SABROE Air Compresser Technical Manual

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SMC /TSMC 100 Mk4 - Engineering Manual

Specifications for SMC and TSMC Mk4, S-L-E


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

The variants featured on the unit are marked with


an 'x' in the following diagram, with the compressor number stated below.

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 _________

UNISAB II Control- and regulating system


Electro Mechanical System

Compressor
cooling

Thermopump
Water cooled top and side covers
Air cooled top and side covers
Oil cooling
Oil cooling

Drive type

(water-cooled side covers)


OSSI/OOKH

Coupling
V-belts

Explosion-proof electrical design


Equipment for parallel operation
SABROE OVUR-type oil separator

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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:

The function and maintenance of each


component.

Service schedules.

This manual describes the compressor and its


component parts as well as safety instructions/regulations. Moreover, the manual explains
the different settings that can be of assistance to
those who are responsible for the daily operation
and maintenance of the equipment.
To prevent any accidents, assembly and disassembly of components should only be carried out
by authorized personnel.
It is essential that the operating personnel familiarize themselves with the contents of this manual
in order to ensure a proper and efficient operation.
YORK Refrigeration is not liable for damage oc-

curring during the warranty period where this is 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

Signs and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


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

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

Physical and Connection Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connection Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connections on SMC / TSMC Mk4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connections for T/SMC104-116 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

99
99
100
100
105
108
110

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Control of the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


1. Pressure Transmitters marked PT1, PT2 and PT3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heating Element for Oil Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

111
111
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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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
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214
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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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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
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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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2. Signs and Warnings

2. Signs and Warnings


The purpose of this document is to describe:

How YORK Refrigeration equipment can be


identified.

All warning signs used on equipment delivered by YORK Refrigeration.

How information important to the safety of


personnel and equipment is presented in instructions belonging to equipment delivered
by YORK Refrigeration.

02 signs and warnings.fm

This document is intended for all user categories.

This document was produced by:


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 must not be imparted to a third party nor
be used for any unauthorised purpose. Contravention will be prosecuted.

This document describes the importance of the individual signs which are attached to the
YORK Refrigeration products.

WDanger!

Before a compressor/unit is put into operation it


must be provided with the warning signs corresponding to the actual type of compressor/unit in
accordance with the rules and regulations in force.

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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2. Signs and Warnings

Identification of YORK Refrigeration Equipment


All YORK Refrigeration equipment can be identified by one or several name plates placed as illustrated
by the following drawing:
Fig. 2.1
2

1. Compressor name plate


2. Vessel name plate
3. Unit pipe system name plate

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2. Signs and Warnings

Unit Pipe System Name Plate


Fig. 2.2

Unit Pipe System Name Plate

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.

Max allowable pressure


Shows max allowable pressure relative to
atmospheric pressure for which the pipe
system has been designed.

Leak test pressure, PT


Shows the pressure with which the pipe system has been leak tested.

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

Leak Test Pressure

PT

Bar

Design Temperature
TS
Min/max

02 signs and warnings.fm

0062

The unit pipe system name plate is positioned on


the frame - (see 3. Unit pipe system name plate).
The name plate contains the following information:

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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2. Signs and Warnings

Compressor Name Plate

Vessel Name Plate

Fig. 2.3

Fig. 2.4

Compressor Name Plate

Vessel Name Plate

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

The vessel name plate is positioned on the shell


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

Vessel 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.

The compressor name plate is positioned on the


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

r
Year
Jahr

No

Type

Type
Nominal Speed

2516-326

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SMC /TSMC 100 Mk4 - Engineering Manual

2. Signs and Warnings

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.

02 signs and warnings.fm

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2. Signs and Warnings

In the following section all signs which may be


found on the equipment are described. However, the number of signs may vary from product to product.

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

Caution

The Sign: High Voltage

WDanger
HIGH VOLTAGE!
Before working on any electrical circuits, turn the
machine Main Disconnect Device OFF and lock
it. Dismantle the main fuses to the compressor
unit.
Unless expressly stated in applicable
YORK Refrigeration documentation or by a
YORK Refrigeration Field Service 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.

Before handling, installing, operating or


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

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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2. Signs and Warnings

The Label: The Temperature of


Tangible Surfaces
When a compressor is working, the surfaces
which are in contact with the warm discharge gas
will also get warm. However, the temperature depends on the refrigerants used as well as the operating conditions of the compressor. Often the
temperature exceeds 70C [158 F], which for
metal surfaces may cause skin burns even at a
light touch.

