .
Description of the Compressors Compressor Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
One-stage Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Two-stage Compressors Type TSMC 100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston Pin Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Suction Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conversion of TSMC Compressors from Two-stage to One-stage . . . . . . . . . . . . . . . . . . .
Oil Separator Type OVUR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mode of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selecting an Oil Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Return to the Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermodynamic Liquid Trap (TLT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Return in Connection with Parallel Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Capacity Regulation of Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Capacity Regulation and Unloading of Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Start Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Regulating Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Schematic Drawings, Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Variable speed drive (VSD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Instrumentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manometers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling of the Intermediate Discharge Gas on TSMC Compressors . . . . . . . . . . . . . . . . .
Automatic Regulation of Intermediate Pressure IP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Determining the Intermediate Pressure IP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling Systems for Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard Cooling Systems for Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting of Cooling Water Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Loss in the Cooling System in SMC/TSMC Compressors . . . . . . . . . . . . . . . . . .
1c: Cooling with Thermo Pump - R717 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description of the Pumping Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ensuring Liquid to the Thermo Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Types of Spare Parts Set: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29
29
31
33
33
43
43
44
45
46
47
47
47
48
50
51
52
55
57
58
58
60
61
62
70
71
72
74
77
79
79
81
81
81
83
88
89
92
94
95
98
99
99
100
100
105
108
110
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113
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data for the SMC 100 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Weight of Electric Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimension Sketches of Compressor Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Planning the Machine Room . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating Limits Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Direction of Rotation of the Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Choice of Electric Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting Torque of the Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Start up torque SMC 100 R717 25% load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Moment of Intertia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Direction of Rotation of Electric Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Handling of Compressor and Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
V-Belt Drive for SMC/TSMC 100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Construction of V-Belt Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Laying the Foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting of Vibration Dampers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Marine Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Noise from Compressors and Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Noise Data for Reciprocating Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reverberation Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vibration Data for Compressors - All Compressor Types . . . . . . . . . . . . . . . . . . . . . . . . . .
Test Pressure Levels for Standard Compressors and Components . . . . . . . . . . . . . . . . .
Charging the Compressor with Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selecting Oil Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Data Sheet for Listed Sabroe Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
List of Part Numbers for Available Sabroe Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
List of Major Oil Companies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selecting Lubricating Oil for SABROE Reciprocating Compressors . . . . . . . . . . . . . . . . .
Oil Changing Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Data Sheet for Listed Sabroe Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
List of Part Numbers for Available Sabroe Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
List of Major Oil Companies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
115
116
118
119
120
124
125
140
141
141
143
144
146
147
148
149
151
153
153
155
157
158
159
161
164
166
170
171
173
175
176
177
177
186
187
191
192
197
198
199
211
Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
213
213
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Installation Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Personnel Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preparing the Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tools and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ordinary Hand Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Local Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Space Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preparing the Mounting Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lifting Accessories and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preparing Lifts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lifting and Loading Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unpacking and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disposal of Materials which are not Reusable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Moving the Equipment to the Mounting Site after Unloading and Unpacking . . . . . . . . . . .
Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1. Alignment of Unit against Foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting on Vibration Dampers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting Directly on Foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. Alignment of Compressor on Base Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3. Alignment of Motor on Base Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting and alignment of coupling type AMR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4. Installation and alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preliminary installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Achieving correct centre height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Achieving parallel shafts in vertical plane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Final installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preliminary Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Achieving Parallel Shafts in Horizontal Plane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Achieving Correct Centre Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Achieving Parallel Shafts in Vertical Plane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Final Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5. Piping Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6. Connecting Electricity Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7. Pressure Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8. Oil Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Final Check of the Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
213
213
214
214
214
214
214
214
214
215
215
215
215
215
215
216
216
217
218
218
218
219
219
220
221
222
222
222
223
223
223
224
224
224
225
226
228
230
231
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Regulating Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Directly Driven . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Belt Driven . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
233
233
233
233
233
234
234
234
234
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Oil Separators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Coolers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Regulating Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electromechanical Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNISAB II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Transducers, marked PT1, PT2, PT3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Temperature Sensors, marked TT5, TT6 and TT7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heating Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
234
234
235
235
236
236
236
236
236
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Qualification Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNISAB II Reading, Safety and Capacity Regulating System . . . . . . . . . . . . . . . . . . . . . .
Notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
237
237
237
239
240
Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hot and Cold Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Qualification Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor Control and Alarm Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alarms and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNISAB II Reading, Safety and Capacity Regulating System . . . . . . . . . . . . . . . . . . . . . .
Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recording Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Menu Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preparations for Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating Mode UNISAB II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checks during Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
243
243
243
243
244
244
245
245
245
247
247
247
248
249
250
251
251
259
Transport Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transport Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Personnel Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loading Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preparations before Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transport Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unloading Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
261
261
262
263
263
264
264
264
264
264
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Commissioning Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preparations for Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Final Check of Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Personnel Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preparations on the Mounting Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Final Check of the Plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Commissioning Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preparations before the First Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Evacuation and Charging of Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checks to be Performed after Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
265
265
266
266
266
266
266
266
266
266
266
267
268
Compliance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conformity with EU Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
269
269
Certificates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
271
271
Final Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disposal of Machine Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disposal of Oil and Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disposal of Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disposal of Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendix - SMC/TSMC 100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque Moments for Screws and Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sundry Clearances and Check Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
273
273
273
273
273
274
274
275
277
278
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
279
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This document describes the importance of the individual signs which are attached to the
YORK Refrigeration products.
WDanger!
Risk of injury to personnel and damage to equipment! Always read the safety precautions belonging to this equipment before starting the installation process. Failure to comply with safety precautions may cause death or injury to personnel. It
may also cause damage to or destruction of the
equipment
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If the unit has been approved by an authority, the design code will be shown here.
Approval no
If the unit has been approved by an authority, the approval no will be shown here.
Pressure system
Low pressure side of compressor piping is
referred to as LP.
High pressure side of compressor piping is
referred to as HP.
Fluid/Group
Refrigerant designation according to
ISO817 or fluid group according to directive
67/548/EEC.
Design temperature, TS
Shows min and max temperatures for which
the pipe system including components have
been designed.
CE xxxx
The four digits compose the registration no
of the notified body in charge of the assessment modules for the vessel.
Refrigeration
DK 8270 Hjbjerg
Unit Pipe System
2516-328
Year
Type
Identification No
Design Code
Approval No
LP
Pressure System
Fluid/Group
HP
Allowable Pressure
Max
PS
Bar
PT
Bar
Design Temperature
TS
Min/max
0062
Type
Manufacturer's type designation.
Year
Year of manufacture.
Identification no
Individual no for identification of supplied
pipe system.
Design code
For PED orders: EN 378-2
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Fig. 2.3
Fig. 2.4
Refrigeration
DK 8270 Hjbjerg
Compressor
No
Refrigeration
2516-327
DK 8270 Hjbjerg
Beholder/Vessel/
Behalter
Year
Beregningsnorm/Design
code/ Berechnungsnorm
RPM
Swept Volume
m3/h
Allowable Pressure
bar
Test Pressure
Godkendelsesnr
Approval no
Abnahme nr
bar
Compressor no
Compressor manufacturing number.
Year
Year of manufacture.
Type
Manufacturer's type designation.
Nominal speed
Shows rotational speed of drive shaft at typical running condition.
Swept volume
Shows swept volume of compressor in m3/h
at nominal speed.
Allowable pressure
Shows max working pressure of compressor.
Volumen/ Volume
Svb/Shell/Mantel Rr/Tube/Rohr
bar
C
-L.
0062
Vessel no
Vessel number stated by
YORK Refrigeration.
Year
Year of manufacture.
Type
Manufacturer's type designation.
Design code
Shows the design code according to which
the vessel was manufactured.
Approval no/CAT
Shows the approval no of the vessel issued
by the relevant authority as well as the category according to PED 97/23/EEC,
Article 9.
Side
Refers to the columns Shell and Tube.
Test pressure
Shows pressure at which compressor enclosure has been strength tested.
12/288
/CAT.
Side/Seite Medie/Media
Tilladeligt tryk/Allowable pressure/ZulsPS
siger Druck
Tilladelig temp./Allowable
temp./Zulssiger Temp.
r
Year
Jahr
No
Type
Type
Nominal Speed
2516-326
0178-931 - ENG
Rev. 27.10.03
Media
Shows the refrigerant designation according to ISO817.
Allowable temperature, TS
Shows min and max temperatures for which
the vessel has been designed.
Allowable pressure, PS
Shows min and max pressure relative to atmospheric pressure for which the vessel or
vessel part has been designed.
Volume
Shows volume of the vessel in litres.
CE xxxx
The four digits compose the registration no
of the notified body in charge of the assessment modules for the vessel.
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Signs in Instructions
The Sign: CAUTION
A CAUTION tag like the one illustrated below is
fixed to the compressor. The sign imposes the users to read the Safety Precautions section in the
manual before handling, operating or servicing
the compressor and unit.
Caution
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 Representative, 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 marcha o dar servicio al compresor y la unidad, leer la seccin Precauciones de
seguridad en el Libro de Instrucciones.
Es respondabilidad del operaro o de su
patrn, que el libro de instrucciones
permanezca siempre al alcance de la
mano.
Esta seal no debe de ninguna manera
2516-297
suprimirse o daarse.
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Pfyldt beskyttelsesgas
Charged with inert gas
Enthlt Schutzgas
Charg du gaz protecteur
Contiene gas protector
N2
0,2 bar
3 PSI
1534-169
Hazardous substance!
Internal overpressure!
Cold surfaces!
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Emergency Stop
Fig. 2.5
Emergency stop
Fig. 2.6
Springs
Top cover
Make sure that the motor cannot start up inadvertently. It is recommended to remove
all main fuses.
16/288
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Warnings in Instructions
This section describes warnings used in instructions pertaining to YORK Refrigeration equipment.
Information of importance to the safety of personnel or equipment is given at three levels.
Danger!
Warning!
Caution!
Failure to observe information marked with Danger! may cause death or serious injury to personnel or even to a third party.
WWarning!
Risk of damage to compressor! Always consult
your supplier before using a compressor under
operating conditions outside the specified working
range.
WCaution!
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.
0178-931 - ENG
Rev. 27.10.03
17/288
18/288
0178-931 - ENG
Rev. 27.10.03
3. Safety Precautions
3. Safety Precautions
The purpose of this document is to provide general 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 was produced by:
03 safety precautions.fm
YORK Refrigeration
Chr. Xs Vej 201
DK-8270 Hoejbjerg
Denmark
Copyright 2003 YORK Refrigeration
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.
W Danger!
Risk of injury to personnel and damage to equipment! Always read the safety precautions belonging 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.
W Warning!
Read related safety precautions before operating
the compressor/unit. Failure to follow safety instructions may result in serious personal injury or
death.
Important!
The safety precautions for this
YORK Refrigeration compressor have been prepared to assist the operator, programmer and
0178-931 - ENG
Rev. 27.10.03
b.
c.
19/288
3. Safety Precautions
Before lifting or carrying a compressor/unit or other parts, determine the weight and size by means
of e.g. tags, shipping data, labels, marked information or manuals.
Never operate or service this equipment if affected by alcohol, drugs or other substances or if in a
condition which decreases alertness or judgment.
Tool Safety
Always make sure that the hand tools are in proper working condition.
Remove hand tools such as wrenches, measuring
equipment, hammers, etc. from the compressor/unit immediately after use.
20/288
Never place any part of your body under a suspended 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 equipment, 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 lifting 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.
0178-931 - ENG
Rev. 27.10.03
3. Safety Precautions
W Warning!
Failure to follow safety instructions on this page
may result in serious personal injury or death.
03 safety precautions.fm
0178-931 - ENG
Rev. 27.10.03
Safety guards, shields, barriers, covers and protective devices must not be removed while the
compressor/unit is operating.
All safety features, disengagements and interlocks must be in place and function correctly before this equipment is put in operation. Never bypass or wire around any safety device.
Keep all parts of your body off the compressor/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 Safety
Do not attempt to perform maintenance on the
compressor unit until you have read and understood all the safety instructions.
Assign only qualified service or maintenance personnel trained by YORK Refrigeration to perform
maintenance and repair work on the unit. They
should consult the service manual before attempting 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 compressor/unit.
Before removing or opening any electrical enclosure, 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-
21/288
3. Safety Precautions
W Danger
HIGH VOLTAGE!
Before working on any electrical circuits, place
the Main Disconnect Device of the compressor/unit in the "OFF" position and lock it. Dismantle the main fuses to the compressor unit.
Unless expressly stated in applicable
YORK Refrigeration documentation or by appropriate YORK Refrigeration Field Service
Representative, do NOT work with the electrical power "ON". If such express statement or
advice exists, 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.
FAILURE TO FOLLOW THIS INSTRUCTION
MAY RESULT IN DEATH OR SERIOUS
PERSONAL SHOCK INJURY.
When maintenance is to be performed in an area
away from the disconnect, and the switch is not
locked, tag all start button stations with a DO
NOT START tag.
Adequate precautions such as warning notices or
other equally effective means must be taken to
prevent electrical equipment from being activated
electrically when maintenance work is being performed.
22/288
0178-931 - ENG
Rev. 27.10.03
3. Safety Precautions
W Warning!
No plant can ever be said to be too safe - safety is
a way of life.
General
03 safety precautions.fm
Ammonia is not a cumulative poison. It has a distinctive, 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 voluntarily in hazardous concentrations. Since ammonia 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 limited concentrations, ammonia can form ignitable
mixtures with air and oxygen and should be treated with respect.
0178-931 - ENG
Rev. 27.10.03
23/288
3. Safety Precautions
W Warning!
No plant can ever be said to be too safe - safety is
a way of life.
General
HFC/HCFC form colourless and invisible gasses
which are heavier than air and smell faintly of
chloroform at high concentrations.
Characteristics:
non-toxic
non-inflammable
non-explosive
non-corrosive
24/288
0178-931 - ENG
Rev. 27.10.03
3. Safety Precautions
W Warning!
No plant can ever be said to be too safe - safety is
a way of life.
Increasing industrialisation threatens our environment. It is therefore absolutely imperative to protect nature against pollution.
To this end, many countries have passed legislation 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.
03 safety precautions.fm
Halogenated refrigerants
HFC
Vol.%
Warning smell
Vol.%
Rev. 27.10.03
CO2
HCFC
R134a
R404a
R407C
R410a
R507
R22
R717
R744
0.1
0.1
0.1
0.1
0.1
0.1
0.005
0.5
Unit
TWA
Time weighted
average during a
week
0178-931 - ENG
Ammonia
0.2
0.002
25/288
3. Safety Precautions
If released into the atmosphere, halogenated 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 contribute to an intensification of the greenhouse
effect. They must, therefore, never be released into the atmosphere. Use a separate
compressor to draw the refrigerant into the
plant condenser/receiver or into separate
refrigerant cylinders.
Ammonia
26/288
0178-931 - ENG
Rev. 27.10.03
3. Safety Precautions
When purging an R717 plant, use an approved air purger. The purged air must pass
through an open container of water for any
remaining R717 to be absorbed. The water
Note: The occurrence of air is usually an indication of poor maintenance or lack of thoroughness
at installation.
03 safety precautions.fm
0178-931 - ENG
Rev. 27.10.03
27/288
3. Safety Precautions
Cooling Media
Salt 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 refrigeration 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
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.
28/288
0178-931 - ENG
Rev. 27.10.03
4. Technical Description
4. Technical Description
The 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.
frigerants: R717 - R22 - R134a - R407C R404A - R507 - R600 - R600A - R290 LPG. This manual only deals with the ones
written in bold letters.
The compressors can be used with other refrigerants, but only following a written agreement with YORK Refrigeration.
The compressors are approved for application in an explosion-prone environment, provided they have been fitted with explosion-proof equipment. This can be seen
from the Ex nameplates, , fixed on each
unit.
04 technical description.fm
0178-931 - ENG
Rev. 27.10.03
Fig. 4.1
T2516273_0
Please, note that specially made tools which cannot cause any sparks must be used in connection
with maintenance work on the compressor.
29/288
4. Technical Description
WWarning!
The compressor must NOT be used:
As an air compressor.
WDanger!
YORK Refrigeration does not take any responsibility for injuries to personnel or damage to equipment resulting from using this equipment for other
purposes than the ones stated above.
Application of Combustion Engines
If combustion engines are installed in rooms containing refrigeration machinery or rooms where
there are pipes and components containing refrigerant, make sure that in case of leakage the combustion 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 refrigerant; at worst this may lead to corrosion and damage of the engine.
30/288
0178-931 - ENG
Rev. 27.10.03
4. Technical Description
Fig. 4.2
04 technical description.fm
Short Block
SABROE
Long Block
0178-931 - ENG
Rev. 27.10.03
31/288
4. Technical Description
The operating limits (including number of revolutions) depend on the compressor type and refrigerant. As the extension of the operating limits is an
ongoing process, please make sure that the diagram in question is the latest revision before making a conclusion.
SMC 108 L
Compressor type:
Cylinder Diameter: 100 mm
Number of Cylinders: 4-6-8-12 or 16
Stroke: S, L or E
Two-stage compressor
TSMC 116 S
Compressor type:
Cylinder Diameter: 100 mm
Number of Cylinders: 8 or 16
Stroke: S, L or E
An entire list of the compressor series can be
seen in the table Technical Data for SMC 100 Series 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.
DK 8270 Hjbjerg
Compressor
No
Refrigeration
2516-327
Year
Type
Nominal Speed
RPM
Swept Volume
m3/h
Allowable Pressure
Test Pressure
32/288
bar
bar
0178-931 - ENG
Rev. 27.10.03
4. Technical Description
Compressor Description
One-stage Compressors
Fig. 4.3
20
04 technical description.fm
19H
19A
0178-931 - ENG
Rev. 27.10.03
ring ensuring optimum tightness, low oil consumption as well as long life.
33/288
4. Technical Description
Fig. 4.4
Piston
17B
TSMC HP
18
17A
17B
SMC and
TSMC LP
34/288
17
0178-931 - ENG
Rev. 27.10.03
4. Technical Description
must be disposed of according to existing environmental legislation, see also Section 11 Maintenance Instructions and Section 20 Final Disposal.
Fig. 4.6
24
04 technical description.fm
34A
34C
34E
34B
24C
24B
0178-931 - ENG
Rev. 27.10.03
35/288
4. Technical Description
Fig. 4.9
49A
6
16
36/288
0178-931 - ENG
Rev. 27.10.03
4. Technical Description
Fig. 4.10
Fig. 4.11
49A
Pointed screw
04 technical description.fm
0178-931 - ENG
Rev. 27.10.03
Fig. 4.12
Pos. 33A
External oil filter, pos. 9A. After the oil pump, the
oil is furthermore filtered in an external oil filter of
the full flow filter type, pos. 9A, before it is led into
the lubricating system. The filter element is a disposable 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 reducing the refrigerant pressure on the compressor.
37/288
4. Technical Description
Fig. 4.13
4D
Fig. 4.14
4E
4Q
4F
4L
11B
4E
4D
4F
4K
9A
11A
4L
4k
9A
38/288
0178-931 - ENG
Rev. 27.10.03
4. Technical Description
Fig. 4.15
Oil diagram
4L-1
PDI
4N-1
H
9A
04 technical description.fm
4D-1
4E-1
4K-1
11A-1
33A-1
0178-931 - ENG
Rev. 27.10.03
39/288
4. Technical Description
Fig. 4.16
Shaft seal
Fig. 4.17
Pos. 10
23
1B
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 problematic to maintain the oil temperature sufficiently
high, it may be an advantage to keep the heating
cartridge on during operation.
40/288
57
0178-931 - ENG
Rev. 27.10.03
4. Technical Description
Fig. 4.18
25-3
42
25-4
04 technical description.fm
0178-931 - ENG
Rev. 27.10.03
41/288
42/288
Name plate
45J -- 1
D
D
45
39B -- 1
99
UNISAB II
31C -- 1
31A
30A
31C -- 1
39A -- 1
D
45
39B -- 1
safety system
UNIS AB II
31C -- 1
30A
31C -- 1
31A
99
Fig. 4.19
39
Name plate
45J -- 1
39
39A -- 1
4. Technical Description
Instrumentation
0178-931 - ENG
Rev. 27.10.03
4. Technical Description
04 technical description.fm
TSMC 100 compressors are connected to installations where the compression ratio (PC/PE) is
higher than the permissible compression ratio
for one-stage compressors. This is described in
detail in Section 6, Technical Data, Operating Limits.
As mentioned previously all compressor types in
the SMC 100 and TSMC 100 series - with a few
exceptions - are built up of the same components
and with the same facilities.
However, the TSMC 100 compressors
deviate on the following points:
Compressor Block
The interior of the compressor block is constructed 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 116:
12 low-pressure (LP) cylinder
4 high-pressure (HP) cylinder
0178-931 - ENG
Rev. 27.10.03
43/288
4. Technical Description
Fig. 4.20
17B
TSMC HP
17A
17B
TSMC LP
17
19M
44/288
0178-931 - ENG
Rev. 27.10.03
4. Technical Description
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 compressors and is characterised by square holes in
the shell and openings at both ends.
Fig. 4.22
TSMC 108
HP
04 technical description.fm
LP
TSMC 116
LP
HP
Depending on the type of refrigerant and the suction and discharge pressures, a by-pass system
is sometimes used to regulate the intermediate
pressure PI in order to prevent it from falling below
the specified pressure.
The system is either built onto the compressor at
the factory or mounted on the refrigeration plant if
several two-stage compressors work in parallel.
0178-931 - ENG
Rev. 27.10.03
45/288
4. Technical Description
3.
4.
5.
Ensuring that the correct suction and discharge valves are fitted.
6.
7.
b.
Altering the compressor and changing the refrigerant from R717 to HFC/HCFC at the
same time
c.
Altering the compressor and changing the refrigerant from HFC/HCFC to R717 at the
same time
2.
46/288
Moreover, it is necessary to replace the compressor name plate and the name plates on the safety
valves.
Please contact YORK Refrigerations After Market Sales Department for further information.
0178-931 - ENG
Rev. 27.10.03
4. Technical Description
Fig. 4.24
Oil Separator
A
04 technical description.fm
Oil Separator
Mode of Operation
The 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 separated from the discharge gas. The filters consist
of a stainless steel wire mesh which usually needs
no cleaning and which is not worn down. Consequently, the filters cannot be removed from the oil
separator.
0178-931 - ENG
Rev. 27.10.03
L
A: Discharge gas inlet
B: Discharge gas outlet
L: Oil return to compressor
47/288
4. Technical Description
Valve block A
Pos. 80A-1
Solenoid valve
Orifice
Pos. 80B-1
stop valve
Filter
48/288
TLT valve
Pos. 80C-1
0178-931 - ENG
Rev. 27.10.03
4. Technical Description
In valve block, pos. A, Fig. 4.26, the oil first passes a stop valve which is normally completely
open. This is not a regulating valve and it is
closed only during maintenance work on the compressor and during cleaning of the filter in the
valve block.
Fig. 4.26
Inlet
04 technical description.fm
Nozzle
Outlet
Wire mesh
0178-931 - ENG
Rev. 27.10.03
Coil Sizes
220/230 Volt
50/60 Hz
10 Watt
115 Volt
50/60 Hz
10 Watt
240 Volt
50 Hz
10 Watt
49/288
4. Technical Description
4
1
6
Replace the cap - no gasket is required but a suitable high temperature anti-sieze grease without
copper should be applied to the threads.
4 : Strainer
5 : Strainer Cap
6 : Gasket
50/288
1 : Housing
2 : Cap
3 : Disc
Mounting
In principle, the liquid trap can function in all positions but to minimise uneven wear (and thereby
achieving maximum life time) mounting it in a horizontal line with the cap up or down is recommended. See also Fig. 4.25.
The surface of the connection is machined to
make a tight sealing using Al gasket.
Fig. 4.28
TLT 15
Reciprocating
compressor
EVRB
245893
Nozzle 3.3 mm
0178-931 - ENG
Rev. 27.10.03
4. Technical Description
The pipe connection with valve B acts as a pressure equalizer between the two vessels. The float
can be dismantled for servicing.
04 technical description.fm
To the compressor
0178-931 - ENG
Rev. 27.10.03
However, also in modern, automated R717 refrigeration 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 description of the three systems most commonly
used.
The following passages describe each of the
three systems in general. For more detailed information, please contact YORK Refrigeration.
51/288
4. Technical Description
System A
System A is used where two or more compressors 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.
Fig. 4.30
Principle Diagram
Standard
Oil seperator with solenoil valve
controlled oil return
Alternative
Oil seperator with float valve
controlled oil return
3
4
10
9
14
12
14
9
11 13
15
16
Table 4.2
1.
Compressor
9.
Oil vessel
2.
Float valve
10.
3.
Filter
11.
Solenoid valve
4.
Stop valvet
12.
5.
Oil separator
13.
Filter
6.
14.
Heating cartridge
7.
Non-return valve
15.
8.
Float valve
16.
52/288
0178-931 - ENG
Rev. 27.10.03
4. Technical Description
Pipe
connection
Vent valve
Oil level glass
on compressor
04 technical description.fm
To common
suction line
15
16
14
240 W
To float
valves
0178-931 - ENG
Rev. 27.10.03
53/288
4. Technical Description
The Oil Return Systems from the Oil Separators are the same as the ones described in Oil return to the compressor in this section. The only difference is that the oil return system is not connected to the compressor but taken to the common oil
vessel, pos. 9.
float valves, pos. 2. Solenoid valve, pos. 11, closes when the plant stops and all the compressors
are stopped.
Fig. 4.33
In case the oil return system from the oil separators is controlled by a float valve, which is also described in this section, it will be necessary to
mount a pipe connection to the discharge pipe as
illustrated in Fig. 4.33.
54/288
12
14
9
11
13
0178-931 - ENG
Rev. 27.10.03
4. Technical Description
System B
System B is used where more than two compressors are working in parallel but where they do not
have any joint suction line. The refrigerant may be
HFC, HCFC or R717.
Fig. 4.34
To condenser
ET 5
Alternative
Oil seperator with float valve
controlled oil return
ET+
04 technical description.fm
6a
2a
10
6b
14
2b
12
9
11
13
15
9
14
16
Table 4.3
A-B
Compressor
9.
Oil vessel
2a-2b.
Level Switch
10.
3.
Filter
11.
Solenoid valve
4.
Stop valve
12.
5.
Oil separator
13.
Filter
6a-6b.
14.
Heating cartridge
7.
Non-return valve
15.
8.
Float valve
16.
0178-931 - ENG
Rev. 27.10.03
55/288
4. Technical Description
There is a risk, however, that the differential pressure between the oil vessel, pos. 9, and the crankcase 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
56/288
0178-931 - ENG
Rev. 27.10.03
4. Technical Description
System C
System C is a float regulated oil return system
which is used when only two compressors are operating 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.
04 technical description.fm
Fig. 4.35
3a
10/8
1a
4a
2a
SNV8 CD
10/8
3b
1b
2b
4b
0178-931 - ENG
Rev. 27.10.03
57/288
4. Technical Description
13
58/288
Capacity Regulation
As mentioned in the introduction to this section all
SMC and TSMC compressors are fitted with a hydraulic 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 extended 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 unloading 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.
0178-931 - ENG
Rev. 27.10.03
4. Technical Description
Fig. 4.37
19F
04 technical description.fm
19B
19A
Unloading System
15A
13
12
15B
0178-931 - ENG
Rev. 27.10.03
59/288
4. Technical Description
Start Unloading
As already mentioned the compressor cylinders
are unloaded when there is no oil pressure on the
unloading cylinders. This means that when the
compressor is stopped, i.e. without any oil pressure, all the unloading cylinders are unloaded and
consequently there is no compression resistance
during start-up.
This unloading during start-up reduces the starting torque of the compressor considerably.
Fig. 4.39
12
3
1
60/288
0178-931 - ENG
Rev. 27.10.03
4. Technical Description
Fig. 4.40
04 technical description.fm
Regulating Sequence
As described earlier, the compressors are always
completely unloaded during start up exept for
the compressor with extra capacity stages (extended unload), which will always have one or two
cylinders loaded during start up (SMC104-108)
and (SMC 112-116).
0178-931 - ENG
Rev. 27.10.03
61/288
4. Technical Description
SMC/HP 104
TSMC 108
TSMC 188
SMC 112
5
2
%
%
100
50
L
HP
100
83
Y
4
SMC/HP 106
SMC 186
67
1
2
1
2
100
67
33
0
L
N
Y
50
33
3
N
Y
TSMC 116
SMC 116
N
%
Y
SMC/HPC 108
SMC 188
1
5
100
1
3
87
100
75
50
25
L
1
2
3
N
Y
100
83
2
5
S
67
75
1
3
63
4
2
50
37
25
L
50
8
62/288
100
67
33
L
1
S
33
4
S
L
Y
0178-931 - ENG
Rev. 27.10.03
4. Technical Description
04 technical description.fm
Fig. 4.41 illustrates the regulating system in principle. The percentages indicate the compressor
capacity at every stage. When unloading a compressor without extra capacity stages, the solenoid 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 simultaneously 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 Unloading
Besides the standard equipment as described in
the previous passage the compressor can be fitted with a solenoid valve marked S (optional).
Fig. 4.41.
The TSMC compressors, however, are always
equipped with this S solenoid valve.
0178-931 - ENG
Rev. 27.10.03
63/288
4. Technical Description
Fig. 4.41
SMC/HPC 104
SMC 188
Compressor seen
from the shaft end
S
100
50
0
L
100
75
50
25
0
L
SMC/HPC 106
SMC 186
Relief cylinder
Oil return
1
2
3
N
Y
Oil pressure
SMC 116
SMC 112
S
S
100
67
33
0
L
1
2
100
100
87
75
SMC/HPC 108
83
63
67
%
S
100
75
50
25
50
33
0
L
0
L
N
Y
50
2
4
37
25
0
4
2
6
S
6
S
L
Y
64/288
0178-931 - ENG
Rev. 27.10.03
4. Technical Description
Table 4.4
Compressor
Type
33
37
50
63
67
75
83
87
100
SMC 104
SMC 106
SMC 108
SMC 112
SMC 116
TSMC 108
04 technical description.fm
TSMC 116
0178-931 - ENG
Rev. 27.10.03
pacity regulate the compressor in steps of one cylinder 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 stated capacity stages (load).
65/288
4. Technical Description
Table 4.5
Extended unloading
Base: Capacity step by one cylinder. For SMC 112 and SMC 116 min. load two cylinders.
TSMC not included.
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%
66/288
0178-931 - ENG
Rev. 27.10.03
4. Technical Description
106
12.5%
108
112
16.7%
0
0
18.8%
25.0%
A
0
31.3%
S
37.5%
AB
3
41.7%
6AB
4A
04 technical description.fm
43.8%
56B
S
3S
4AB
56.3%
34B
62.5%
23
66.7%
2S
456AB
34AB
68.8%
3456B
1
23S
234A
81.3%
12
87.5%
234AB
123
91.7%
23456AB
1234B
93.8%
0178-931 - ENG
Rev. 27.10.03
3456AB
23456A
83.3%
100.0%
56AB
456A
58.3%
75.0%
AB
6A
33.3%
50.0%
116
123456B
1S
12S
123S
1234AB
123456AB
67/288
4. Technical Description
Extended Unloading
The additional capacity stages are obtained by
changing the unloading of one (SMC 104, 106 and
108) or two (SMC 112 and 116) cylinder pairs in
such a way that the relief system only works the
one cylinder while the other one is constantly connected.
Note: When the mentioned systems are used,
the compressor will not start up completely unloaded but with capacity as shown in Table 4.7.
Table 4.7
19J
104
106
108
112
116
25%
16.5%
12.5%
16.5%
12.5%
68/288
0178-931 - ENG
Rev. 27.10.03
4. Technical Description
Fig. 4.43
04 technical description.fm
SMC 106
SMC 108
12
15 11
16
9
3
2
11
10
14
1
13
SMC112
Rev. 27.10.03
SMC 104
0178-931 - ENG
12
2
5
6
4
S MC116
69/288
4. Technical Description
Fig. 4.44
Solenoid
valve
Nonreturn valve or
automatically controlled
stop valve
70/288
0178-931 - ENG
Rev. 27.10.03
4. Technical Description
Compressor Units
The compressor units can be delivered as standard units with base frames adapted to IEC electric
motors. Against additional payment base frames
can also be delivered for non-standard electric
motors. On the base frame one oil separator can
Fig. 4.45
04 technical description.fm
frame as standard units as illustrated on dimension sketches in Section 6, Technical Data, see
also Dimension and Piping diagrams. Furthermore, 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 indicates this Nitrogen charge.
Fig. 4.46
Pfyldt beskyttelsesgas
Charged with inert gas
Enthlt Schutzgas
Charg du gaz protecteur
Contiene gas protector
N2
0,2 bar
3 PSI
1534-169
Extent of Delivery
The compressors can be delivered as blocks
only in standard execution or mounted on a base
0178-931 - ENG
Rev. 27.10.03
71/288
4. Technical Description
Instrumentation
In the standard version the compressors are available with one of the following two systems:
A:
B:
In its standard execution the analogue system consists of controls, built onto the compressor on delivery, but without electrical
connections.
The controls are not factory adjusted and
should therefore be adjusted before the initial 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 pressure 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
72/288
0178-931 - ENG
Rev. 27.10.03
4. Technical Description
1.
Adjusted to stop the compressor if the discharge pressure rises to a pressure 2 bar
[29 psi] lower than the setting pressure of
the by-pass valve.
04 technical description.fm
2.
5.
Adjusted to stop the compressor if the suction pressure drops to a pressure corresponding to 5K lower than the lowest evaporating pressure.
4.
0178-931 - ENG
Rev. 27.10.03
73/288
4. Technical Description
Manometers
For reciprocating compressors the following three
types of manometers are available:
10.
Fig. 4.48
10
8.
9.
8-9
R717 manometers
74/288
On delivery of compressors using other refrigerants the manometers are graded for
that particular refrigerant. The standard
units on the scale is bar/C but others can
be delivered on request.
0178-931 - ENG
Rev. 27.10.03
4. Technical Description
04 technical description.fm
Fig. 4.49
UNISAB II is designed for safe control, monitoring and optimization of compressor operation and a minimum of unintended opera-
0178-931 - ENG
Rev. 27.10.03
75/288
4. Technical Description
76/288
0178-931 - ENG
Rev. 27.10.03
4. Technical Description
04 technical description.fm
Fig. 4.50
Oil separator
Oil separator
0178-931 - ENG
Rev. 27.10.03
CT
Equalizing pipe
IP HP
Mixing
chamber
LP
IP
HP
Solenoid
valve
LP
Float valve
Liquid subcooling
spiral
Intermediate
cooler type
DVEA
Fig. 4.51
Oil separator
CT
LP
IP
HP
LP
IP
Mixing chamber
Equalizing pipe
Solenoid valve
Intermediate
cooler
Float valve
Liquid subcooling
spiral
Oil drain off
In the liquid subcooling spiral the refrigerant flowing from the receiver to the evaporator in the refrigeration plant is cooled. The intermediate cooler
is dimensioned so that the cooled gas is free of liquid refrigerant before leaving the top of the intermediate 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.
77/288
4. Technical Description
The intermediate cooling system is designed as illustrated in Fig. 4.53. Here the intermediate cooling 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
KP 77
1.
T
Oil separator
CT
Fig. 4.52
LP
TSMC
IP HP
LP IP
Mixing chamber
Oil separator
LP
CT
A
TEAT
LP
Liquid supply
To evaporator
From receiver
Mixing chamber
HESI
Opt
B
TEA or TEX
Solenoid valve
Stop valve
Filter
78/288
The sensor of the TEAT valve is placed in a sensor pocket at the HP discharge branch of the compressor, 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 55C [131F].
0178-931 - ENG
Rev. 27.10.03
4. Technical Description
In two-stage plants with reciprocating compressors it should be pointed out that the intermediate
pressure is not allowed to drop excessively.
04 technical description.fm
LP
IP HP
If a TSMC compressor is working at 100% capacity, 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 pressure will drop accordingly.
The intermediate discharge pressure is determined by entering the suction tempera-ture ET
and the condensing temperature CT into the calculation programme COMP 1. The lower limits for
the intermediate discharge pressure are the same
as stated above:
-15C [5F] for R717 plants and
-25C [-13F] 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 capacity regulating system in such a way that the compressor 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:
LP LP
LP
Opt.
B
0178-931 - ENG
Rev. 27.10.03
79/288
4. Technical Description
Table 4.8
Compressor
Type
80/288
Number of
Cylinders
Working
Capacity
%
Ratios
LP
HP
TSMC 108
100
66
33
6
4
2
2
2
2
3:1
2:1
1:1
TSMC 116
100
83
67
50
33
12
10
8
6
4
4
4
4
2
2
3:1
2.5:1
2:1
3:1
2:1
0178-931 - ENG
Rev. 27.10.03
4. Technical Description
Fig. 4.56
04 technical description.fm
R717
a.
2.
SMC only:
Air-cooled top and side covers and
refrigerant-cooled oil cooler.
b.
c.
SMC only:
Compressor cooling with thermopump
R22-R134a-R404A-R507-R410A-R744
a.
b.
Description
c.
0178-931 - ENG
Rev. 27.10.03
81/288
4. Technical Description
LP
HP
LP
Fig. 4.58
T
Liquid from
receiver
TEA
Oil cooler
Filter
Oil
separator
Stopvalve
LP
Solenoid valve
IP
Liquid from
receiver
Oil cooler
TEAT
Filter
Stopvalve
Solenoid valve
Fig. 4.59
HP
Oil
Separator
Oil
Separator
LP
1
IP HP
LP IP
IP
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.
Liquid from
receiver
Stop valve
82/288
TEAT
Filter
Solenoid valve
0178-931 - ENG
Rev. 27.10.03
4. Technical Description
The TEAT valve is set to inject liquid into the compression chamber of the compressor via the oil
cooler in order for the discharge gas to maintain a
temperature between +55 and 95C [131 F and
203 F].
Fig. 4.60
04 technical description.fm
0178-931 - ENG
Rev. 27.10.03
83/288
4. Technical Description
Fig. 4.62
4
5
3
3
2
715
115
505
645
835
730
125
335
375
515
1100
6
3
3
2
1
3
3
2
1
84/288
L (mm)
760
150
340
255
230
1090
0178-931 - ENG
Rev. 27.10.03
4. Technical Description
Fig. 4.63
Cooling of side covers only
Side covers 3185-235 SMC 104106-108 and TSMC 108
Pos. No.
Hose Type
L (mm)
715
175
230
765
04 technical description.fm
L (mm)
SMC 112
750
130
750
220
Hose Type
L (mm)
SMC 116
TSMC 116
740
160
770
215
0178-931 - ENG
Rev. 27.10.03
85/288
4. Technical Description
Fig. 4.64
Cooling of top and side covers
SMC 186-188 and TSMC 188
SMC 186 3185-242
5
Pos. no.
6
3
3
2
1
Hose type
L (mm)
815
1830
605
245
1165
595
Pos. no.