02 signs and warnings.fm

Consequently, the compressors are equipped


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

Pfyldt beskyttelsesgas
Charged with inert gas
Enthlt Schutzgas
Charg du gaz protecteur
Contiene gas protector

N2
0,2 bar
3 PSI
1534-169

Other Warning Labels

Hazardous substance!

Dangerous noise level,


use hearing protectors!

Internal overpressure!

The Label: Internal Protection


Compressor blocks and units are usually delivered without any refrigerant or oil.
To protect the compressors against internal corrosion, they are delivered evacuated of all atmospheric air and charged with Nitrogen (N2) to an
overpressure of 0.2 bar [3 psi].

Cold surfaces!

In such cases a yellow label like the one shown


below is affixed to a visible spot on the compressor.

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2. Signs and Warnings

Emergency Stop
Fig. 2.5

Switch off all electric components on the


compressor/unit before the dismantling/servicing.

Make sure that there is neither overpressure


nor any refrigerant in the part to be dismantled. Close all necessary stop valves.

Use gloves and safety goggles and make


sure to have a gas mask ready for use.

Use the prescribed tools and check that


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

When dismantling the top covers, attention


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

Emergency stop on the reciprocating


compressor unit

Electromechanical control system

Emergency stop, mounted when


installing the unit

UNISAB II control system

Emergency stop

Fig. 2.6
Springs
Top cover

Safety during Service


Before dismantling or servicing a compressor or
unit attention should be paid to the following
points:

Read the Safety Precautions in section 3


before opening the compressor and other
parts of the refrigeration plant.

Make sure that the motor cannot start up inadvertently. It is recommended to remove
all main fuses.

16/288

Before dismantling the side covers, empty


the crankcase of its oil content.

Check that the heating rod in the crankcase


is de-energized.

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2. Signs and Warnings

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!

02 signs and warnings.fm

There is an important distinction between these


three levels. However, as shown below, the principle is the same at all three levels.

Failure to observe information marked with Danger! may cause death or serious injury to personnel or even to a third party.

Texts Marked with Warning!


The example below shows how information of importance to the safety of involved personnel or of
major importance to the safety of the equipment is
presented.

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

Note: Information is sometimes given in a Note.


A Note is used to emphasise information but it is
never used for information vital to the safety of
personnel and equipment.

Texts Marked with Caution!

Texts Marked with Danger!

The example below shows how information vital to


the safety of involved personnel is presented.

The example below shows how information vital to


the safety of involved personnel is presented.

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

Risk of incorrect viscosity! Always make sure that


all oils used are mixable without causing chemical
reactions. Chemical reactions might have serious
effects on the viscosity.
Failure to observe information marked with Caution! may cause damage to the equipment.

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2. Signs and Warnings

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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

maintenance personnel in practicing good shop


safety procedures.
Operator and maintenance personnel must read
and understand these precautions completely before operating, setting up, running or performing
maintenance on the compressor/unit.
These precautions are to be used as a supplement to the safety precautions and warnings included in:
a.

All other manuals pertaining to the compressor/unit.

b.

Local, plant and shop safety rules and codes.

c.

National safety rules and regulations.

General Safety Instructions and


Considerations
Personal Safety
Owners, operators, set-up, maintenance and
service personnel must be aware that constant
day-to-day safety procedures are a vital part of
their job. Accident prevention must be one of the
principal objectives of the job, regardless of the
activity involved.
Know and respect the compressor/unit. Read and
carry out the prescribed safety and checking procedures.
Make sure that everyone who works for, with or
near you fully understands and - more importantly
- complies with the following safety precautions
and procedures when operating this compressor/unit.
Observe the safety warnings on the compressor/unit.
Use safety equipment. Wear approved eye or face
protection as well as gloves when working with

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3. Safety Precautions

parts containing refrigerant and lubricating oil.


Safety shoes with slip-proof soles can help you
avoid injuries. Keep your safety equipment in
good condition.

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.

Use power hoists or other mechanical lifting and


carrying equipment for heavy, bulky or unwieldy
objects. Use hook-up methods recommended by
your safety department and familiarise yourself
with the signals for safely directing a crane operator.

Work Area Safety


Always keep your work area clean. Dirty work areas with such hazards as oil, debris or water on
the floor may cause someone to fall onto the floor,
into the machine or onto other objects resulting in
serious personal injury.
Make sure your work area is free of hazardous obstructions and be aware of protruding machine
members.
Always keep your work area tidy so you are able
to escape should a dangerous situation arise.
Report unsafe working conditions to your supervisor or safety department.