4
4
3
3
2
1
Hose type
L (mm)
335
1755
535
245
1175
340
Hose type
L (mm)
1165
245
1315
410
3
4
86/288
0178-931 - ENG
Rev. 27.10.03
4. Technical Description
Note:
04 technical description.fm
In the supply pipe to the water system a solenoid 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.
0178-931 - ENG
Rev. 27.10.03
87/288
4. Technical Description
TSMC 108
SMC 108
SMC 106
SMC 104
Pressure loss
p(mWc)
116
SMC
186
T/SMC
188
500
100
1000
Volumetric flow
V(l/hour)
Water Quality
Water that can be used as cooling water:
Water from the water works or sea water
88/288
0178-931 - ENG
Rev. 27.10.03
4. Technical Description
04 technical description.fm
Fig. 4.66
0178-931 - ENG
Rev. 27.10.03
89/288
4. Technical Description
98D
98B
98A
A
98Q
C
98H
98C
98X
90/288
Connection pos. C is connected to the bottom 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.
0178-931 - ENG
Rev. 27.10.03
4. Technical Description
Fig. 4.68
SMC 108
98U
98M 98M
4
98M 98Z
HP
98X
Filling and evacuation of the pump vessel is controlled by two level sensors, pos. 98C, Fig. 4.67.
By means of the control box, pos. 98B, the sensors control the solenoid valves, pos. 98G and
pos. 98H, so that they open and close simultaneously.
LP
98G
98T
98B
98M
98
a.
98H
C
B
98K
98V
98Y
98K
80
04 technical description.fm
Fig. 4.69
TSMC 108
b.
98M
98Z
IP
98X
2
98G
98B
98
98H
C
98K
80
98K
98V
98Y
0178-931 - ENG
Rev. 27.10.03
HP
c.
91/288
4. Technical Description
92/288
Closed
100%
100 - 67%
100 - 75%
100 - 83 - 67%
50%
33%
50 - 25%
50 - 33%
0178-931 - ENG
Rev. 27.10.03
4. Technical Description
Fig. 4.70
SMC 112
Fig. 4.71
SMC 116
98M
98M
98M
98M
98M
98Z
LP
LP
98Z
4
2
98M
98M
98G
A
8
98G
98B
98
98B
98H
98
98K
98H
98K
98K
98M
98D
98V
98Y
98D
98M
98M
98M
HP
LP
98G
98 5
98T
04 technical description.fm
98B
98Z
3 LP
B
5
98K
98K
98B
B
98M
98H
98
98H
Fig. 4.72
98K
80
98V
98Y
80
98K
98V
98Y
TSMC 116
C
98M
98M
D
S
4
IP
HP
3
A
98G
98B
98
98H
98K C
B
98K
98V
98Y
98D
98U
1
98T
98M
0178-931 - ENG
Rev. 27.10.03
93/288
4. Technical Description
SMC 112
SMC 116
Not Working
100 - 83 - 67%
100-87-75-63%
50 - 33%
50 - 37 - 25%
94/288
Table 4.10
Compr.
Capacity
0178-931 - ENG
Rev. 27.10.03
4. Technical Description
Fig. 4.73
1
Receiver
3
B
B
04 technical description.fm
1:
2:
3:
B:
Power Connection
Fig. 4.74
K1
Terminal 1
K3
Terminal 2
PT100 sensor
M1
Terminal 1
Terminal 4
GND
K2
M2
GND
Terminal 2
N
Upper level sensor
L
GND
Terminal 1
0178-931 - ENG
Rev. 27.10.03
95/288
4. Technical Description
Table 4.11
Pos No
Hose type
Length (mm)
715
175
230
765
3
4
96/288
0178-931 - ENG
Rev. 27.10.03
4. Technical Description
fCompressor Accessories
04 technical description.fm
0178-931 - ENG
Rev. 27.10.03
When servicing compressor and unit, it is always 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.
97/288
4. Technical Description
Standard spare parts set: Contains a suitable selection of O-rings as well as valve
ring plates and valve spring.
98/288
0178-931 - ENG
Rev. 27.10.03
WDanger!
Risk of injury to personnel and damage to equipment! Always read the safety precautions belonging to this equipment before start. Failure to comply with safety precautions may cause death or in-
0178-931 - ENG
Rev. 27.10.03
Safety Precautions
In 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 regarding pipe bend, flange design, etc.
Electrical connection must be carried out so
that it complies with current legislation within 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 cable trays.
99/288
Physical Data
Dimension Sketches
Dimension sketches of all compressor blocks and
units are included in a separate binder Dimensions and Piping Diagrams.
Connection Data
100/288
The table Table 5.6 show the possible connections 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.
0178-931 - ENG
Rev. 27.10.03
Table 5.1
Nominal diameters DN for standard welding connections (in mm)
Suction
Discharge
Interstage LPD+)
Oil
Separator
Interstage HPS+)
Compressor
Conn.
SABR.
type
Conn.
SABR.
type
Conn.
SABR.
type
Conn.
SABR.
type
Conn.
SABR.
type
SMC 104
SMC 106
SMC 108
TSMC 108
129.5
65
80
80
80
80
100
100
100
90.5
90.5
90.5
F
65
65
65
50
65
65
65
50
90.5
65
65
FS
50
50
FP
65
65
65
65/50
++)
SMC 112
SMC 116
TSMC 116
154.5
125
125
125
125
125
125
129.5
129.5
90.5
100
100
65
100
100
65
129.5
100
100
FS
80
80
FP
100
100
100/
65++)
Table 5.2
05 physical and connection data.fm
Discharge
Interstage LPD+)
Oil
Separator
Interstage HPS+)
Compressor
Conn.
SABR.
type
Conn.
SABR.
type
Conn.
SABR.
type
Conn.
SABR.
type
Conn.
SABR.
type
SMC 104
SMC 106
SMC 108
TSMC 108
129.5
2 1/2"
3"
3"
3"
3"
4"
4"
4"
90.5
90.5
90.5
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 112
SMC 116
TSMC 116
154.5
5"
5"
5"
5"
5"
5"
129.5
129.5
90.5
4"
4"
2 1/2"
4"
4"
2 1/2"
129.5
4"
4"
FS
3"
3"
FP
4"
4"
4"/
2 1/2"
++)
Table 5.3
Available Welding Connections
Connec.
type
1)
Pipe
type
90.5
R-KB
ANSI
129.5
R-KB
ANSI
154.5
R-KB
ANSI
219.5
R-KB
ANSI
40
50
65
095
122
100
124
102
126
102
127
105
129
80
100
107
131
108
132
109
133
125
150
110
134
111
135
0178-931 - ENG
Rev. 27.10.03
101/288
+)
++)
FP
Fixed connection
FS
102/288
Fixed pipe
0178-931 - ENG
Rev. 27.10.03
If you wish to connect the welding nipples to a pipe with a thicker wall, the nipples can be shortened and thus the internal 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
305
1
OD2
OD1 OD ID1
ID3 ID2
ID2
155
S
L
A
Table 5.4
Standard welding end for R-KB
pipes according to DIN 2448
1)
INCH
DN
OD
ID1
OD1
OD2
ID 2
ID3
Mat.
2"
50
60.3
2.9
54.5
76.0
90.5
52.5
57.0
55
4.0
2 1/2"
65
76.1
2.9
70.3
76.1
90.5
62.7
57.0
65
14.0
2 1/2"
65
76.1
2.9
70.3
113.5
129.5
62.7
93.0
75
14.0
3"
80
88.9
3.2
82.5
113.5
129.5
77.9
93.0
70
9.0
4"
100
114.3
3.6
107.1
114.3
129.5
102.3
93.0
65
9.0
5"
125
139.7
4.0
131.7
144.0
154.5
128.1
125.0
80
7.0
0178-931 - ENG
Rev. 27.10.03
103/288
1
OD2
OD1 OD
ID1
ID2 ID1
ID2
S
A
Table 5.5
Standard welding end
for ANSI B31.5 pipes
schedule 80 + 40
INCH.
DN
OD
OD1
OD2
ID1
ID2
Mat.
2"
50
60.3
3.9
76.0
90.5
52.5
57.0
51.0
2 1/2"
65
76.1
6.7
90.5
62.7
57.0
51.0
2 1/2"
65
76.1
6.7
113.5
129.5
62.7
93.0
61.0
3"
80
88.9
5.5
113.5
129.5
77.9
93.0
61.0
4"
100
114.3
6.0
129.5
102.2
93.0
56.0
5"
125
139.7
5.8
144.0
154.5
128.1
125.0
73.0
Material:
1:
RST 37-2 DIN 17100
2: SIS 2142/SKF 280
104/288
0178-931 - ENG
Rev. 27.10.03
AF
N
T
G
U
C
V
D
Fig. 5.4
Z
AF
H
AE
AH
AK
AJ
0178-931 - ENG
Rev. 27.10.03
AD
Y
AA
105/288
Fig. 5.5
AC
AF
M
H
4
R
3
Fig. 5.6
H, AL
AG
AD
Y
AK
Fig. 5.7
Top cover
Fig. 5.8
X, AN
S
Z, AL
106/288
0178-931 - ENG
Rev. 27.10.03
Fig. 5.9
BE
Fig. 5.10
Pump end
BT
BD
BL
BX
BB
BP
BN
BJ
BS
BA
BQ
F
K
AB
0178-931 - ENG
Rev. 27.10.03
AM
107/288
1) SMC10X
3) TSMC108
2) SMC11X
4) TSMC116
PRESSURE
OIL, GAS
OR LIQUID
AIR-COOLED
wATER-COOLED
AIR-COOLED WITH
BUILT-IN OIL
COOLER
TERMOPUMP
WITH BUILT-IN OIL
COOLER
1 1/4
Suction
Oil
Heating rod
Fig. 5.3
3/4
Suction
Oil
Fig. 5.3
1/2
Suction
Oil
Oil temperature
Fig. 5.3
1/2
Suction
Oil
Plugged
Plugged
Oil temperature
Fig. 5.3
1/4
Suction
Gas
Plugged
Plugged
Plugged
Available
Fig. 5.3
1/4
Oil
Oil
Fig. 5.10
FIG. NO.
THREAD
(ISO228/1-G)
NORMAL
APPLICATION
POS
(COMP. TYPE)
Table 5.6
G (1)
1/2
Suction
Gas
Plugged
Fig. 5.3
G (3)
1/2
Suction
Gas
Plugged
Plugged
Fig. 5.3
G (2+4)
1/2
Suction
Gas
plugged
Plugged
Plugged
Available
1)
1/4
Discharge
Gas
Fig. 5.3
Fig. 5.3, Fig. 5.4,
Fig. 5.5 and Fig. 5.6
1/4
Suction
Gas
Fig. 5.3
1/4
Oil
Oil
Fig. 5.10
1/4
Suction
Gas
Fig. 5.3
Intermediate pressure
connection
Oil return from oil separator
M1) (3+4)
1/4
Intermediate
Gas
1/4
Suction
Gas
1/2
Suction
Gas
Plugged
Plugged
Plugged
Available
Fig. 5.3
P (1+2+3)
1/4
Suction
Gas
Plugged
Plugged
Fig. 5.3
Q (1+2+4)
1/4
Discharge
Gas
Plugged
Plugged
Fig. 5.3
Q (3)
1/4
Discharge
Gas
Plugged
Plugged
Plugged
Available
Fig. 5.3
Fig. 5.3
R (3+4)
1/4
Suction
Gas
1/4
Discharge
Gas
Plugged
Plugged
Fig. 5.7
Fig. 5.3
Gas
1/4
Suction
1/4
Discharge
Fig. 5.3
1/2
Suction
Oil
Plugged
Fig. 5.3
1/2
Discharge
Gas
Fig. 5.8
Fig. 5.5 and Fig. 5.6
Y (2+4)
3/4
Suction
Gas
Plugged
Plugged
Plugged
AN (3)
1/2
Intermediate
Gas
Plugged
Plugged
Plugged
Available
Fig. 5.8
Fig. 5.4
Z (2)
3/4
Discharge
Gas
Z (4)
1/2
Discharge
Gas
Fig. 5.8
Z (1+3)
1/2
Discharge
Gas
Fig. 5.8
AA (2+4)
1 1/4
Suction
Oil
AB
3/8
Suction
Oil
Plugged
Plugged
Plugged
108/288
Heating rod
Available
0178-931 - ENG
Rev. 27.10.03
OIL, GAS
OR LIQUID
AIR-COOLED
wATER-COOLED
1/2
Suction
Gas
FIG. NO.
PRESSURE
AC
NORMAL
APPLICATION
THREAD
(ISO228/1-G)
TERMOPUMP
WITH BUILT-IN OIL
COOLER
POS
(COMP. TYPE)
AIR-COOLED WITH
BUILT-IN OIL
COOLER
AD (2+4)
1/4
Suction
Gas
AE (2)
1/4
Suction
Gas
Plugged
Fig. 5.4
AF (1+2)
1/4
Discharge
Gas
Plugged
Plugged
AF (3+4)
1/4
Discharge
Gas
Plugged
Fig. 5.6
Fig. 5.4
AG (4)
1/4
Intermediate
Gas
Plugged
Plugged
AH (2)
1/4
Suction
Gas
AJ (2)
1/4
Suction
Gas
AK (2+4)
1/2
Suction
Gas
Plugged
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
Fig. 5.9
Prelubrication of compressor
bearings
Fig. 5.9
Fig. 5.9
Oil
Oil
Fig. 5.4
Fig. 5.4 and Fig. 5.6
BB
1/4
BD
1/4
Oil
Oil
Plugged
Plugged
Plugged
BE
1/2
Suction
Oil
Plugged
Plugged
Plugged
Fig. 5.9
BJ
1/8
Oil
Oil
Plugged
Plugged
Plugged
Fig. 5.9
BL
1/4
Suction
Oil
Plugged
Plugged
Plugged
Fig. 5.9
BN
1/4
See
application
Oil
BP
1/8
See
application
Oil
Fig. 5.9
Fig. 5.9
BQ
1/4
Oil
Oil
Plugged
Plugged
Plugged
Fig. 5.9
BX
1/8
Oil
Oil
Plugged
Plugged
Plugged
Fig. 5.9
BS
1/4
Oil
Oil
Oil pressure
Fig. 5.9
1/4
See
application
BT
1
Oil
Fig. 5.9
Fig. 5.3, Fig. 5.4,
Fig. 5.5 and Fig. 5.6
2 (3+4)
3 (3+4)
1) Positioning
0178-931 - ENG
Rev. 27.10.03
109/288
Electrical Connections
Fig. 5.11
TT7
Electromechanical Control
TT5
PT2
7
PT1
PT3
TT6
1+2
PT1
Suction pressure
PT2
Discharge pressure
PT3
Oil pressure
TT5
TT6
Oil temperature
TT7
Heating element
UNISAB II:
MOTOR
Supply voltage:
115 VAC
230 VAC
24 VAC
Permissible variation: +10%/-15%
Frequency:
45-65 Hz
Power:
50 VA
110/288
VAC
+10%/-15%
45-65 Hz
kW
0178-931 - ENG
Rev. 27.10.03
b.
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 regulation. Control and safety automatics is described in detail in Section 4, Technical Description - 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 installation 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 components in Section 21, Appendices. The fundamental 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 damages for personal injuries or for damage to the unit
or the refrigeration plant if caused by malfunctioning of the control system.
0178-931 - ENG
Rev. 27.10.03
On delivery the compressor is fitted with instruments, but not with any other electrical installations.
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.
111/288
112/288
0178-931 - ENG
Rev. 27.10.03
NV 50
30
30
50
G 1 1/4
L1
L2
80
Table 5.7
Heating rods
Power
Watt
Voltage
V
270
270
270
250
230
115*
460
460
460
250
230
115*
L1
mm
Used for
L2
mm
CMO - TCMO - SMC 100 - TSMC 100
158
175
HPO - HPC, SMC 180 - TSMC 180
VMY 347 /447 - 536
SAB 110 - 128 - 163 - 202 - 330
50/60 Hz 10 Watt
240 Volt
50 Hz
10 Watt
The coils form part of solenoid valve for capacity regulation, oil cooler and thermopump.
0178-931 - ENG
Rev. 27.10.03
113/288
114/288
0178-931 - ENG
Rev. 27.10.03
6. Technical Data
6. Technical Data
The purpose of this document is to provide the
technical data of the equipment. In this
document technical data is defined as:
Working range
Area of application
Vibration data
06 technical data.fm
0178-931 - ENG
Rev. 27.10.03
YORK Refrigeration
Chr. Xs Vej 201
DK-8270 Hoejbjerg
Denmark
115/288
6. Technical Data
Number of
cylinders
Bore
Stroke
mm
Two stage
Single stage
1)
1)
2)
Max/min
speed
nominal
rpm
2)
Swept
volume
at max
speed
m3/h
Weight of
compressor
block
Weight of
compressor
block
kg
lb
SMC 104S
271
580
1279
SMC 106S
407
675
1488
SMC108S
542
740
1631
SMC112S
12
815
1250
2756
SMC 116S
16
1086
1350
2976
SMC104L
283
580
1279
SMC106L
424
675
1488
SMC108L
565
740
1631
SMC112L
12
848
1250
2756
SMC116L
16
1131
1350
2976
SMC104E
339
600
1323
SMC106E
509
700
1543
SMC108E
679
770
1698
SMC112E
12
1018
1300
2866
SMC116E
16
1357
1400
3086
339
775
1709
679
1400
3086
424
775
1709
848
1400
3086
509
800
1764
1018
1450
3197
TSMC108S
6 LP + 2 HP
TSMC116S
12 LP + 4 HP
TSMC108L
6 LP + 2 HP
TSMC116L
12 LP + 4 HP
TSMC116L
6 LP + 2 HP
TSMC116E
12 LP + 4 HP
80
1800/700
100
100
1500/700
120
80
100
120
116/288
0178-931 - ENG
Rev. 27.10.03
6. Technical Data
Table 6.2
Compressor Type
Direct driven
Belt driven
Remarks
Kg
lb
Kg
lb
SMC 104
SMC 106
SMC 108
SMC 112
SMC 116
830
925
990
1660
1400
1830
2039
2183
3660
3086
880
970
1030
1820
1920
1940
2138
2271
4012
4233
TSMC 108
TSMC 108
1060
1400
2337
3086
1130
1410
2491
3109
TSMC 116
TSMC 116
1900
2350
4189
5181
2080
2530
4586
5578
06 technical data.fm
0178-931 - ENG
Rev. 27.10.03
117/288
6. Technical Data
MOTOR TYPE
SHORCH
IP 23
kg
LEROY SOMER
IP 54
lb
IEC 160L
PLS
LS
FLS
kg
lb
kg
lb
kg
lb
kg
lb
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
190
419
170
375
260
573
205
452
290
639
235
518
388
855
IEC 225S
235
518
309
681
340
750
IEC 225M
355
783
240
529
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
1500
3307
1510
3329
1550
3417
IEC 355S
IEC 355M
1790
3946
1600
3527
IEC 355L
2095
4619
1750
3858
IEC 355L
118/288
(LA)1900
(LB)2150
855
1885
0178-931 - ENG
Rev. 27.10.03
6. Technical Data
Compressor Capacity
06 technical data.fm
0178-931 - ENG
Rev. 27.10.03
119/288
6. Technical Data
120/288
0178-931 - ENG
Rev. 27.10.03
0178-931 - ENG
ALL
SMC 108
200--315M
200--315M
SMC106
SMC108
2020
2010
2050
IEC
200--315M
MM
TYPE
TYPE
SMC104
A
MAX
MOTOR
COMPR
ADD 80MM
MM
1095
1130
1125
1115
1090
1130
MM
1030
1035
1000
300
275
275
MM
405
395
440
MM
M114.3x3.6
MM
(H)CFC
M88.9x3.2
M76.1x2.9
M88.9x4.85
R717
M76.1x4.5
SMC 106
SMC 104
DISCHARGE
SUCTION
COMPR.
WELDING CONNECTIONS
G1/4
G1/4
R717 THERMOPUMP.SYSTEM
G1/4
LIQUID REFRIG.
CONNEC.FOR
710
650
COOLING SYSTEM
510
Rev. 27.10.03
405
395
350
MM
600
665
645
635
MM
MIN 250
635
620
635
MM
WEIGHT
171438
171438
171438
NO.
1030 KG
970 KG
880 KG
MOTOR
DRWG. EXCL.
FOUND. OF UNIT
4XM22 HOLES
275
915
1015
1135
1235
1335
225
250
280
315
H MAX
200
IEC
TYPE
MOTOR
I
H MAX
25
DIMENSION H IN TABEL
80
III
II
1455
900
1500
1100
A (OVERALL LENGTH)
200
SABROE
141
200
4833--001_0
205
32
MIN 400
Fig. 6.1
MIN
620
06 technical data.fm
SMC /TSMC 100 Mk4 - Engineering Manual
6. Technical Data
121/288
C (OVERALL HEIGHT)
D
122/288
1130
1125
1053
1193
2010
2020
200--315M
200--315M
SMC106
SMC108
1095
1168
2050
200--315M
IEC
SMC104
MM
MM
MM
TYPE
TYPE
1030
1035
1000
300
275
275
MM
405
395
440
MM
M114.3x3.6
MM
(H)CFC
M88.9x3.2
M76.1x2.9
A
MAX
ALL
MOTOR
DISCHARGE
SMC 108
M88.9x4.85
R717
M76.1x4.5
SMC 104
SMC 106
G1/4
G1/4
WELDING CONNECTIONS
COMPR.
COMPR
SUCTION
CONNEC.FOR
710
650
LIQUID REFRIG.
G1/4
R717 THERMOPUMP.SYSTEM
COOLING SYSTEM
510
MIN 620
405
395
350
MM
600
665
645
635
MM
MIN 250
635
620
635
MM
WEIGHT
171438
171438
171438
NO.
970 KG
1030
KG
880 KG
MOTOR
DRWG. EXCL.
FOUND. OF UNIT
4XM22 HOLES
275
1015
1115
1235
1335
1435
225
250
280
315
H MAX
200
IEC
TYPE
MOTOR
I
H MAX
25
DIMENSION H IN TABEL
80
III
II
1455
900
1500
1100
5
200
141
200
4833--011_0
205
32
MIN 400
Fig. 6.2
A (OVERALL LENGTH)
6. Technical Data
0178-931 - ENG
Rev. 27.10.03
C (OVERALL HEIGHT)
D
MIN
620
MIN 200
Rev. 27.10.03
MIN 400
0178-931 - ENG
250
A APPROX
1250
III
II
M
D
4xM22 HOLES
80
L
390
25
560
500
280
315
181
162
140
114
225
250
280
315
250M
SMC 225--250
200
180
315
197
2450
2350
2250
2200
2000
2400
2300
280
209
2200
250M
2150
1950
S
160--180
200
2250
2100
280
222
108
MM
1900
2150
200
106
A
MAX
250M
225--250
200
160--180
IEC
TYPE
C (OVERALL HEIGHT)
MOTOR
SMC 225--250
104
SMC
TYPE
180
MM
32
COMPR
H
160
IEC
TYPE
MOTOR
TABEL BELOW
DIMENSION M IN
141
B (OVERALL WIDTH)
555
1005
995
995
MM
1125
1130
1095
MM
440
270
440
270
440
270
MM
185
160
135
MM
875
875
900
MM
DISCHARGE
SUCTION
443
418
393
MM
1030
1035
1000
MM
ALL
900
875
CONNEC.FOR
R717
665
645
635
MM
171426
990 KG
925 KG
830 KG
MOTOR
4843--021_0
204847
171427
171426
204847
171427
171426
204847
171427
NO.
DRWG. EXCL.
FOUND. OF UNIT
WEIGHT
M114.3x3.6
M76.1x2.9
M88.9x3.2
M88.9x3.2
(H)CFC
WELDING CONNECTIONS
G3/8
G1/4
G1/4
LIQUID REFRIG.
M76.1x2.9
MM
830
SMC 108
SMC 106
SMC 104
COMPR.
R717 THERMOPUMP.SYSTEM
COOLING SYSTEM
FILTER
Fig. 6.3
205
06 technical data.fm
SMC /TSMC 100 Mk4 - Engineering Manual
6. Technical Data
123/288
510
6. Technical Data
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]
Fig. 6.4
1
Fig. 6.5
124/288
Fig. 6.6
0178-931 - ENG
Rev. 27.10.03
6. Technical Data
2.
To make sure that YORK Refrigerations customers experience a satisfactory compressor operation within the specified operating periods between the service intervals, it is essential that the
operating conditions are kept within certain permitted operating limits.
06 technical data.fm
Fig. 6.8
TC
2
TE
1.
- R717
- R134a
12
- R22
10
- R207C
10
- R404A
14
- R507
14
3.
Fig. 6.7
TC
1
Fig. 6.9
TC
TE
TE
3a.
0178-931 - ENG
Rev. 27.10.03
125/288
6. Technical Data
Fig. 6.10
Fig. 6.12
TC
TC
3a
5
TE
4.
TE
6.
Fig. 6.11
TC
TC
TE
TE
7.
126/288
0178-931 - ENG
Rev. 27.10.03
6. Technical Data
7a.
Fig. 6.14
TC
7a
Fig. 6.13
TC
7
06 technical data.fm
TE
TE
0178-931 - ENG
Rev. 27.10.03
127/288
6. Technical Data
TC
F
Condensing temperature
R717
140
60
122
50
104
40
86
30
68
20
50
10
32
14
-10
-4
-20
-22
-30
4
3
2
BOOSTER
OPERATION
CMO20
SMC100S/L
SMC180
14
-4
10
20
30
40
32
50
68
86
104
TE
Evaporating temperature
T0111123_1 VIEW 2
TYPE
Operating Limits
One Stage
Compressor
Type
CMO & SMC
AREA
1-2
3-4
1-2
3-4
rpm
COOLING
max.
min.
1800
900
1500
750
2-3-4
1000*
700
450
NOTE
1)
1)
Water-cooled
128/288
0178-931 - ENG
Rev. 27.10.03
6. Technical Data
TC
06 technical data.fm
Condensing temperature
140
60
122
50
104
40
86
30
68
20
50
10
32
14
-10
-4
-20
-22
-30
R717
2
1
OPERATION
10
20
30
-76
32
50
68
86 104
SMC100E
-58
-40
-22
-4
14
40
C
F
TE
Evaporating temperature
T0111140_0 view 6
TYPE
Operating Limits
One Stage
Compressor Type
SMC100E
AREA
1
2
rpm
COOLING
max.
min.
1500
700
NOTE
1)
0178-931 - ENG
Rev. 27.10.03
129/288
6. Technical Data
TC
Condensing temperature
R717
158
70
140
60
122
50
104
40
86
30
68
20
50
10
32
14
-10
-4
-20
-22
-30
-40
-40
-70
-60
-50
-40
-30
-20
-10
10
20
30
40 C
-94
-76
-58
-40
-22
-4
14
32
50
68
86
104 F
Type
TCMO
TSMC 100
S-L-E
TSMC 180
Operating limits
Two Stage
Compressors
TCMO
TSMC 100 S-L-E
TSMC 180
1
2
Area
1-2
TE
Evaporating temperature
rpm
Cooling
max
min
top and side
1800
900
Thermopump or water-cooled
Note
1-2
1500
700
Thermopump or water-cooled
1)
1
2
750
1000
450
Water-cooled
1)
130/288
0178-931 - ENG
Rev. 27.10.03
6. Technical Data
TC
06 technical data.fm
Condensing temperature
R22
158
70
140
60
122
50
104
40
86
30
68
20
50
10
32
14
-10
-4
-20
-22
-30
1
2
-58
-40
-22
-4
14
10
20
30
40
32
50
68
86
104 F
TE
Evaporating temperature
T0111-127_0 view 2
TYPE
Operating Limits
One Stage
CMO & SMC
AREA
RPM
MAX.
1
2
CMO20
3
4
SMC100S
1500
900
1800
No
At less than 50% capacity
Yes
1000
No
1200
No
3
4
700
1800
1
2
SMC100L
3
4
2)
1000
1200
No
700
1-2
SMC180
3
4
REMARKS
MIN.
2)
750
450
0178-931 - ENG
Rev. 27.10.03
131/288
6. Technical Data
TC
F
R22
Condensing temperature
140 60
Operating Limits
Two Stage
Compressor type
TCMO & TSMC
122 50
104 40
86
30
68
20
50
10
32
-60
-50
-40
-30
-20
-10
0 C
-76
-58
-40
-22
-4
14
32F
TCMO
TSMC100S
TSMC100L
TSMC180
TE
Evaporating temperature
T0111139_0 view 1
TYPE
AREA
1-2
3
1
2
3
1
2
3
1-2
3
RPM
MAX. MIN.
1500
900
1800
1000
1200
700
1800
OIL COOLING 1)
NOTE
No
Yes
2)
3)
1000
1200
750
700
450
Yes
2)
Yes
3)
2)
2)
3)
Not applicable.
132/288
0178-931 - ENG
Rev. 27.10.03
6. Technical Data
TC
C
176
80
158
70
140
60
122
50
104
40
86
30
68
20
50
10
32
14
-10
-4
-20
-22
-30
-40
-40
-70
-60
-50
-40
-30
-20
-10
10
20
30
40C
-94
-76
-58
-40
-22
-4
14
32
50
68
86
104F
R134a
1
Operating Limits
One Stage
CMO & SMC
T0177128_ V8,1
06 technical data.fm
Condensing temperature
TE
Evaporating temperature
TYPE
AREA
RPM
MAX.
1-2
3
1
SMC100S
1200
1500
CMO
2
3
OIL-COOLING 1)
No
900
1800
1000
1200
No
700
No
No
1500
1
SMC100L
2
3
NOTE
MIN.
2)
1000
1200
No
700
No
At less than 50% capacity
2)
0178-931 - ENG
Rev. 27.10.03
133/288
6. Technical Data
TC
F
R134a
70
140
60
122
50
104
40
86
30
68
20
50
10
32
14
-10
-4
-20
-22
-30
-40
-40
-70
-60
-50
-40
-30
-20
-10
10
20
30
40C
-94
-76
-58
-40
-22
-4
14
32
50
68
86
104F
T0177128_0 V8,1
Condensing temperature
158
Operating limits
Two Stage
Compressors
TCMO
TSMC 100 S-L
2
3
TE
Evaporating temperature
Type
Area
TCMO 28
TSMC
100 S
TSMC
100 L
1-2
3
1
2
3
1
2
3
rpm
max
1500
1800
1000
1200
1500
Oil-cooling required 1)
Note
min
900
1)
700
1)
2)
Not applicable
1000
1200
700
1)
2)
1)
2)
Part-load operation:
By-pass equipment required to maintain intermediate temperature at minimum load.
134/288
0178-931 - ENG
Rev. 27.10.03
6. Technical Data
R404A
Condensing temperature
TC
F
140
60
122
50
104
40
86
30
68
20
50
10
32
14
--10
Operating Limits
CMO & SMC
One Stage
--4 --20
06 technical data.fm
--22 --30
--60 --50 --40 --30 --20 --10
10
20
30 C
--76
32
50
68
86
--4
--14
TE
Evaporating temperature
T0111164_2
TYPE
AREA
RPM
MAX.
CMO20
SMC100S
SMC100L
1500
1800
1200
1500
1200
OIL COOLING 1)
NOTE
MIN.
900
700
700
No
At less than 50% capacity
No
At less than 50% capacity
No
0178-931 - ENG
Rev. 27.10.03
135/288
6. Technical Data
TC
C
R404A
140
60
122
50
104
40
86
30
68
20
50
10
32
14
-10
-70
-60
-50
-40
-30
-20
-10
0 C
-94
-76
-58
-40
-22
-4
14
32 F
Operating Limits
Two Stage
TCMO & TSMC
1
2
274263.3 Rev. 0
Condensing temperature
TE
Evaporating temperature
TYPE
TCMO 28
TSMC100S
TSMC 100L
AREA
1
2
1
2
1
2
RPM
OIL COOLING
NOTE
MAX.
MIN.
1800
900
No
700
No
1)
700
No
1)
1200
1500
1000
1200
136/288
0178-931 - ENG
Rev. 27.10.03
6. Technical Data
R507
06 technical data.fm
Condensing temperature
TC
F
140
60
122
50
104
40
86
30
68
20
50
10
32
14
--10
--4
--20
--22
--30
Operating Limits
One Stage
CMO & SMC
1
10
20
30
--76
32
50
68
86
--58
--40 --22
--4
--14
TE
Evaporating temperature
T0111166_2
TYPE
AREA
RPM
MAX.
CMO20
SMC100S
SMC100L
1500
1800
1200
1500
1200
OIL COOLING 1)
NOTE
MIN.
900
700
700
No
At less than 50% capacity
No
At less than 50% capacity
No
0178-931 - ENG
Rev. 27.10.03
137/288
6. Technical Data
TC
R507
140
60
122
50
104
40
Operating Limits
Two Stage
Compressor
TCMO & TSMC
1
86
30
68
20
50
10
32
14
-10
-70
-60
-50
-40
-30
-20
-10
0 C
-94
-76
-58
-40
-22
-4
14
32 F
274263.4 Rev. 0
Condensing temperature
TE
Evaporating temperature
TYPE
TCMO28
TSMC100S
TSMC100L
AREA
1
2
1
2
1
2
RPM
OIL COOLING
NOTE
MAX.
MIN.
1800
900
No
700
No
1)
700
No
1)
1200
1500
1000
1200
138/288
0178-931 - ENG
Rev. 27.10.03
6. Technical Data
TC
C
F
R407C
60
06 technical data.fm
Condensing temperature
140
122
50
104
40
86
30
68
20
50
10
32
14
-10
-4
-20
-22
Operating Limits
One Stage
Compressor type
CMO & SMC
-30
-70
-60
-50
-40
-30
-20
-10
10
20
30 C
-94
-76
-58
-40
-22
-4
14
32
50
68
86 F
TE
Evaporating temperature
T245411_0 view 2
Type
Area
CMO
SMC 100 S
SMC 100 L
SMC 100 L
SMC
SMC 180
1
2
3
1
2
3
1
2
3
1
2
3
rpm
max
1500
min
1800
1200
1500
1200
1000
1200
1000
750
900
700
700
Oil-cooling
required 1)
Note
no
At less than 50% capacity
yes
no
At less than 50% capacity
yes
no
At less than 50% capacity
yes
NOT APPLICABLE
At less than 50% capacity
450
yes
When oil cooling is required, choose freely between A or B however, for SMC 180, only A may be selected.
0178-931 - ENG
Rev. 27.10.03
139/288
6. Technical Data
Fig. 6.17
Guide pin
An arrow cast into the bearing cover indicates the
direction of rotation as shown in the picture.
Fig. 6.16
140/288
Fig. 6.18
Guide pin
0178-931 - ENG
Rev. 27.10.03
6. Technical Data
B.
06 technical data.fm
Motor Dimension
The size of the motor is determined on the basis
of the power demands of the compressor under
the current operating conditions calculated by
means of the YORK COMP1 PC program.
However, for various reasons, always choose a
motor a little bigger. The reason for this is explained in the following:
A.
Generally speaking, the calculated power demand should be increased by one of the following factors in order to ensure that the motor has sufficient driving power, both during
start-up, at minor deviations from the worked
out operating conditions and with regard to
mechanical transmission loss for instance in
the V-belt drive:
1: Air conditioning plant:
Factor 1.10
Factor 1.15
Factor 1.05
0178-931 - ENG
Rev. 27.10.03
141/288
6. Technical Data
The starting torque for compressors with extended 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.
Fig. 6.20
Starting torque at 0% load
500
116S
450
Start up torque for L-models: Diagram values x 1.6
Start up torque for E-models: Diagram values x 2.6
400
112S
350
R717 (TE = +55C)
HFC/HCFC (R507 TE = +55C)
300
Torque (Nm)
250
108S
200
106S
116S
150
104S
112S
100
108S
106S
104S
50
250
500
750
1000
RPM (/min)
1250
1500
1750
2000
142/288
0178-931 - ENG
Rev. 27.10.03
6. Technical Data
06 technical data.fm
Kpm
[Lb.ft.]
Motor
starters
Motor Y starters
Compressor
0178-931 - ENG
Rev. 27.10.03
143/288
6. Technical Data
144/288
0178-931 - ENG
Rev. 27.10.03
6. Technical Data
Fig. 6.22
06 technical data.fm
Dp
0178-931 - ENG
Rev. 27.10.03
145/288
6. Technical Data
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
Type
No of cylinders:
SMC/TSMC 100
HPC 100
0.154
0.189
Compressor with
free shaft end
12
16
12
16
12
16
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
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
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
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
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
Table 6.4
Type
No of cylinders:
SMC/TSMC 100
HPC 100
3.66
4.49
Compressor with
free shaft end
12
16
12
16
12
16
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
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
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
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
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
146/288
0178-931 - ENG
Rev. 27.10.03
6. Technical Data
Fig. 6.23
SMC 112-116 and TSMC 116
Clockwise, Fig. 6.25.
06 technical data.fm
Fig. 6.25
If the motor is connected by means of a V-belt pulley, the direction of rotation should be as follows:
0178-931 - ENG
Rev. 27.10.03
147/288
6. Technical Data
The unit is lifted in the lifting eyes, which are welded onto the base frame and clearly marked with
red paint. When the unit is lifted, make sure that
148/288
0178-931 - ENG
Rev. 27.10.03
6. Technical Data
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
Coupling Types
AMR 312 for:
- SMC 104-106-108 and TSMC 108.
- HPC 104-106-108.
AMR 350 for:
- SMC 112-116 and TSMC 116.
Just like the flange to the compressor, the
motor coupling flange has been duly balanced from factory. This makes special demands on the accuracy of the boring procedure.
06 technical data.fm
Boring Procedure
The 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
Boring of Hub
The coupling flange or the pulley is usually
mounted on the compressor shaft on delivery of
compressor units.
On delivery of compressor blocks where the customer prefers to bore the hub himself, the following procedure should be observed:
It is recommended to use the types of coupling as
stated for SABROE compressors. If the necessary data is not known on delivery of the compressor, the coupling flange for the motor will be delivered pilot bored and the boring must be completed
on site.
0178-931 - ENG
Rev. 27.10.03
Max. 0.02 mm
149/288
6. Technical Data
Table 6.5
Fig. 6.31
0.02 mm
0.02 mm
H7
+0.2/0.3 mm
H8
Max. dia. 95 mm
150/288
0178-931 - ENG
Rev. 27.10.03
6. Technical Data
Coupling
An AMR coupling is used for
YORK Refrigeration's Sabroe reciprocating compressors. This coupling is resistant to torsional
stress but radially and axially flexible. Torsional
resistance is achieved by a transmission of the rotational 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
A
06 technical data.fm
Fig. 6.33
With the torsionally resistant coupling the oscillatory 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 intermediate piece B which, together with the two laminas "parcel A", creates a cardanic effect. In this
way the two flanges are able to move a little radially in relation to each other, thus equalizing minor
lateral movements of motor and compressor.