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.

Lifting and Carrying Safety


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

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

SMC /TSMC 100 Mk4 - Engineering Manual

3. Safety Precautions

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

Installation and Relocation Safety

03 safety precautions.fm

Before lifting the compressor, unit or other parts of


the plant, consult the instruction manual or
YORK Refrigeration for proper methods and procedures.
An electrician must read and understand the electrical diagrams prior to connecting the machine to
the power source. After connecting the machine,
test all aspects of the electrical system for proper
functioning. Always make sure that the machine is
grounded properly. Place all selector switches in
their O or neutral (disengaged) position. The
doors of the main electrical cabinet must be
closed and the main disconnect switch must be in
the O position after the power source connection is complete.
Before starting the compressor for the first time,
make sure that all the motors rotate in the indicated direction.

Set-Up and Operation Safety


Read and understand all the safety instructions
before setting up, operating or servicing this compressor. Assign only qualified personnel instructed in safety and all machine functions to operate
or service this compressor.
Operators and maintenance personnel must carefully read, understand and fully comply with all
warnings and instruction plates mounted on the
machine. Do not paint over, alter or deface these
plates or remove them from the compressor/unit.
Replace all plates which become illegible. Replacement plates can be purchased from
YORK Refrigeration.

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-

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3. Safety Precautions

tenance is being performed. Dismantle main fuses to the unit.

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

When removing electrical equipment, place


number or labelled tags on those wires not
marked. If wiring is replaced, be sure it is of the
same type, length, size and has the same current
carrying capacity.
Close and fasten all guards, shields, covers,
plates or doors securely before power is reconnected.
An electrician must analyse the electrical system
to determine the possible use of power retaining
devices such as capacitors. Such power retaining
devices must be disconnected, discharged or
made safe before maintenance is performed.
Working space around electrical equipment must
be clear of obstructions.
Provide adequate illumination to allow for proper
operation and maintenance.

Materials Used with this Product


Always use YORK Refrigeration original spare
parts.
Please note the type of refrigerant on which the
compressor operates as well as the precautions
that need to be taken as described in the following
sections:

First aid for accidents with ammonia.

First aid for accidents with HFC/HCFC.

First aid for accidents with HC.

First aid for accidents with CO2

Protecting the operator as well as the


environment.

0178-931 - ENG
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SMC /TSMC 100 Mk4 - Engineering Manual

3. Safety Precautions

First Aid for Accidents with Ammonia


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

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

First Aid Measures


Inhalation: Immediately, move affected personnel into fresh air and loosen clothing restricting
breathing.
Call a doctor/ambulance with oxygen equipment.

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.

Basic Rules for First Aid


Always call a doctor immediately.
Be prepared: Keep an irrigation bottle available
containing a sterile isotonic (0.9%) NaCl-solution
(salt water). A shower or a water tank should be
available near all bulk installations with ammonia.
When applying first aid, the persons assisting
must be duly protected to avoid further injuries.

0178-931 - ENG
Rev. 27.10.03

Keep the patient still and warmly wrapped in blankets.


If mouth and throat are burnt (freeze or acid burn)
and the patient is conscious, let him drink water in
small mouthfuls.
If the patient is conscious and mouth and throat
are not burnt, feed him sweetened tea or coffee
(never feed an unconscious person).
Oxygen may be given to the patient, but only
when authorised by a doctor. If the patient stops
breathing, apply artificial respiration.
Eyes: In case of injuries from liquid splashes or
concentrated vapour, immediately rinse with water (preferably using an eye rinser) and consult a
doctor. Continue rinsing until otherwise stated by
a doctor.
If the affected person wears contact lenses these
must be removed before the rinsing.
Skin: In case of burns from liquid splashes or concentrated vapour, immediately wash with large
quantities of water until the pain stops.
Consult a doctor about actual burns.
After washing, apply wet compresses - wetted
with a sterile isotonic (0.9%) NaCl-solution (salt
water) - to affected areas until medical advice is
available.

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3. Safety Precautions

First Aid for Accidents with HFC/HCFC


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

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

When heated to above approx. 300C, they break


down into toxic, acid gas components, which are
strongly irritating and aggressive to nose, eyes
and skin and generally corrosive.
Besides the obvious risk of unnoticeable, heavy
gases displacing the atmospheric oxygen, inhalation of larger concentrations may have an accumulating, anaesthetic effect which may not be immediately apparent. 24 hours medical observation
is therefore recommended.