Table 6.6
Compressor
Distance
C mm
102
113
0178-931 - ENG
Rev. 27.10.03
151/288
6. Technical Data
Table 6.7
Compressor
Coupling hub - motor
Coupling hub - compressor
152/288
HPC/SMC 104-106-108
TSMC 108
SMC 112-116
TSMC 116
Balancing G
mm
AMR 312 S
AMR 350 S
550
AMR 312
AMR 350
400
0178-931 - ENG
Rev. 27.10.03
6. Technical Data
such narrow tolerances that they can be fitted immediately, which means that it is no longer necessary to check whether the belts match. A V-belt
drive which has been set up and adjusted correctly will usually have a service life of approx. 20,000
operating hours.
06 technical data.fm
Fig. 6.36
13
The V-belts are of an excellent quality. Under normal 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
0178-931 - ENG
Rev. 27.10.03
Transmission Ratio
The required transmission of speed between motor 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.
153/288
6. Technical Data
Table 6.8
400
Motor
60 Hz 1760 rpm
Length of V-belts
mm
SMC 104- 106-108 SMC 112- 116
TSMC 108
TSMC 116
180
792
1900
190
836
2650
1900
200
*730
880
2650
1900
224
817
985
2650
2000
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
154/288
0178-931 - ENG
Rev. 27.10.03
6. Technical Data
Power Transmission
The number of V-belts which must be used to
transmit the necessary power from the motor to
the compressor - which usually corresponds to the
nominal capacity of the motor - is stated in the following 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
Table 6.9
SMC/TSMC 100
The compressor pulleys are always delivered with
4 - 6 or 8 grooves.
Number of
V-belts
06 technical data.fm
817
912
976
1022
1150
1295
1460
22
22
30
30
30
37
45
45
30
37
45
45
45
55
55
75
37
45
55
55
55
75
90
90
45
55
75
75
90
110
110
55
75
75
90
90
110
132
132
75
90
106
110
118
132
150
169
Number of
V-belts
rpm
kW
836
880
985
1100
1166
1232
1386
1474
26
36
36
36
44
44
26
26
36
44
44
54
54
66
66
36
44
44
54
66
66
66
90
90
54
54
54
66
90
90
108
108
66
66
90
108
108
132
132
90
90
127
132
143
158
171
6
8
66
0178-931 - ENG
Rev. 27.10.03
108
rpm
kW
155/288
6. Technical Data
Table 6.10
Number of
V-belts
817
912
976
1022
3
4
55
55
6
90
106
Number of
V-belts
1295
1460
55
55
55
55
55
75
75
90
75
75
90
90
110
90
110
110
132
110
132
150
169
75
1150
110
kW
836
880
985
1100
1166
3
4
54
54
54
66
156/288
rpm
54
90
66
66
66
66
66
108
1232
1386
1474
54
66
66
66
90
90
90
108
108
132
132
rpm
90
108
108
kW
132
158
158
0178-931 - ENG
Rev. 27.10.03
6. Technical Data
Fig. 6.39
On standard units the nominal shaft distance between 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
06 technical data.fm
900 mm
Fig. 6.38
III
Nominal
center
distance
500 mm
0178-931 - ENG
Rev. 27.10.03
157/288
6. Technical Data
Fig. 6.42
For measuring the correct belt tension, use Tension 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 compressor.
1
2
158/288
Service
The V-belt drive has an average service life of approx. 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 After-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 obtained from our After-Market Service Department.
0178-931 - ENG
Rev. 27.10.03
6. Technical Data
Fig. 6.44
Fig. 6.43
300
06 technical data.fm
Stationary Plant
In stationary refrigeration plants the compressor
unit is either mounted directly on a concrete foundation or positioned on vibration dampers,
Fig. 6.43 and Fig. 6.44.
0178-931 - ENG
Rev. 27.10.03
159/288
6. Technical Data
Fig. 6.46
Foundation plate
10
300
250
Foundation bolts
125
Compressor
Motor
500
125
300
1250
110 x 110
350
After the foundation has hardened, the unit is located, leaving it to rest on wooden blocks in a
flush position and without twisting the base frame.
160/288
0178-931 - ENG
Rev. 27.10.03
6. Technical Data
06 technical data.fm
0178-931 - ENG
Rev. 27.10.03
rpm
Damping of 1st
order
vibrations
Damping of
2nd order
vibrations
950
1150
1450
1750
2.3-3mm
1.6-2.4mm
1.2-2.0mm
0.8-1.4mm
25-50%
30-60%
40-72%
40-74%
87-92%
87-92%
90-94%
89-94%
161/288
6. Technical Data
Fig. 6.48
3000
Damping
98%
2500
2000
95%
90%
85%
80%
70%
1400
50%
Vibrationspeed rpm
97%
1000
0%
Natural
frequency
700
500
30
20 16
12 10 8
6 5 4
1.6
mm
Since each part of the unit has its own weight, the
whole unit does not rest with the same weight on
all supports.
162/288
As a consequence, vibration dampers with different 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.
0178-931 - ENG
Rev. 27.10.03
6. Technical Data
Fig. 6.49
5
Vibration absorber type
Compressor
Compressor
Motor
Unit A
Unit B
06 technical data.fm
Motor
Pos.
A-B-C
LM
LM
LM
LM
LM
LM
LM
LM
LM
LM
a loaded state, corresponding to the deflection referred 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
2
Baseframe
h
H
LM1
80
30
38
LM3-4T025
120
37
49
LM3-33
120
32
44
0178-931 - ENG
Rev. 27.10.03
163/288
6. Technical Data
This could be in connection with housing and office buildings or e.g. hospitals.
Marine Installations
Fig. 6.53
Liner plate
164/288
0178-931 - ENG
Rev. 27.10.03
6. Technical Data
Fig. 6.54
06 technical data.fm
0178-931 - ENG
Rev. 27.10.03
Unit A
Unit B
165/288
6. Technical Data
Fig. 6.55
1.
166/288
0178-931 - ENG
Rev. 27.10.03
6. Technical Data
1.3. Frequency
The sound pressure measuring is, however, dependent on the room in which the measuring is
carried out. As a consequence, this may yield different results from one room to another.
The human ear can normally perceive frequencies 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 perceptual capacity of the ear (the A-weighting).
06 technical data.fm
0178-931 - ENG
Rev. 27.10.03
To this must be added the purely subjective perception of sound as most human beings feel considerable unease on hearing the so-called "pure"
notes. If a frequency is followed by a sound pressure 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 annoying whereas reciprocating machines issue a
more low-frequency (pleasant) sound.
167/288
6. Technical Data
2.
Fig. 6.56
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.
3,0
2,5
2,0
L 1,5
dB
1,0
0,5
5,0
10,0
15,0
Difference (L2-L1) dB
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:
168/288
0178-931 - ENG
Rev. 27.10.03
6. Technical Data
Fig. 6.57
3 compressors
56
52
61
dB
63 dB
61
62
57,5
62,6
6 compressors
48
54
62
58
dB
67 dB
55,0
62,0
65,0
66,7
67,2
06 technical data.fm
2.3.
It is essential that during a potential check measuring 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 measured values stated for a certain unit should comprise a complete unit incl. compressor, motor, oil
0178-931 - ENG
Rev. 27.10.03
169/288
6. Technical Data
3.
Table 6.12
3.1.
Compressor block
LW
Lp
SMC 104 S
SMC 106 S
SMC 108 S
SMC 112 S
SMC 116 S
95
96
97
99
100
79
80
81
82
83
SMC 104 L
SMC 106 L
SMC 108 L
SMC 112 L
SMC 116 L
96
97
98
100
101
80
81
82
83
84
SMC 104 E
SMC 106 E
SMC 108 E
SMC 112 E
SMC 116 E
96
97
98
100
101
80
81
82
83
84
3.2.
If using sound pressure Lp meters only, an additional 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!
Two-stage
LW and Lp values are measured at the following
conditions:
Evaporating temperature ET= 35C [-31F]
Condensing temperature CT= +35C [+95F]
Refrigerant=
R22/R717
Number of revolutions
= 1450 rpm
Refrigerant =
R22/R717
Number of revolutions =
1450 rpm
Table 6.13
Compressor block
LW
LP
Heat Pump
Evaporating temperature ET = 20C
TSMC 108 S
TSMC 116 S
95
97
79
81
TSMC 108 L
TSMC 116 L
96
98
80
82
TSMC 108 E
TSMC 116 E
96
98
80
82
Refrigerant =
R22/R717
Number of revolutions =
1450 rpm
Table 6.11
Compressor block
LW
LP
HPO 24
HPO 26
HPO 28
91
93
94
76
78
79
HPC 104 S
HPC 106 S
HPC 108 S
97
98
99
81
82
84
170/288
0178-931 - ENG
Rev. 27.10.03
6. Technical Data
4.
On planning or renovating a machine room, attention 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 ceiling or which is part of the building construction
06 technical data.fm
It is recommended to seek advice from a consulting 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-fabricated and tested noise baffle boards.
In General
The following paragraphs include a description of
the factors that influence the acoustic quality of a
machine room.
Reverberation Time
By a correct application of noise absorbing materials 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 absorption coefficient for the noise absorbing materials that are fitted in the room as they should be.
Absorption Coefficient
Usually the absorption coefficient for noise absorbing materials is 0.5 to 0.8. See the following illustration, Fig. 6.59.
Fig. 6.59
Noise damping
material
Fig. 6.58
Incident
sound power
Absorbed
sound power
Transmitted
sound power
X=
0178-931 - ENG
Rev. 27.10.03
171/288
6. Technical Data
Table 6.14
Reduction of sound pressure
by noise insulation of
compressor unit
Subjective perception of
the improved acoustic quality
of the room
dB
dB
Relative
reverberation time
0,5
0,9
Insignificant
0,8
Perceivable
0,6
Distinct
10
0,5
Considerable
20 *
0,25
Very considerable
*The YORK Refrigeration prefabricated Version 2.0 noise baffle board for compressor units
172/288
0178-931 - ENG
Rev. 27.10.03
6. Technical Data
DV
AV
BV
AA
xAH
BH
DHx
DA
06 technical data.fm
BA
CA
x
CH
0178-931 - ENG
Rev. 27.10.03
173/288
6. Technical Data
Fig. 6.61
The materials to be used for the individual components of the compressors have been selected in
view of a long life, wear resistance as well as re-
Table 6.15
Designation
Material
Form
Cast iron
Ductile cast iron
Cast iron
EN-GJL-250, EN 1561
EN-GJS-500-7, EN 1563
EN-GJL-250, EN 1561
EN-GJS-500-7, EN 1563
Cast iron
Cast iron
Ductile cast iron
Ductile cast iron
Ductile cast iron
Ductile cast iron
Phosphor bronze
White metal on a steel base
EN-GJL-250, EN 1561
EN-GJL-250, EN 1561
EN-GJS-500-7, EN 1563
EN-GJS-800-2, EN 1563
EN-GJS-700-2, EN 1563
EN-GJS-700-2, EN 1563
BS1400, PB1-C
Cr-Mo steel
Aluminium alloy
Cast iron
Cr-steel
Cast iron w/special heat treatment
Special steel
174/288
EN-GJS-600-3, EN 1563
54SiCr6, DIN 17221
A62P
AISI 316
AISI 304
C75, DIN 17222
Compound 2347
0178-931 - ENG
Rev. 27.10.03
6. Technical Data
06 technical data.fm
The approving authorities determine the test pressure levels on the basis of various criteria. However, the test pressure requirements can be summarized into a number of standard pressure levels
which in practice meet the requirements set up,
and which can therefore be approved by all authorities involved.
The following table, Table 6.16, shows the standard pressure levels used by YORK Refrigeration.
In case of specific applications, the authorities
may, however, demand a higher test pressure level. Within certain limits such requirements can be
met for SABROE compressors - against an addi-
Table 6.16
Standard Test Pressure Levels
Compressor Type
Compressor Side
CMO
SMC 100
SMC 180
Strength
Testing
bar
[psi]
bar
[psi]
42
[609]
25
[363]
27
[392]
14
[203]
42
[609]
25
[363]
TCMO
TSMC
27
[392]
14
[203]
42
[609]
25
[363]
HPO
80
[1160]
40
[580]
HPC
45
[653]
22
[319]
SAB 110
SAB 128
SAB 163
SAB 202
The entire
compressor block
42
[609]
21
[305]
39
[566]
26
[377]
[102]
SAB 283L/E
SAB 355 L
Compressor
Unit
Vessels
in general
0178-931 - ENG
Rev. 27.10.03
All types
The entire unit
Individual pressure testing in accordance with the local rules and regulations.
Consequently, no table can be set up.
175/288
6. Technical Data
Fig. 6.62
10 mm
Oil Charging
Compressor
Amount of oil
in crankcase
Type
Size
Liter
US gal.
HPC 100
SMC 100
TSMC 100
Mk 4 S-L-E
104
106
108
112
116
26
28
30
47
50
6.9
7.4
7.9
12.4
13.2
T0177162_0
Table 6.18
Compressor
Type
Difference in oil
level of 10 mm
corresponds to:
Size
HPC 100
SMC 100
TSMC 100
S-L-E
104
106
108
- 2 litres of oil
[0.5 US gal.]
112
116
- 6 litres of oil
[1.6 US gal.]
To compressor
Gasket
B
Cap
176/288
T0177131_0V
0178-931 - ENG
Rev. 27.10.03
6. Technical Data
Oil Consumption
In refrigeration compressors there will always be
a minor oil consumption, which means that a little
oil is bound to follow the warm discharge gas out
of the compressor.
In order to separate this oil, an oil separator is normally used. The separator is built into the discharge pipe, right next to the compressor. The
separated oil is returned to the compressor as described in Section 4, Technical Description - Oil
Separator.
In return, the oil in larger and ramified R717 refrigeration plants should be drained off and never reused in the compressor. This amount of oil represents the so-called oil consumption measured in
ppm. Ppm is the abbreviation for parts per million
and is calculated by using the following formula:
A minor part of the oil, however, present in the discharge gas as vapour, cannot be separated and
06 technical data.fm
0178-931 - ENG
Rev. 27.10.03
177/288
6. Technical Data
Table 6.19
Oil Separators
Code no.
Part no.
Type
4241.280
4241.280
4241.280
4241.280
4241.280
4241.280
OVUR 3206D
OVUR 3206D
OVUR 3206D
OVUR 3206D
OVUR 3206D
OVUR 3206D
4241.280
4241.280
4241.281
4241.280
4241.280
4241.280
4241.281
4241.280
OVUR 3206D
OVUR 3206D
OVUR 4107D
OVUR 3206D
OVUR 3206D
OVUR 3206D
OVUR 4107D
OVUR 3206D
4241.280
4241.280
4241.281
4241.280
4241.280
4241.280
4241.281
4241.280
OVUR 3206D
OVUR 3206D
OVUR 4107D
OVUR 3206D
OVUR 3206D
OVUR 3206D
OVUR 4107D
OVUR 3206D
4241.281
4241.281
4241.342
4241.281
4241.281
4241.281
4241.342
4241.281
OVUR 4107D
OVUR 4107D
OVUR 5008 HP
OVUR 4107D
OVUR 4107D
OVUR 4107D
OVUR 5008 HP
OVUR 4107D
4241.281
4241.281
4241.282
4241.342
4241.281
4241.281
4241.281
4241.282
4241.342
4241.281
OVUR 4107D
OVUR 4107D
OVUR 6006D
OVUR 5008 HP
OVUR 4107D
OVUR 4107D
OVUR 4107D
OVUR 6006D
OVUR 5008 HP
OVUR 4107D
178/288
Refr.
0178-931 - ENG
Rev. 27.10.03
6. Technical Data
06 technical data.fm
Code no.
Part no.
Type
TSMC 108S-B301
TSMC 108L-B301
TSMC 108E-B301
TSMC 108S-B311
TSMC 108L-B311
TSMC 108E-B311
TSMC 108S-B302
TSMC 108L-B302
TSMC 108E-B302
TSMC 108S-B312
TSMC 108L-B312
TSMC 108E-B312
4241.279
4241.279
4241.279
4241.279/4241.280
4241.279/4241.280
4241.279/4241.280
4241.279
4241.279
4241.279
4241.279/4241.280
4241.279/4241.280
4241.279/4241.280
OVUR 2106D
OVUR 2106D
OVUR 2106D
OVUR 2106D/OVUR 3206D
OVUR 2106D/OVUR 3206D
OVUR 2106D/OVUR 3206D
OVUR 2106D
OVUR 2106D
OVUR 2106D
OVUR 2106D/OVUR 3206D
OVUR 2106D/OVUR 3206D
OVUR 2106D/OVUR 3206D
TSMC 116S-B301
TSMC 116L-B301
TSMC 116E-B301
TSMC 116S-B311
TSMC 116L-B311
TSMC 116E-B311
TSMC 116S-B302
TSMC 116L-B302
TSMC 116E-B302
TSMC 116S-B312
TSMC 116L-B312
TSMC 116E-B312
4241.280
4241.280
4241.280
4241.280/4241.281
4241.280/4241.281
4241.280/4241.281
4241.280
4241.280
4241.280
4241.280/4241.281
4241.280/4241.281
4241.280/4241.281
OVUR 3206D
OVUR 3206D
OVUR 3206D
OVUR 3206D/OVUR 4107D
OVUR 3206D/OVUR 4107D
OVUR 3206D/OVUR 4107D
OVUR 3206D
OVUR 3206D
OVUR 3206D
OVUR 3206D/OVUR 4107D
OVUR 3206D/OVUR 4107D
OVUR 3206D/OVUR 4107D
Refr.
OVUR 3206D
SMC 106E:
SMC 108E:
SMC 112E:
SMC 112E:
0178-931 - ENG
Rev. 27.10.03
179/288
6. Technical Data
180/288
General
This recommendation will only deal with the lubrication 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 refrigeration compressors.
To achieve the best lubrication, the oil must:
Moreover, the extent to which different refrigerants dissolve in the oil must be determined so that
the oil return system, etc. can be designed to perform at its optimum.
Stratification
Note that the oil in some plants is layered in refrigerant receivers and evaporators under certain operating conditions and at certain oil concentrations.
Plants with Several Different Compressor
Types/Makes
In plants where several different compressor
types/makes are connected, it is strongly recommended to use the same type of oil in all the compressors. This is very important where automatic
oil return systems are used.
0178-931 - ENG
Rev. 27.10.03
6. Technical Data
06 technical data.fm
Code
design
Oil types
Mineral oil
PAO
AP
E
0178-931 - ENG
Rev. 27.10.03
Oil type
Compressor type
181/288
6. Technical Data
182/288
0178-931 - ENG
Rev. 27.10.03
6. Technical Data
06 technical data.fm
Fig. 6.64
TC
F
122
50
104
40
86
30
68
20
50
10
32
14 -10
-4
-20
-22 -30
-60
-50
-40
-30
-20
-10
10
20
-76
-58
-40
-22
-4
14
32
50
68
TE
Area no. 1
/
See note
0178-931 - ENG
Rev. 27.10.03
183/288
6. Technical Data
184/288
0178-931 - ENG
Rev. 27.10.03
6. Technical Data
06 technical data.fm
SH
0178-931 - ENG
Rev. 27.10.03
185/288
6. Technical Data
Viscosity
Viscosity
Spec.
Flash p.
Pour p.
Anilin
Acid no.
code
cSt
40C
cSt
100C
Index
grav. at
15C
COC
C
C
point
mg
KOH/g
M1
63
6.4
14
0.91
202
-36
81
0.02
A3
97
8.1
13
0.86
206
-32
78
0.05
AP1
64
9.3
121
0.858
195
-51
121
0.04
PAO3
66
10.1
136
0.835
266
<-45
138
0.03
PAO5
94
13.7
147
0.838
255
<-45
144
0.03
PAO9
208
25
149
0.846
260
<-39
154
0.03
E3
E5
E9
Due to the great difference between polyolester-based lubricants from various suppliers, it is not possible to present any typical data for these oils. When using another oil brand than the one recommended by YORK Refrigeration, please contact the oil supplier to select the correct oil type.
E11
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.
186/288
0178-931 - ENG
Rev. 27.10.03
6. Technical Data
Part no.
20 litre pail
M1 (M68)
1231-264
1231-296
A3 (A100)
1231-263
1231-262
AP1 (AP68)
1231-257
1231-260
PAO3 (P68)
1231-256
1231-259
PAO5 (P100)
1231-282
1231-283
PAO9 (P220)
1231-284
1231-285
E3 (E68)
1231-272
1231-273
E5 (E100)
1231-274
1231-275
E9 (E220)
Sabroe H oil
E11 (E370)
1)
06 technical data.fm
1231-279
3914 1512 954
1)
The oils recommended by the former Stal Refrigeration correspond to the following oils:
Stal Refrigeration oil type
A
0178-931 - ENG
Rev. 27.10.03
Sabroe oil
187/288
6. Technical Data
R717
TC
F
one-stage
reciprocating
compressor
122 50
Condensing temperature
104 40
86
30
68
20
50
10
32
14 -10
-4 -20
-22 -30
-60
-50
-40
-30
-20
-10
-76
-58
-40
-22
-4
14
10
20
32
50
68
TE
Evaporating temperature
Code no
PAO 3
AP 1
M1
Area no 1
s
/
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.
j:
:
188/288
0178-931 - ENG
Rev. 27.10.03
6. Technical Data
R717
TC
F
two-stage
reciprocating
compressors
122 50
Condensing temperature
104 40
86 30
68
20
50
10
32
14 -10
06 technical data.fm
-4 -20
-22 -30
-60
-50
-40
-30
-20
-10
10
20
-76
-58
-40
-22
-4
14
32
50
68
TE
Evaporating temperature
Code no
Area no 1
PAO 3
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.
j:
:
0178-931 - ENG
Rev. 27.10.03
189/288
6. Technical Data
R717
TC
F
176 80
Condensing temperature
158 70
140 60
122 50
104 40
86 30
68 20
50 10
32
0
-30
-20
-10
10
20
30
40
50
-22
-4
14
32
50
68
86
104
122
TE
Evaporating temperature
Code no
PAO 5
Area no 1
Note: Please observe: PAO 5 oil is the only oil which can be used in the HPO and HPC compressors
j:
190/288
0178-931 - ENG
Rev. 27.10.03
6. Technical Data
Oil Types
06 technical data.fm
PAO
AP
Aral
Avia
BP
Castrol
DEA
Esso/Exxon
Fina
Fuchs
Hydro-Texaco
ICI
Mobil
Petro-Canada
Shell
Statoil
Sun Oil
0178-931 - ENG
Rev. 27.10.03
191/288
6. Technical Data
f.
192/288
Moreover, the extent to which different refrigerants dissolve in the oil must be determined so that
the oil return system, etc. can be designed to perform at its optimum.
Stratification
Note that the oil in some plants is layered in refrigerant receivers and evaporators under certain operating conditions and at certain oil concentrations. This applies in particular to HFC/HCFC
plants.
The oil recommendation diagrams for SABROE
compressors with HFC and HCFC refrigerants indicate the limits for Sabroe oils where stratification
occurs. The oil concentrations stated in these diagrams must not be exceeded. This makes it possible to adjust the oil rectification/return systems
to the oil consumption of the compressor so that
the maximum concentration is not exceeded. For
area A in the diagrams, the oil concentration in the
liquid phase must not exceed 2%. For the other
0178-931 - ENG
Rev. 27.10.03
6. Technical Data
06 technical data.fm
Oil types
Mineral oil
PAO
AP
0178-931 - ENG
Rev. 27.10.03
193/288
6. Technical Data
Oil type
Refrigerant type
Compressor type
Oil temperature
194/288
0178-931 - ENG
Rev. 27.10.03
6. Technical Data
Fig. 6.65
140 60
06 technical data.fm
TC
F C
158 70
122 50
Condensing temperature
Mineral oil can be used in refrigeration plants, provided 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.
R134a
104 40
w w
86 30
68 20
50 10
32
14 10
4
20
22 30
60
50 40
76
58 40
30
20 10
10
20 30 C
4 14 32 50 68 86 F
22
Evaporating temperature
TE
Area no.
1
E5
E9
0178-931 - ENG
Rev. 27.10.03
195/288
6. Technical Data
the compressor, oil separator or plant. Oil residues 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 obtained 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.
196/288
0178-931 - ENG
Rev. 27.10.03
6. Technical Data
06 technical data.fm
SH
0178-931 - ENG
Rev. 27.10.03
197/288
6. Technical Data
Viscosity
Viscosity
Spec.
Flash p.
Pour p.
Anilin
Acid no.
code
cSt
40C
cSt
100C
Index
grav. at
15C
COC
C
C
point
mg
KOH/g
M1
63
6.4
14
0.91
202
-36
81
0.02
A3
97
8.1
13
0.86
206
-32
78
0.05
AP1
64
9.3
121
0.858
195
-51
121
0.04
PAO3
66
10.1
136
0.835
266
<-45
138
0.03
PAO5
94
13.7
147
0.838
255
<-45
144
0.03
PAO9
208
25
149
0.846
260
<-39
154
0.03
E3
E5
E9
Due to the great difference between polyolester-based lubricants from various suppliers, it is not possible to present any typical data for these oils. When using another oil brand than the one recommended by YORK Refrigeration, please contact the oil supplier to select the correct oil type.
E11
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.
198/288
0178-931 - ENG
Rev. 27.10.03
6. Technical Data
Part no.
20 litre pail
M1 (M68)
1231-264
1231-296
A3 (A100)
1231-263
1231-262
AP1 (AP68)
1231-257
1231-260
PAO3 (P68)
1231-256
1231-259
PAO5 (P100)
1231-282
1231-283
PAO9 (P220)
1231-284
1231-285
E3 (E68)
1231-272
1231-273
E5 (E100)
1231-274
1231-275
E9 (E220)
Sabroe H oil
E11 (E370)
1231-279
3914 1512 954
1)
06 technical data.fm
The oils recommended by the former Stal Refrigeration correspond to the following oils:
Stal Refrigeration oil type
A
0178-931 - ENG
Rev. 27.10.03
Sabroe oil
199/288
6. Technical Data
ContactYORK Refrigeration
TC
R22
Condensing temperature
one-stage
reciprocating
compressors
122
50
104
40
86
30
68
20
50
10
32
14 -10
-4
-20
-22 -30
-60
-50
-40
-30
-20
-10
-76
-58
-40
-22
-4
14
Code no
a:
c:
10
20 C
32
50
68 F
TE
Evaporating temperature
Area no 1
A3
200/288
0178-931 - ENG
Rev. 27.10.03
6. Technical Data
R22
TC
F
two-stage
reciprocating
compressors
122 50
Condensing temperature
104 40
86
30
68 20
50 10
32
14 -10
06 technical data.fm
-4 -20
-22 -30
-60
-50
-40
-30
-20
-10
10
20
-76
-58
-40
-22
-4
14
32
50
68
TE
C Evaporating temperature
Code no
Area no 1
A3
a:
c:
0178-931 - ENG
Rev. 27.10.03
201/288
6. Technical Data
TC
R134a
158 70
one-stage
reciprocating
compressors
140 60
Condensing temperature
122 50
104 40
86
30
68
20
50
10
32
14 -10
-4 -20
-22 -30
-60 -50 -40 -30 -20 -10
10
20
30 C
32
50
68
86 F
-4
14
TE
Evaporating temperature
Code no
Area no
1
E5
E9
L:
202/288
0178-931 - ENG
Rev. 27.10.03
6. Technical Data
R134a
TC
F
C
158 70
two-stage
reciprocating
compressors
Condensing temperature
140 60
122 50
104 40
86
30
68
20
50
10
32
14 -10
-4
06 technical data.fm
-20
-22 -30
-40 -40
-70 -60 -50 -40 -30 -20 -10
-94 -76 -58 -40 -22
-4
10
20
30 C
14 32
50
68
86 F
TE
Evaporating temperature
Code no
Area no
1
E5
0178-931 - ENG
Rev. 27.10.03
203/288
6. Technical Data
R407C
TC
F
one-stage
reciprocating
compressors
122 50
Condensing temperature
104 40
86
30
68 20
50 10
32
14 -10
-4 -20
-22 -30
-60
-50
-40
-30
-20
-10
10
20
-76
-58
-40
-22
-4
14
32
50
68
Code no
TE
Evaporating temperature
Area no
1
E3
: :
b:
c:
204/288
0178-931 - ENG
Rev. 27.10.03
6. Technical Data
R407C
TC
F
two-stage
reciprocating
compressors
122 50
Condensing temperature
104 40
86
30
1
B
68 20
50 10
32
14 -10
-4 -20
06 technical data.fm
-22 -30
-60
-50
-40
-30
-20
-10
10
20
-76
-58
-40
-22
-4
14
32
50
68
Code no
TE
Evaporating temperature
Area no
1
E3
: :
b:
c:
0178-931 - ENG
Rev. 27.10.03
205/288
6. Technical Data
R404A
TC
F
one-stage
reciprocating
compressors
122 50
Condensing temperature
104 40
86
30
68 20
50 10
32
14 -10
-4 -20
-22 -30
-60
-50
-40
-30
-20
-10
10
20
-76
-58
-40
-22
-4
14
32
50
68
TE
Evaporating temperature
Code no
Area no
1
E3
E5
: :
c:
L:
206/288
0178-931 - ENG
Rev. 27.10.03
6. Technical Data
TC
R404A
F
two-stage
reciprocating
compressors
122 50
Condensing temperature
104 40
86
30
68
20
50 10
32
14 -10
06 technical data.fm
-4 -20
-22 -30
-60
-50
-40
-30
-20
-10
10
20
-76
-58
-40
-22
-4
14
32
50
68
Code no
TE
Evaporating temperature
Area no
1
E3
: :
c:
0178-931 - ENG
Rev. 27.10.03
207/288
6. Technical Data
R410A
TC
122
60
Condensing temperature
104
50
40
86
30
68
20
50
10
32
0
A
-10
14
-20
-4
-30
-22 -40
-60 -50 -40 -30 -20 -10
-76 -58 -40 -22
Code no
Area no
-4
10
20
14 32
50
68
30
40
50
F
Evaporating temperature
E5
: :
a:
208/288
0178-931 - ENG
Rev. 27.10.03
6. Technical Data
R507
TC
F
one-stage
reciprocating
compressors
122 50
Condensing temperature
104 40
86
30
68 20
50 10
32
14 -10
-4 -20
06 technical data.fm
-22 -30
-60
-50
-40
-30
-20
-10
10
20
-76
-58
-40
-22
-4
14
32
50
68
Code no
TE
Evaporating temperature
Area no
1
E5
: :
c:
0178-931 - ENG
Rev. 27.10.03
209/288
6. Technical Data
R507
TC
F
two-stage
reciprocating
compressors
122 50
Condensing temperature
104 40
86
30
1
68 20
50 10
32
14 -10
-4 -20
-22 -30
-60
-50
-40
-30
-20
-10
10
20
-76
-58
C
-40
-22
-4
14
32
50
68
TE
Code no
Evaporating temperature
Area no
1
E5
: :
c:
210/288
0178-931 - ENG
Rev. 27.10.03
6. Technical Data
Oil Types
06 technical data.fm
PAO
AP
Aral
Avia
BP
Castrol
DEA
Esso/Exxon
Fina
Fuchs
Hydro-Texaco
ICI
Mobil
Petro-Canada
Shell
Statoil
Sun Oil
0178-931 - ENG
Rev. 27.10.03
211/288
6. Technical Data
212/288
0178-931 - ENG
Rev. 27.10.03
7. Installation Instructions
7. Installation Instructions
The purpose of this document is to describe:
Safety Precautions
the dangers which may occur when the instructions and safety precautions pertaining
to the installation phase are not followed,
Read Section 3, Safety Precautions, carefully before commencing the installation. If in doubt,
please contact YORK Refrigeration.
07 installation instructions.fm
This document is intended primarily for the installation 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 compressor unit.
YORK Refrigeration
Chr. Xs Vej 201
DK-8270 Hoejbjerg
Denmark
Copyright 2003 YORK Refrigeration
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 equipment! Always read the safety precautions belonging to this equipment before starting the installation process. Failure to comply with safety precautions may cause death or injury to personnel. It
may also cause damage to or destruction of the
equipment.
0178-931 - ENG
Rev. 27.10.03
Installation Data
The physical data of the compressor are included
in Section 5, Physical and Connection Data. See
also Section 6, Technical Data - Noise from compressors and units, Laying the foundation.
Installation Drawings
Before commencing the installation, make sure
that drawings showing how to connect the unit are
available.
Personnel Requirements
The personnel which carry out the installation
must be well-trained within the area of refrigeration technique, possess knowledge of refrigeration systems and have experience with pipe as
well as wiring installations. Where authorisation is
required, the electrician must possess an approved authorisation.
The compressors must only be connected by
an authorised refrigeration company.
213/288
7. Installation Instructions
Safety shoes
Gloves
Oxygen equipment
Eye protectors
Fire-fighting appliances
Local Regulations
The 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 Requirements
Dimensions for all compressor types and units are
included in the binder Dimensions and Piping Diagrams. Note in particular the minimum distances, which must ensure that the compressor can be
serviced under all kinds of conditions, e.g. replacement 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.
WDanger!
Risk of injury to personnel and damage to equipment! Always read the safety precautions belonging 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.
2.
3.
4.
214/288
0178-931 - ENG
Rev. 27.10.03
7. Installation Instructions
Preparing Lifts
07 installation instructions.fm
0178-931 - ENG
Rev. 27.10.03
215/288
7. Installation Instructions
Installation Instructions
WDanger!
Risk of injury to personnel and damage to equipment! Always read the safety precautions belonging 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.
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:
Coupling is untrue.
216/288
on vibration dampers.
0178-931 - ENG
Rev. 27.10.03
7. Installation Instructions
1
A1
A2
H
Hmax
07 installation instructions.fm
A1
A2
T0177040_0
Industrial type
Marine type
Flexion
min 1.0
A1A2
max 2.0
min 3.0
max 5.0
Height
adjustment
Hmax= H+12
with disks
supplied as
shown
0178-931 - ENG
Rev. 27.10.03
217/288
7. Installation Instructions
218/288
0178-931 - ENG
Rev. 27.10.03
7. Installation Instructions
Important!
Fig. 7.2
1
Z
07 installation instructions.fm
A
F
Table 7.1
Distance mm
Compressor
Coupling
size
Torque Nm
C
Nominal*
SMC
104-106-108
312 S
102
25
147
55
44
SMC 112-116
350 S
113
27
147
128
44
0178-931 - ENG
Rev. 27.10.03
219/288
7. Installation Instructions
Preliminary installation
Note: Never tighten the cone screws "D" unless
there is a shaft inside the bore. Otherwise it might
damage the cone system.
Place the hub at the compressor side, observing the measurement "F".
Assemble the intermediate piece and the lamella segments with the 8 screws, applying
the prescribed torque. Remember the
shaped washers facing the lamellas.
220/288
Insert the coupling intermediate piece. Create 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 coupling flange.
0178-931 - ENG
Rev. 27.10.03
7. Installation Instructions
Alignment
Check that the motor with loose bolts is positioned
with all four feet on the base frame. Insert any liner
plates needed where there is an air gap beneath
the feet. Tighten the bolts loosely.
07 installation instructions.fm
y= X
b
2xa
Fig. 7.3
Table 7.2
Maximum variation (mm) measured with feeler gauge at a
180 turning of the coupling
Compressor
Pos 1
Coupling size
Pos 2
Horizontal
Vertical
max.
max. mm
min./max. mm
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
0178-931 - ENG
Rev. 27.10.03
221/288
7. Installation Instructions
After securing the motor, repeat the measurement and compare the result with the table 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 minimum of 0.1 mm distance less at the top position of the alignment gauge.
Final installation
Check the alignment of the coupling in horizontal and vertical planes for pos. 1 and
pos. 2.
Guide both measuring pins towards the coupling with a 1.0 mm feeler gauge in between.
222/288
0178-931 - ENG
Rev. 27.10.03
7. Installation Instructions
Preliminary Installation
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.
Guide measuring pin (Pos. 2) towards coupling flange by means of a 1.0 mm feeler
gauge and fix pin. Remove feeler gauge.
Shift motor coupling flange to achieve distance "C" in table, Fig. 7.2.
07 installation instructions.fm
0178-931 - ENG
Rev. 27.10.03
y = X
b
2xa
223/288
7. Installation Instructions
Fig. 7.4
Turn coupling so that alignment gauge faces out to one side horizontally.
Guide both measuring pins towards coupling with a 1.0 mm feeler gauge in between.
2.
y
b
After tightening motor bolts, repeat measurement and compare result with values in
table under Pos. 2, Fig. 7.2
Guide measuring pin (pos. 1) towards coupling flange by means of a 1.0 mm feeler
gauge and fix pin. Remove feeler gauge.
Final Installation
Readjust flange distance "C" so that lamellae are aligned by moving motor flange on
shaft and securing motor flange.
1.
224/288
0178-931 - ENG
Rev. 27.10.03
7. Installation Instructions
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 compressive stresses or tensile strains in the event of expansions or contractions due to temperature
changes. Steel pipes expand approx. 1 mm per
metre per 100C.
We recommend that piping be laid as shown in example 2 of the sketch, Fig. 7.5. Example 1 demonstrates too rigid pipe laying.
Fig. 7.5
> 1.5 m
07 installation instructions.fm
0178-931 - ENG
Rev. 27.10.03
225/288
7. Installation Instructions
WDanger!
Risk of injury to personnel and damage to equipment! Always read the safety precautions belonging 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.
Before connecting, make sure that
there is no power on the cables which
are to be connected,
the power cannot be connected accidentally. 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 connections should be checked by an electrician.
Remember! Check that the direction of rotation 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 Diagrams. 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 diagrams.
Fig. 7.6
226/288
0178-931 - ENG
Rev. 27.10.03
07 installation instructions.fm
7. Installation Instructions
former XXX/1 A AC, which reads the motor current 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 terminals 107 and 108. The alarm output is supplied
by applying max. 230 V to terminal 107 - see page
020 in diagram 2347-003.
Connections to Motor
The control supply of the motor must be connected 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-
0178-931 - ENG
Rev. 27.10.03
UNISAB II is prepared for connection of thermopump. The connection is shown on page 028 in diagram 2347-003.
6.3 Control without UNISAB II
Where the unit is to be controlled by a control system 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 detailed descriptions of how to carry out the connection.
227/288
7. Installation Instructions
7. Pressure Testing
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 between the nitrogen cylinder and the plant.
During pressure testing, it is important to ensure 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.
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.
228/288
By way of a second tightness test, examine all welds, flange joints etc. for
leakage by applying soapy water while
maintaining the pressure of 10 bar.
comments.
0178-931 - ENG
Rev. 27.10.03
7. Installation Instructions
07 installation instructions.fm
Important!
Never use the refrigeration compressor to
evacuate the plant.
For an evacuation to be performed satisfactorily, 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 10C. In such
cases it will be necessary to supply heat to
the component surroundings, as ice evaporates with difficulty.