24/288

Basic Rules for First Aid


When affected persons are moved from low-lying
or poorly ventilated rooms where high gas concentrations are suspected, the rescuer must wear
a lifeline and be under constant observation from
an assistant outside the room.
Do not use adrenaline or similar heart stimuli.
Inhalation: Immediately move affected persons
into fresh air. Keep them still and warm and loosen clothing restricting breathing.
If the patient is unconscious, call a doctor/ambulance with oxygen equipment immediately.
Apply artificial respiration until a doctor authorizes
other treatment.
Eyes: Immediately rinse with water (preferably
using an eye rinser) and consult a doctor. Continue rinsing until otherwise stated by a doctor.
If the affected person wears contact lenses these
must be removed before the rinsing.
Skin: In case of frost-bite, immediately rinse with
luke-warm water (max. 37C) and remove all
clothes impeding blood circulation.
Consult a doctor.
Avoid direct contact with contaminated oil/refrigerant mixtures from electrically burnt-out hermetic
compressors.

0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

3. Safety Precautions

Protecting the Operator as well as the Environment

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

Pay extra attention to the following substances:


refrigerants
cooling media (brine, etc.)
lubricating oils
Refrigerants usually have a natural boiling point
considerably below 0C. This means that liquid refrigerants can be extremely harmful if they come
into contact with skin or eyes.
High concentrations of refrigerant vapours can be
suffocating when they displace air.

If high concentrations of refrigerant vapours are


inhaled, they will attack the human nervous system.
When halogenated gasses come into contact with
open flame or hot surfaces (over approx. 300C),
they will decompose to produce poisonous chemicals. These have a very pungent odour and will
thus warn personnel of their presence.
At high concentrations R717 causes respiratory
problems. When the amount of ammonia vapour
in air is between 15 and 28 vol. % the combination
is explosive and can be ignited by an electric
spark or open flame.
Oil vapour in the ammonia vapour increases this
risk significantly as the point of ignition falls below
that of the mixture ratio stated.
Usually the strong smell of ammonia will warn
personnel before the concentration becomes
dangerous.
The following table shows the values for the max.
permissible refrigerant content in air measured in
volume %. Certain countries may, however, have
official limits different from the ones stated.

Halogenated refrigerants
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

SMC /TSMC 100 Mk4 - Engineering Manual

3. Safety Precautions

Furthermore, it can be said about


refrigerants:
HFC/HCFC

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

Ammonia is easily absorbed by water:


At 15C 1 litre of water can absorb approx.
0.5 kg liquid ammonia (or approx. 700 litres
ammonia vapour).

Even small amounts of ammonia in water


(2-5 mg per litre) are enough to wreak havoc
with marine life if allowed to pollute waterways and lakes.
As ammonia is alkaline, it will damage plant
life if released into the atmosphere in large
quantities.

Hydro Carbons (HC)

HC gasses are a group of B1 refrigerants


characterized as very flammable.

26/288

Hydro carbons are odourless and non-toxic


gasses. Specific mixtures of air and gas create danger of explosion. As the gasses are
heavier than air, they will be concentrated at
the lowest possible level in case of leaks.

Carbon Dioxide (CO2)

Carbon dioxide (CO2) is a greenhouse gas


with a GWP (Global Warming Potential) factor of 1. It is found in the atmosphere in a
concentration of 0.036 vol. % (360 parts per
million, ppm). As CO2 is extracted from atmospheric air, it can safely be released into
the atmosphere and does not contribute to
enhancing the greenhouse effect.

The boiling point for CO2 is -78.5C at 1.013


bar.

CO2 is an odourless, non-toxic non-inflammable gas. At concentrations higher than


5000 ppm the gas can be dangerous for humans. The gas is heavier than air and will
thus be concentrated on the lowest level of
the room in case of a leak. In closed rooms
the gas can displace oxygen and cause suffocation.

Refrigerant evacuated from a refrigeration plant


must be charged into refrigerant cylinders intended for this specific refrigerant.
If the refrigerant is not to be reused, return it to
the supplier or to an authorized incineration plant.
Halogenated refrigerants must never be mixed.
Nor must R717 ever be mixed with halogenated
refrigerants.

0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

3. Safety Precautions

Purging a Refrigeration Plant


If it is necessary to purge air from a refrigeration
plant, make sure to observe the following:
Refrigerants must not be released into the
atmosphere (exept CO2).

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

Halogenated refrigerants cannot be absorbed by water. An approved air purger


must be fitted to the plant. This must be
checked regularly by use of a leak detector.