It is recommended to carry out evacuation
as follows:
Table 7.3
Boiling point
of water C
At pressure
mm HG
bar
6.63
0.0088
10
9.14
0.0122
15
12.73
0.0170
20
17.80
0.0237
0178-931 - ENG
Rev. 27.10.03
229/288
7. Installation Instructions
8. Oil Charging
Since the compressor is usually delivered without
any oil in the crank case, oil must be charged in
230/288
0178-931 - ENG
Rev. 27.10.03
7. Installation Instructions
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
07 installation instructions.fm
OK
Level foundation
Measure flexion
Pressure testing: After putting the unit under pressure, paint with soapy water around welds, thread
connections and union nuts.
Torque
Electrical connection
Oil charging
0178-931 - ENG
Rev. 27.10.03
231/288
7. Installation Instructions
232/288
0178-931 - ENG
Rev. 27.10.03
8. Components
8. Components
The 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 mounted.
This document is primarily intended for constructing engineers, service technicians, future customers, sales personnel and personnel in the process
of training.
This document was produced by:
YORK Refrigeration
Chr. Xs Vej 201
DK-8270 Hoejbjerg
Denmark
Valves
Suction valve
Discharge valve
Purge valve
08 components.fm
Variable speed drive (VSD) in connection with computerized capacity regulating system.
Equipment
General
SMC 100 and TSMC 100 compressor blocks and
units are available in different versions with different components.
Regulating Systems
0178-931 - ENG
Rev. 27.10.03
Oil separator
Oil cooler
Heating element
233/288
8. Components
Motors
The standard SMC 100 and TSMC 100 units are
available with motors in different sizes, with different enclosures, power and supply voltage.
The necessary motor power depends on the operating conditions of the unit. The motor size can be
determined on the basis of the calculations in the
calculation program COMP1.
Oil Separators
Section 6, Technical Data - Oil separators includes a complete list of application areas for the
individual oil separators.
The function and mode of operation of the oil separator are described in detail in Section 4, Technical Description.
Transmission Systems
Oil Coolers
Directly Driven
The power transmission between motor and compressor 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 coupling hub with bushing is mounted on the compressor. 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 coupling 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 Driven
The power transmission takes place by means of
V-belts. The compressor is always delivered with
234/288
The table below shows which oil cooler (depending on the type of refrigerant) forms part of the
units.
Table 8.1
Refrigerant
OSSI
R 717
OOKH
HFC/HCFC
Table 8.2
Combinations
Water-cooled top and side covers
Air-cooled top covers and
water-cooled side covers
Air-cooled top and side
covers, refrigerant-cooled
oil cooler
Chosen on the
basis of
operating
limits
Thermo pump
0178-931 - ENG
Rev. 27.10.03
8. Components
Regulating Components
Electromechanical Control
The following components form part of the electromechanical control:
Moreover, the compressor is equipped with manometers for visual control of the pressure conditions.
KP15
KP5
Intermediate cut-out
MP55
KP98
KP98
Oil thermostat
KZD4/M3
08 components.fm
0178-931 - ENG
Rev. 27.10.03
235/288
8. Components
UNISAB II
The UNISAB II control receives its impulses from
pressure transducers and temperature sensors.
236/288
Heating Element
The compressor is equipped with a heating element 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.
Accessories
If the compressor is to be installed in rooms where
explosive gases may occur, special explosion-proof components can be delivered, see
Section 4, Technical Description - Compressor
Accessories.
0178-931 - ENG
Rev. 27.10.03
9. Settings
9. Settings
The purpose of this document is to provide information 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 was produced by:
YORK Refrigeration
Chr. Xs Vej 201
DK-8270 Hoejbjerg
Denmark
09 settings.fm
Safety Precautions
WDanger!
Risk of injury to personnel and damage to equipment! In addition to the safety precautions in this
document, always read the safety precautions belonging to this equipment before changing the settings. Failure to comply with safety precautions
may cause death or injury to personnel. It may
also cause damage to or destruction of the equipment.
Qualification Requirements
Changes in the factory settings must only be carried 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 operation, 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.
0178-931 - ENG
Rev. 27.10.03
237/288
9. Settings
Table 9.1
R 134
R 404A
R 507
R 717
SafetyEquipment
ControlEquipment
Min. setting
(own setting)
24 bar (standard)
22 bar (special)
MT
12 bar
KP5
(KP15)
Low-pressure cut-out
KP1
(KP15)
MP55
3.5 bar
KP98
Oil thermostat
KP98
KP77
T (E) X
T (E) N
T (E) S
Safety valve on
compressor
HT
TEAT
Injection valve for intermediate cooling
By-pass valve
Oil filter differential
pressure
Oil pressure regulating valve
Refrigerant
T (E) X
TEA
KZD4/M3
* 120 C
X
* 150 C
80 C
55 C
PMC+ CVC
-15 C
2,0 bar
-25 C
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. Adjustment 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.
238/288
0178-931 - ENG
Rev. 27.10.03
9. Settings
Mesuaring
Max.
Factory
Setting
Note
Suction pressure
[bar]
High alarm
High warning
Low warning
Low alarm
1,5
-1,0
-1,0
9,0
6,0
6,0
5,0
2,5
1,5
Discharge pressure
[bar]
High alarm
High warning
Low warning
Low alarm
4,0
3,0
-1.0
24,0
22,0
-1.0
16,0
15,0
-1.0
1+6
1+6
Intermediate pressure
[bar]
For two-stage
compressors only
High alarm
High warning
Low warning
Low alarm
4,0
3,0
-1,0
-1,0
24,0
22,0
10,0
10,0
7,0
6,0
-1,0
-1,0
1+6
1+6
1+6+16
1+6+16
Oil pressure
[bar]
High alarm
High warning
Low warning
Low alarm
5,0
5,0
0,5
0,5
7,0
7,0
5,0
5,0
6,0
5,5
4,0
3,5
2+5+16
2+5
2+5+14
2+5+14
Note
Calculated value
09 settings.fm
Min.
Table 9.3
3+4+5
3+4+5
3+4+5
1+5
Measuring
Min.
Max.
Factory
Setting
Discharge temperature
[C]
High alarm
High warning
Low warning
Low alarm
60,0
50,0
-65,0
-
155,0
155,0
-65,0
-
125,0
120,0
-65,0
-
1+6
1+6
Oil temperature
[C]
High alarm
High warning
Low warning
Low alarm
40,0
30,0
0,0
0,0
105,0
105,0
50,0
40,0
80,0
75,0
30,0
25,0
2
2
2+7
2+7
Brine temperature
[C]
High alarm
High warning
Low warning
Low alarm
-60,0
-60,0
-100,0
-100,0
100,0
100,0
100,0
100,0
60,0
50,0
4,0
2,0
1+6
1+6
1+6
1+6
Intermediate gas
temperature [C]
For two-stage
compressors only
High alarm
High warning
Low warning
Low alarm
50,0
50,0
-20,0
-20,0
155,0
120,0
50,0
50,0
100,0
95,0
4,0
2,0
2+7
2+7
2+7
2+7
High alarm
High warning
Low warning
Low alarm
6,0
5,0
0,0
0,0
120,0
120,0
40,0
40,0
110,0
100,0
4,0
2,0
2+7
2+7
2+7+13
2+7+13
High alarm
High warning
5,0
0,0
40,0
40,0
10,0
0,0
2+7+10
2+7+10
Calculated value
Disch. gas superheat
[C]
Calculated value
0178-931 - ENG
Rev. 27.10.03
239/288
9. Settings
Auxiliary input
(4-20 mA)
Min.
Max.
Factory
Note
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
Notes:
Note 1
The alarm cannot be switched off until the problem has been solved.
Note 13
Note 2
Note 14
Note 3
Note 15
Note 4
Note 16
Note 5
Note 17
Note 6
Alarm monitoring always active - except when "BLOCKED" has been selected in the picture COMPRESSOR
CTRL MODE.
Note 7
For VMY Mk 2-2.5, calculate the following below: Oil pressure = Oil
pressure 3 (after oil filter) - Discharge pressure 2. For all other
compressor types (except for SAB
80, see Note 20), calculate the following: Oil pressure = Oil pressure 3
(after oil filter) - Suction pressure 1 .
Note 18
Note 19
Note 8
Note 9
Note 10
Note 11
Note 12
240/288
0178-931 - ENG
Rev. 27.10.03
9. Settings
Table 9.4
09 settings.fm
No.
Min.
+35
-20
-20
0178-931 - ENG
Rev. 27.10.03
Note 22:
Oil Cooling
Regulator Type
Note 21:
Max.
Factory
Setting
+75
+75
+150
+150
Unit
+55
5(fixed)
+35
5(fixed)
+100
5(fixed)
+100
5(fixed)
241/288
242/288
30
20
59
52
58
48
53
45
50
44
49
25 6.6
30 7.7
67
52
57
62
67
72
77
62
67
72
76
84
68
80
88 102 117 14.3 59
97 113 11.0 60
72
59
70
78
86
82 16.5 81
8.2 48
8
9.5 57
9
12.7 73
84 12
14.5 82
89 14
16.5 90
92 16
9.5 69
9
69
11.1 65
76 11
8.2 59
8
65
75
79
11.1 75
86 11
74
58
62
68
74
79
84
68
72
78
67
53
58
63
68
73
77
63
68
73
63
51
55
60
64
69
73
61
65
70
45 11.5 61
48
54
59
63
69
30 7.7
35 8.8
45 11.5 71
64
25 6.6
40 10.1 67
58
20 5.7
20 5.7
25 6.6
30 7.7
87
87
91
86
81
76
71
66
81
76
71
66
61
56
71
66
61
56
51
46
20
9.1
7.6
20
30
91 110 131
10
71
77
65
53
+10
9.1
7.6
9.1
78
87
7.6
82
77
65
81 10.7
77
72
75 12.6
71 10.7
67
62
40
or
intermediate temperature
Evaporating temperature
R717
92
87
83
78
73
87
82
77
73
68
63
77
72
67
63
58
53
30
83
82
89
83
79
40 10.1 77
45 11.5 81
76
12.7 84
94 12
84
78
74
73
35 8.8
62
82
14.5 72
79 14
69
63
59
40 10.1 57
98
57
99 115 16.2 54
85
74
74 12.7 68
64
58
54
52
92 108 14.3 49
77
65
11.1 55
66 11.
47
84 101 12.5 44
69
57
9.5 47
9
42
91 11.0 40
76
61
48
8.2 37
8
53
35 8.8
55
48
43
41
38
20 5.7
10
30
20
10
+10
Evaporating temperature
or
intermediate temperature
R404A/R507
10
30
20
10
Evaporating temperature
or
intermediate temperature
R22
Fig. 9.1
Evaporating temperature
or
intermediate temperature
Condensing temp. C
+10
R134a
HFC HCFC
9. Settings
0178-931 - ENG
Rev. 27.10.03
Safety Precautions
WDanger!
10 operating instructions.fm
WDanger!
Risk of injury to personnel and damage to equipment! Always read the safety precautions belonging 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.
0178-931 - ENG
Rev. 27.10.03
Ventilation
Before 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 associated with using the refrigerant and oil. Pay close attention to the fact that large amounts of escaping
(or released) refrigerant entail risk of suffocation.
The safety instructions also explain the risks generally associated with refrigerants. Body contact
with leaking liquid refrigerant entails high risk for
injuries caused by intense cold.
Pressure
A compressor unit comprises a pressurized system. Never loosen threaded joints (such as a
union nut) while the system is under pressure and
never open pressurized parts of the system.
243/288
Qualification Requirements
A compressor unit contains both hot and cold system parts. Always wear and use the re-commended safety items.
The personnel must also fulfil all national requirements for authorization.
244/288
0178-931 - ENG
Rev. 27.10.03
10 operating instructions.fm
Analogue System
The 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 components:
0178-931 - ENG
Rev. 27.10.03
245/288
1.
2.
0.0 BAR
DISCH. PRESS.
0.0 BAR
MOTOR CURR.
0A
STOPPED
0%
UNISAB II
UNISAB II
246/288
0178-931 - ENG
Rev. 27.10.03
Display
Pos. 1
Pos. 4
Pos. 5
Pos. 6
Pos. 7
Pos. 8
10 operating instructions.fm
Front Panel
The UNISAB II front panel is divided into two
sections:
Control Section
Pos. 2
0178-931 - ENG
Rev. 27.10.03
247/288
Fig. 10.2
I
R
11 13 12 14 15
Suct.temp.
Dish.temp.
Oil press.
Ready
-25C
38C
4,3 bar
0%
Set
UNISAB II
Pos. 9
Pos. 10
248/288
Recording Section
Pos. 11
Pos. 13
0178-931 - ENG
Rev. 27.10.03
Pos. 14
Menu Structure
The UNISAB II features a number of different pictures 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 Instruction Manual for UNISAB II
10 operating instructions.fm
Pos. 15
J Used for moving upwards in a picture in order to point at a certain value, or when changing to a higher value.
0178-931 - ENG
Rev. 27.10.03
249/288
1.
3.
2.
Check that the safety equipment is set correctly. All safety functions are factory set.
4.
Table 10.1
Pos no
Qty
Open
Open
Closed
Closed
Open
Open
Open
Fig. 10.3
Designation
In operation position
Remarks
Must be opened by only a
couple of turns.
To Conderser
From Condenser
Note!
Other valves may occur. See
Dimensions and Piping Diagram
6
Open
Closed
Receiver
To Evaporator
5.
250/288
0178-931 - ENG
Rev. 27.10.03
Fig. 10.4
Operator's Panel
Put the capacity regulation on minimum capacity. TSMC ia allowed to operate in a totally unloaded position for a maximum of 5
minutes. The operating temperature will otherwise be too high.
Check suction and oil pressure. For compressors with variable speed drive (VSD),
the oil pressure has to be adjusted at min.
rpm and checked at max. rpm.
Starting
Emergency
stop button
Fig. 10.5
10 operating instructions.fm
3 Amp
U N IS AB II
0178-931 - ENG
Rev. 27.10.03
251/288
It is now possible to select the desired form of operation with the keys J K.
SUCTION SIDE
BRINE
DISCH. SIDE
STOPPED
HOT WATER
MANUAL
EXT. COOL
AUTO
EXT. HEAT
REMOTE
These regulators have three set values in common: Set point (Sp), Neutral zone (Nz) and Proportional band (Pb).
252/288
0178-931 - ENG
Rev. 27.10.03
Fig. 10.6
2001.07.01
YORK Refrigeration
Chr. Xs Vej 201
DK-8270 Hoejbjerg
Denmark
"QUICK REFERENCE"
LEAFLET FOR
UNISAB II - One-stage
Reciprocating Compressor
MAIN PICTURE
Factorysetting
Press H until the picture remains unchanged and this is your MAIN PICTURE.
READY
XXXX
XXXX
XX
X
CONTROL ON
XXXX
SUCT.PRESS
DISCH.PRES
MOTOR CURR
XXX
XX
XX
AUTO STOP
COLD STORE
10 operating instructions.fm
START START
XXX
XXX
STOP START
START DELAY
STOP DELAY
XXX
XXX
HIGH ALARM
HIGH WARNING
XXX
XXX
SETPOINT 1
SETPOINT 2
XXX
XXX
LOW WARNING
LOW ALARM
k
XXX
NEUTRAL ZONE
PROP. BAND
XXX
XXX
XXX
10
0178-931 - ENG
Rev. 27.10.03
253/288
11
12
13
14
254/288
0178-931 - ENG
Rev. 27.10.03
Fig. 10.7
I
PARAMETER SETTING
HIGH ALARM
HIGH WARN.
LOW WARN.
LOW ALARM
ACTUAL SP.
SETPOINT 1
SETPOINT 2
NEUTRALZONE
PROP.BAND
Suction
SUCT.PRES.
C/R
SUCT.TEMP.
C
SUCT.SUPERH.
C
RUNNING
100%
C/R
C/R
C/R
C/R
C/R
C/R
C/R
C/R
C/R
Discharge
DISCH.PRES.
C/R
DISCH.TEMP.
C
DISC.SUPERH.
C
RUNNING
100%
Oil
SUCT.PRES.
OIL PRES.
OIL TEMP.
RUNNING
Multisab state
BAR
BAR
C
100%
START NO.
SYSTEM NO.
SYS.CONTROLLER
Motor
10 operating instructions.fm
Main picture
SUCT.PRES.
DISCH.PRES.
MOTOR CURR
RUNNING
C/R
C/R
A
100%
Main menu
SUCTION
DISCHARGE
OIL
MOTOR
BRINE
ALARM
WARNING
SETUP
All compressors
MOTOR CURR
A
CAPACITY
%
NOT USED
%
RUNNING
100%
COMPR. # 01 MANUAL
SYSTEM # 01
START # 01
100%
RUNNING
Brine
BRINE TEMP.
SUCT.PRES
EXT.INPUT
RUNNING
Timers
C
C/R
START START
STOP START
START DELAY
STOP DELAY
100%
Alarms
NO ALARMS
Control
COMPR. CTRL. MODE
MANUAL
Warnings
Multisab
NO WARNINGS
MULTISAB
MULTISAB STATE
ALL COMPRESSORS
PARALLEL CONTR.
SEC
SEC
SEC
SEC
Service-timers
ON TIME
HOUR
SINCE START
Date-time
HOUR
MIN
SEC
DAY
Dig. input
Setup
CONTROL CALIBRATE
MULTISAB
TIMERS
CONFIG
DIAGNOSIS LANGUAGE
Timers
TIMERS
TIMERS
TIMER SETUP
SERVICE TIMERS
Diagnosis
DIAGNOSIS
INSPECT OLD ALARMS
MISC.FUNCTIONS
SOFTWARE VERSION
Calibrate
D.INPUT
D.INPUT
D.INPUT
D.INPUT
Dig. output
D.OUTPUT
D.OUTPUT
D.OUTPUT
D.OUTPUT
Analog. input
PRES. INP 1
PT 100 INP 1
EXT.
CALIBRATE
PRESS TRANSDUCER
BRINE TEMP.
CAPACITY
4-20 MA input
4 MA
20 MA
CAPACITY SETPOINT
Config.
TYPE
REFRIGERANT
CONTROL ON
VOLUME RATIO
Auxiliary output
AUXILIARY OUTPUT
ACTIVE WHEN
AT MAX.CAP
Language
0178-931 - ENG
Rev. 27.10.03
CONTRAST
LANGUAGE
GB
255/288
Fig. 10.8
2001.07.01
YORK Refrigeration
Chr. Xs Vej 201
DK-8270 Hoejbjerg
Denmark
"QUICK REFERENCE"
LEAFLET FOR
UNISAB II - Two-stage
Reciprocating Compressor
MAIN PICTURE
Factorysetting
Press H until the picture remains unchanged and this is your MAIN PICTURE.
READY
XXXX
XXXX
XX
X
TYPE
XXXX
SUCT.PRESS
DISCH.PRES
MOTOR CURR
REFRIGERANT
XXX
XX
XX
CONTROL ON
VOLUME RATIO
k
3
START START
XXX
XXX
STOP START
XXX
START DELAY
STOP DELAY
XXX
k
HIGH ALARM
HIGH WARNING
XXX
XXX
SETPOINT 1
SETPOINT 2
XXX
XXX
LOW WARNING
LOW ALARM
k
XXX
NEUTRAL ZONE
PROP. BAND
XXX
XXX
XXX
10
256/288
0178-931 - ENG
Rev. 27.10.03
11
12
13
14
10 operating instructions.fm
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.
0178-931 - ENG
Rev. 27.10.03
257/288
Fig. 10.9
UNISAB II - Menu Tree
Two-stage Reciprocating
Compressor
PARAMETER SETTING
HIGH ALARM
HIGH WARN.
LOW WARN.
LOW ALARM
ACTUAL SP.
SETPOINT 1
SETPOINT 2
NEUTRALZONE
PROP.BAND
Suction
SUCT.PRES.
C/R
SUCT.TEMP.
C
SUCT.SUPERH.
C
RUNNING
100%
C/R
C/R
C/R
C/R
C/R
C/R
C/R
C/R
C/R
Discharge
DISCH.PRES.
C/R
DISCH.TEMP.
C
DISC.SUPERH.
C
RUNNING
100%
Oil
SUCT.PRES.
OIL PRES.
OIL TEMP.
RUNNING
Multisab state
BAR
BAR
C
100%
START NO.
SYSTEM NO.
SYS.CONTROLLER
Motor
Main picture
SUCT.PRES.
DISCH.PRES.
MOTOR CURR
RUNNING
C/R
C/R
A
100%
Main menu
SUCTION
DISCHARGE
OIL
MOTOR
BRINE
ALARM
WARNING
SETUP
All compressors
MOTOR CURR
A
CAPACITY
%
NOT USED
%
RUNNING
100%
COMPR. # 01 MANUAL
SYSTEM # 01
START # 01
100%
RUNNING
Intermed.
Timers
INTERM.PRES C/R
INTERM.TEMP C/R
EXT.INPUT
RUNNING
100%
Alarms
NO ALARMS
START START
STOP START
START DELAY
STOP DELAY
Control
COMPR. CTRL. MODE
MANUAL
Warnings
Multisab
NO WARNINGS
MULTISAB
MULTISAB STATE
ALL COMPRESSORS
PARALLEL CONTR.
SEC
SEC
SEC
SEC
Service-timers
ON TIME
HOUR
SINCE START
Date-time
HOUR
MIN
SEC
DAY
Dig. input
Setup
CONTROL CALIBRATE
MULTISAB
TIMERS
CONFIG
DIAGNOSIS LANGUAGE
Timers
TIMERS
TIMERS
TIMER SETUP
SERVICE TIMERS
Diagnosis
DIAGNOSIS
INSPECT OLD ALARMS
MISC.FUNCTIONS
SOFTWARE VERSION
Calibrate
D.INPUT
D.INPUT
D.INPUT
D.INPUT
Dig. output
D.OUTPUT
D.OUTPUT
D.OUTPUT
D.OUTPUT
Analog. input
PRES. INP 1
PT 100 INP 1
EXT.
CALIBRATE
PRESS TRANSDUCER
BRINE TEMP.
CAPACITY
4-20 MA input
4 MA
20 MA
SUCT.PRES
Config.
TYPE
REFRIGERANT
CONTROL ON
VOLUME RATIO
Auxiliary output
AUXILIARY OUTPUT
ACTIVE WHEN
AT MAX.CAP
Language
258/288
CONTRAST
LANGUAGE
GB
0178-931 - ENG
Rev. 27.10.03
10 operating instructions.fm
0178-931 - ENG
Rev. 27.10.03
259/288
260/288
0178-931 - ENG
Rev. 27.10.03
14 transport instructions.fm
0178-931 - ENG
Rev. 27.10.03
WDanger!
Risk of injury to personnel and damage to equipment! Always read the safety precautions belonging to this equipment before start. Failure to comply with safety precautions may cause death or injury to personnel. It may also cause damage to or
destruction of the equipment.
Safety Precautions
WDanger!
Risk of injury to personnel and damage to equipment! In addition to the safety precautions in this
document, always read the safety precautions belonging 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.
261/288
Transport Data
Table 14.1
Weight
Compressor
Type
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
Table 14.2
Compressor
type
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
TSMC 108
1400
3086
1410
3109
TSMC 116
1900
4189
2080
4586
TSMC 116
2350
5181
2530
5578
262/288
0178-931 - ENG
Rev. 27.10.03
Table 14.3
14 transport instructions.fm
Sizes
IEC 160L
IEC 180M
IEC 180L
IEC 200M
IEC 200L
IEC 225S
IEC 225M
IEC 250S
IEC 250M
IEC 280S
IEC 280M
IEC 315S
IEC 315M
IEC 315L
IEC 355S
IEC 355M
IEC 355L
IEC 355L
IP 23
Leroy Somer
IP 54
kg
lb
190
210
240
265
419
462
529
584
355
455
480
625
680
875
945
1050
783
1003
1058
1378
1499
1929
2083
2315
1790
2095
3946
4619
PLS
LS
FLS
kg
lb
kg
lb
kg
lb
kg
lb
102
173
188
225
381
414
172
220
243
120
135
184
265
298
406
518
681
750
176
216
282
364
419
78
100
110
235
309
340
80
98
128
165
190
260
290
388
573
639
855
981
1257
1389
1984
2072
2646
3307
3527
3858
(LA)1900
(LB)2150
529
739
794
1014
1135
375
452
518
445
570
630
900
940
1200
1500
1600
1750
(LA)1900
(LB)2150
240
335
360
460
515
170
205
235
730
830
1609
1830
340
445
490
720
785
750
981
1080
1587
1731
395
475
565
850
1000
1050
871
1047
1246
1874
2205
2315
855
1885
1510
1550
3329
3417
Personnel Requirements
Fig. 14.1
Loading Instructions
Lift the packed unit with a forklift truck. As a minimum the lifting capacity of the truck must correspond 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.
0178-931 - ENG
Rev. 27.10.03
263/288
Unloading Instructions
Loading
Transport Instructions
WDanger!
Risk of injury to personnel and damage to equipment! YORK Refrigeration does not assume responsibility for injury to personnel or damage to
equipment caused by the use of transport methods which are not recommended in this document
or stated in a separate agreement between a
transport company and YORK Refrigeration.
Transport Regulations
It is the transport company's responsibility that all
regulations pertaining to the transport are observed.
It is moreover the transport company's responsibility that the unit or parts of the unit are properly
secured and that they do not shift during the transport and thus get damaged.
264/288
Storage
On delivery the compressor units are charged with
a protective gas (N2) with an overpressure of 0.2
bar to prevent moisture from entering the compressor. 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 regular 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 lubricate them if necessary.
0178-931 - ENG
Rev. 27.10.03
15 commissioning instructions.fm
0178-931 - ENG
Rev. 27.10.03
WDanger!
Risk of injury to personnel and damage to equipment! Always read the safety precautions belonging to this equipment before start. Failure to comply with safety precautions may cause death or injury to personnel. It may also cause damage to or
destruction of the equipment.
Safety Precautions
WDanger!
Risk of injury to personnel and damage to equipment! In addition to the safety precautions in this
document, always read the safety precautions belonging 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.
265/288
Before the plant is put into operation, the installation must be checked one last time, see Section 7,
Installation Instructions - Final Check of the Installation.
Personnel Requirements
The personnel who are going to start up the plant
must be well-qualified and have a thorough knowledge of refrigeration technique. It is moreover
necessary that the personnel know the refrigeration plant and its construction and mode of operation. 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 question. It is recommended that both the supervisor
and the operator take these courses.
Training
the coupling between motor and compressor are set up as indicated in Section 7, Installation Instructions.
Commissioning Instructions
Documentation
Operating Manual
Carry out configuration and setting as well as setting of alarms and warnings as described in Before Connecting Voltage in the Starting-up Manual
for UNISAB II. Check that set values and alarm
values correspond to the operating conditions of
266/288
0178-931 - ENG
Rev. 27.10.03
WDanger!
15 commissioning instructions.fm
0178-931 - ENG
Rev. 27.10.03
267/288
268/288
0178-931 - ENG
Rev. 27.10.03
This document is primarily intended for commissioning engineers, inspecting bodies and authorities.
This document was produced by:
16 compliance instructions.fm
YORK Refrigeration
Chr. Xs Vej 201
DK-8270 Hoejbjerg
Denmark
Copyright 2003 YORK Refrigeration
This document must not be copied without the
written permission of YORK Refrigeration and the
0178-931 - ENG
Rev. 27.10.03
269/288
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.
Manufacturer:
YORK Refrigeration
Operations Europe
Chr. X's Vej 201
DK-8270 Hoejbjerg
Tel.: +45 87367000 - Fax: +45 87367005
DS/EN 418
____________________________
____________________________
Agent/dealer stamp
270/288
0178-931 - ENG
Rev. 27.10.03
17. Certificates
17. Certificates
The purpose of this document is to give an overall
view of all certificates belonging to screw compressors.
der. It will not be possible to make a separate certificate for the compressor at a later time.
Approvals
17 certificate.fm
0178-931 - ENG
Rev. 27.10.03
Compressor Units
Are designed to comply with common legislation in the EC-countries and former EFTA
member states.
The technical design complies with the requirements in the directives, most importantly 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 designed to fulfil the standards of other countries and classification societies than the
ones mentioned above
271/288
17. Certificates
272/288
0178-931 - ENG
Rev. 27.10.03
20 final disposal.fm
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.
General
Disposal of Machine Parts
Safety Precautions
Authorized refrigeration personnel must participate in the first part of the dismantling process as
fundamental knowledge of refrigerating systems
and the risks involved is required.
Oil and refrigerant must be delivered for destruction or regeneration at a receiving station for hazardous waste, including used oil filters. The receiving station must comply with the prevailing
rules and regulations of the individual country.
WDanger!
0178-931 - ENG
Rev. 27.10.03
273/288
Disposal of Batteries
Used batteries from e.g. the backup of the computer control must be delivered for destruction at a
receiving station. The receiving station must comply with the prevailing rules and regulations of the
individual country.
274/288
0178-931 - ENG
Rev. 27.10.03
2.
3.
4.
Valves
Danvalve installation instructions SCV 40-200, 2 pages.
PM valves, 10 pages
Pilot valve, 3 pages
5.
21 appendices.fm
6.
Danfoss automatic
Pressure cut-outs type KP, 4 pages
Pressure cut-outs type MP, 7 pages
Thermostats type KP, 5 pages
Thermostatic expansion valves, 9 pages
Thermostatic injection valves, 5 pages
0178-931 - ENG
Rev. 27.10.03
275/288
Fig. 21.1
1
Z
D
a
Table 21.1
Compressor
AMR
type of
coupling
Nominal
Distance
C
Torque moment
Pos. 1
mm
mm
Nm
Nm
Nm
Horizontal max.
mm
Pos. 2
Vertical
min./max.
mm
max.
mm
HPC/SMC
104-108
312 S
103,5
25
147
55
44
0,2
0,1/0,3
0,2
SMC
112-116
350 S
114,5
27
147
128
44
0,2
0,1/0,3
0,2
276/288
0178-931 - ENG
Rev. 27.10.03
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
21 appendices.fm
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
0178-931 - ENG
Rev. 27.10.03
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
277/288
CMO 2
TCMO 2
SMC 65
TSMC 65
HPO
SMC 100
TSMC 100
4-10 cyl.
HPC
SMC 100
TSMC 100
12-16 cyl.
SMC 180
TSMC 180
Mk 1 & Mk 2
Main bearings
manufactured
max.
0.08
0.20
0.08
0.20
0.08
0.20
0.08
0.20
0.08
0.20
0.14
0.35
Connecting rod
bearings
manufactured
max.
0.08
0.15
0.08
0.15
0.08
0.15
0.10
0.20
0.10
0.20
0.14
0.30
manufactured
max.
0.04
0.10
0.04
0.10
0.04
0.10
0.04
0.10
0.04
0.10
0.09
0.20
Parallel to
piston pin
manufactured
max.
0.18
-
0.18
-
0.20
-
0.20
-
0.20
-
0.25
-
Al right angles
to piston pin
manufactured
max.
0.11
0.30
0.11
0.30
0.11
0.30
0.15
0.40
0.15
0.40
0.35
0.90
Piston
Piston pin
bearings
Crankshaft end-play
min.
0.30
0.30
0.40
0.40
0.75
0.95
max.
0.55
0.55
0.55
0.64
1.00
1.20
The end-play can be adjusted by means of the gasket under the bearing cover.
The gasket is available in the following thicknesses: 0.3, 0.5, 0.75, 1.0, 1.3, 1.5, 1.75 and 2.0 mm.
0.25
0.25
0.25
0.33
0.33
0.66
max.
1.00
1.00
1.00
1.30
1.30
1.50
The piston ring gap must be measured with the ring placed in the cylinder liner.
New
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 rod
bearing 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
80
-0.010
-0.029
Ground down
Intermediate 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
79.5
-0.010
-0.029
Intermediate journals
Bushing and bearing valves can be supplied for all above journals.
278/288
0178-931 - ENG
Rev. 27.10.03
Index
Accidents with Ammonia ....................................................................................... 23
Accidents with HFC/HCFC .................................................................................... 24
Achieving Parallel Shafts in
Horizontal Plane .................................................................................................. 223
Air-Cooled Top and Side Covers ........................................................................... 96
Air-Cooled Top and Side Covers and Refrigerant-Cooled Oil Cooler ................... 96
Air-Cooled Top Covers and Water Cooled Side Covers ....................................... 96
Alignment of
Compressor on Base Frame .......................................................................... 218
Motor on Base Frame .................................................................................... 218
Alignment of Unit against Foundation .................................................................. 216
AMR ..................................................................................................................... 151
Analogue Reading ................................................................................................. 72
anti-clockwise ...................................................................................................... 140
Area of Application ................................................................................................ 33
Areas of Application ............................................................................................... 29
0178-931 - ENG
279/288
0178_931IX.fm
Rev. 27.10.03
Compressor Block
TSMC ...............................................................................................................43
Compressor Name Plate .......................................................................................12
Compressor Shaft ................................................................................................149
Compressor Units ..................................................................................................71
Connecting Rod
SMC .................................................................................................................34
Connection Data ..................................................................................................100
Connections on SMC
Long block ......................................................................................................105
Control Section ....................................................................................................247
Conversion of TSMC Mk2 to SMC ........................................................................46
Cooling Media ........................................................................................................28
Cooling of Compressor and Oil
SMC .................................................................................................................41
Cooling system
Booster Compressor ........................................................................................82
Pressure Loss ..................................................................................................88
R22 ..................................................................................................................81
R717 ................................................................................................................81
Thermo pump .............................................................................................89, 90
Water flow ........................................................................................................87
Water pressure ................................................................................................87
Water temp. .....................................................................................................87
Cooling Systems ....................................................................................................81
Cooling with Thermo Pump ...................................................................................89
Correct Centre .....................................................................................................224
Coupling
AMR ...............................................................................................................151
Coupling Types ....................................................................................................149
Crankshaft
SMC .................................................................................................................36
280/288
Danger
Texts Marked with Danger ...............................................................................17
Description .............................................................................................................78
Additional unloading .........................................................................................64
Analogue Reading ...........................................................................................72
By-pass system ................................................................................................45
Capacity Regulation .........................................................................................58
Solenoid Valves ..........................................................................................60
Capacity Stages ...............................................................................................63
Conversion of TSMC Mk2 to SMC ...................................................................46
Cooling of the Intermediate Gas ......................................................................45
Cooling system
R22 .............................................................................................................81
R717 ...........................................................................................................81
Determining the Intermediate Pressure IP .......................................................79
0178-931 - ENG
Rev. 27.10.03
0178_931IX.fm
0178-931 - ENG
Rev. 27.10.03
281/288
282/288
Filter bag
SMC .................................................................................................................34
Final Check of the Installation .............................................................................231
Final Disposal ......................................................................................................273
First aid
Accidents with Ammonia ..................................................................................23
Accidents with HFC/HCFC ...............................................................................24
Foundation ...........................................................................................................159
Mounting Directly on Foundation ...................................................................160
Front Panel ..........................................................................................................247
Front Panel of UNISAB II .....................................................................................248
Fuses ...................................................................................................................251
0178-931 - ENG
Rev. 27.10.03
Hub
Boring of Hub ................................................................................................. 149
KP 15 ................................................................................................................... 245
KP 5 ..................................................................................................................... 245
KP 98 ................................................................................................................... 245
KP15 ...................................................................................................................... 73
KP5 ........................................................................................................................ 73
KP98 ...................................................................................................................... 73
Machine Room
Planning ......................................................................................................... 124
Maintenance Safety ............................................................................................... 21
Manometers
Description
Manometers ............................................................................................... 74
Marine Installations .............................................................................................. 164
Max. Power Transmission ................................................................................... 155
Measured and Calculated temp. .......................................................................... 239
Menu Tree
SMC ............................................................................................................... 255
TSMC ............................................................................................................. 258
0178-931 - ENG
283/288
0178_931IX.fm
Rev. 27.10.03
284/288
Needle bearing
TSMC ...............................................................................................................44
Nitrogen charge .....................................................................................................71
Noise ...................................................................................................................166
Damping Acoustic Noise ................................................................................171
Reverberation Time .......................................................................................171
Normal set of tools .................................................................................................97
Nozzle size ............................................................................................................49
0178-931 - ENG
Rev. 27.10.03
Quick Reference
One Stage ...................................................................................................... 253
SMC ............................................................................................................... 253
TSMC ............................................................................................................. 256
Refrigerants .....................................................................................................27, 28
Regulation of Intermediate Pressure IP ................................................................. 79
0178-931 - ENG
285/288
0178_931IX.fm
Rev. 27.10.03
286/288
0178-931 - ENG
Rev. 27.10.03
TEA ........................................................................................................................ 78
Technical Data ..................................................................................................... 116
Technical Description ............................................................................................ 29
Temperature Sensors .......................................................................................... 112
Discharge Gas TT5 ........................................................................................ 112
Oil TT6 ........................................................................................................... 112
Suction Gas TT7 ............................................................................................ 112
Test Pressure ...................................................................................................... 175
Test pressure ....................................................................................................... 228
Test Pressure Levels ........................................................................................... 175
TEX ........................................................................................................................ 78
The compressor must NOT be used ..................................................................... 30
Thermo Pump
Capacity Regulation ......................................................................................... 92
Thermo pump ........................................................................................................ 89
Description of the Pumping Cycle .................................................................... 92
Ensuring Liquid ................................................................................................ 94
Power Connection ............................................................................................ 95
Structure .......................................................................................................... 90
Thermodynamic Liquid Trap .................................................................................. 50
TLT Thermodynamic Liquid Trap .......................................................................... 50
Tool Safety ............................................................................................................ 20
Total Unloading ..................................................................................................... 63
Transport
Data ............................................................................................................... 262
Instructions ..................................................................................................... 261
TT5 ...................................................................................................................... 112
TT6 ...................................................................................................................... 112
TT7 ...................................................................................................................... 112
TWA-Werte ............................................................................................................ 25
Two-stage .............................................................................................................. 32
Two-stage Compressors
TSMC ............................................................................................................... 43
Type
E ....................................................................................................................... 31
L ....................................................................................................................... 31
S ....................................................................................................................... 31
Types of Spare Parts Set ...................................................................................... 98
0178-931 - ENG
287/288
0178_931IX.fm
Rev. 27.10.03
288/288
UNISAB II ..............................................................................................................75
Operating Mode .............................................................................................251
Settings ..........................................................................................................239
Unisab II ..............................................................................................................246
Control Section ..............................................................................................247
Display ...........................................................................................................247
Front Panel ............................................................................................247, 248
Fuses .............................................................................................................251
Menu Tree SMC .............................................................................................255
Menu Tree TSMC ..........................................................................................258
Quick Reference ............................................................................................253
Quick Reference SMC ...................................................................................253
Quick Reference TSMC .................................................................................256
Starting ...........................................................................................................251
Unit Pipe System Name Plate ...............................................................................11
Warning
Texts Marked with Warning .............................................................................17
Warnings in Instructions ........................................................................................17
Water flow ..............................................................................................................87
Water pressure ......................................................................................................87
Water Quality .........................................................................................................88
Water temp. ...........................................................................................................87
Weight of Electric Motors .............................................................................118, 263
Welding Nipples for ANSI ....................................................................................104
Welding Nipples for R-KB ....................................................................................103
Work Area Safety ..................................................................................................20
0178-931 - ENG
Rev. 27.10.03