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

03 safety precautions.fm

mixture must be sent to an authorized incineration plant.

0178-931 - ENG
Rev. 27.10.03

27/288

SMC /TSMC 100 Mk4 - Engineering Manual

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.

protective equipment - goggles and gloves - when


charging oil.
Refrigeration compressors are lubricated by one
of the following oil types depending on the refrigerant plant type, and operating conditons.
Mineral oil (M oil)
Hydro treated mineral oil (H oil)
Semi-synthetic oil (mix of M oil and synthetic oil)
Alkyl benzene-based synthetic oil (A oil)
Polyalphaolefine-based synthetic oil
(PAO oil)
Polyalkylen Glycol-based synthetic oil
(PAG oil)
Ester oil (E oil)

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

See the section Selecting lubricating oil for


YORK Refrigeration compressors in section 6,
Technical Data.
When changing the oil in the compressor or draining oil from the vessel of the refrigeration plant, always collect the used oil in containers marked
waste oil and send them to an approved incineration plant. It is not recommended to re-use oil.

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

28/288

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SMC /TSMC 100 Mk4 - Engineering Manual

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.

Compressor types SMC 100 and TSMC 100


in an E execution are as standard compressors used with R717 only.

The compressors can be used with other refrigerants, but only following a written agreement with YORK Refrigeration.

SMC 100 and TSMC 100 compressors in S,


L or E executions may be used at a max discharge design pressure of 25 bar. See Test
Pressure Levels for Standard Compressors
and Components in section 6.

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.

This document was produced by:


YORK Refrigeration
Chr. X's Vej 201
DK-8270 Hoejbjerg
Denmark

04 technical description.fm

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.

Areas of Application of the


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

As a refrigeration compressor with the


number of revolutions pr. minute specified
by YORK Refrigeration and the operating
limits as stated in this manual or in a written
agreement with YORK Refrigeration.
Compressor types SMC 100 and TSMC 100
in an S or L execution can - as standard
compressors - be used with the following re-

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

SMC /TSMC 100 Mk4 - Engineering Manual

4. Technical Description

WWarning!
The compressor must NOT be used:

For evacuating the refrigeration plant of


air and moisture,

For putting the refrigeration plant under


air pressure in view of a pressure testing,

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

SMC /TSMC 100 Mk4 - Engineering Manual

4. Technical Description

Description of the Compressors


Compressor Types
Reciprocating compressor types SMC 100 and
TSMC 100 represent a series of open compressors with 4 to 16 cylinders in one and the same
block. The cylinders are positioned in a V or W position and have the same internal diameter of 100

mm. The series comprises 15 one-stage and 6


two-stage compressors with the following type
designations:
Compressors with 4, 6 and 8 cylinders are called
short blocks whereas compressors with 12 and 16
cylinders are called long blocks.

Fig. 4.2

04 technical description.fm

Short Block

SABROE

Long Block

One-stage compressors are designated SMC


which is an abbreviation of SABROE Multi-cylinder Compressor. As for the two-stage compressors the letter T has been added to indicate Two
stages.
Further, the compressors can be delivered with
the following three strokes, designated S, L or E,
respectively:

0178-931 - ENG
Rev. 27.10.03

Type S has an 80 mm piston stroke and is


used with all approved refrigerants.

Type L has a 100 mm piston stroke and is


used with all approved refrigerants.

Type E has a 120 mm piston stroke and is


used only in connection with R717. The
compressor has 50% more capacity than
type S.

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SMC /TSMC 100 Mk4 - Engineering Manual

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.

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


One-stage compressor

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

Similarly, the serial number of each compressor is


stamped into the compressor block. The letter S,
L or E, which refers to the compressor stroke, is
stamped into the end surface of the crankshaft.
Whenever contacting YORK Refrigeration
about a compressor, please state its
serial number.

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

SMC /TSMC 100 Mk4 - Engineering Manual

4. Technical Description

Compressor Description

One-stage Compressors

With a few exceptions, all compressors of the


SMC 100 or TSMC 100 types use the same spare
parts as the ones described in the following section.

The compressors are equipped with replaceable


cylinder liners, pos. 19A, Fig. 4.3, which are
made of special cast iron and are easy to dismantle for inspection. They are honed and surface
hardened, which makes them very wear resistant.
Underneath each top cover there are always two
cylinders.

Fig. 4.3

SMC 100 Cylinder Liner Complete


21

20

04 technical description.fm

19H

19A

The pistons, pos. 18, are made of aluminium with


two hard-plated piston rings and one oil scraping

0178-931 - ENG
Rev. 27.10.03

ring ensuring optimum tightness, low oil consumption as well as long life.

33/288

SMC /TSMC 100 Mk4 - Engineering Manual

4. Technical Description

Fig. 4.4

Piston

a downward force during suction. This is different


from the top of the LP pistons which are affected
by a pressure lower than the suction pressure
which gives the piston an upward force during
suction.
Fig. 4.5

Connecting Rod, SMC 100

17B
TSMC HP

18
17A

17B
SMC and
TSMC LP

Suction valve, pos. 19H, which is of the ring plate


type, is fitted at the top of the cylinder liner and
can be removed together with the cylinder liner.
Discharge valve, pos. 20, forms the top of the
cylinder and is kept in place by a powerful spring,
pos. 21. This spring is also called the safety
spring as it enables the complete discharge valve
to lift a little at particularly high pressures in the
cylinder due to liquid or oil in the compressed gas
(liquid slugging). Thus overloading of the bearings
in the connecting rod is avoided.
The compressor is designed for operation with liquid slugging for a short time only. If liquid slugging
occurs (the sound of hard metal hammering), the
compressor must be stopped and the cause must
be removed.
Connecting rod, pos. 17, Fig. 4.5 is made of cast
iron with a large elongation after fracture. It has replaceable slide bearings, pos. 17A and B, at both
ends on single stage compressors and on the first
stage (LP) on TSMC. On the second stage (HP)
on TSMC, the small end bearing is of the rolling element type.
The reason for this is that the top of the HP pistons
are affected by the intermediate pressure, which
is higher than the suction pressure, and thus gives

34/288

17

Suction filter: All the compressors are equipped


with very large built-in suction filters, pos. 34A,
Fig. 4.6, with great filtering capacity which effectively filters off the dirt particles conveyed with the
gas from the refrigeration plant to the compressor.
The suction filters are made of stainless steel and,
by dismantling the covers, pos. 34E, they are easy
to pull out and clean.
When a compressor is delivered, a fine-meshed
filter bag, pos. 34B, has been fitted in the suction
filters. The filter bag filters off the tiny rust particles
that may pass the suction filters and is thus providing the compressor with considerable protection from dirt mixing with oil. The filter bags are
used no longer than 50 hours after initial start up
of the compressor. This also applies when changes, which may cause impurities in the suction gas,
are made on the plant. After the 50 hours, the filter
bags and the inserts for the filter bags pos. 34C
must be taken out and discarded. Used filter bags

0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

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

SMC 100 Filter Section and by-pass valve

24

04 technical description.fm

34A

34C

34E
34B

By-pass valve: The compressor is equipped with


a built-in mechanical by-pass valve, Fig. 4.6 and
Fig. 4.7, pos. 24, which safeguards the compressor against unintended over-pressure in case the
Fig. 4.7

electric safety equipment should fail. The bypass


valve acts as a kind of over-pressure safeguard
between the discharge and suction side of the
compressor.

SMC/TSMC 100 - By-pass Valve

24C

24B

0178-931 - ENG
Rev. 27.10.03

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SMC /TSMC 100 Mk4 - Engineering Manual

4. Technical Description

The by-pass valve is delivered pre-set, sealed and


adjusted to the following opening pressures:

Fig. 4.9

TSMC 112-116 Long Block

Standard for SMC and TSMC (HP


stage) compressors: 24 bar [348 psi].
Special for SMC - and TSMC (HP stage)
compressors: 22 bar [319 psi]; this is
only delivered following a specific order
and applied in accordance with local
rules and regulations concerning pressure vessels as e.g. oil separators. The
current set pressure is stamped into the
name plate pos. A.
Standard for TSMC (LP stage) compressors: 12 bar [174 psi].
The by-pass valve is of the high-lifting type,
which makes it robust and durable.
Moreover, the by-pass valve is independent of the
pressure on the suction side of the compressor.
Consequently, it opens only when the pressure on
the discharge side exceeds the set pressure compared to that of the atmosphere.
Note: The by-pass valve should not be considered a safety valve.
Fig. 4.8

SMC 104-108 Short Block

49A

The crankshaft, pos. 16, Fig. 4.8, rests in large


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

6
16

36/288

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SMC /TSMC 100 Mk4 - Engineering Manual

4. Technical Description

Fig. 4.10

SMC 112 - 116 and TSMC 116

Fig. 4.11

Oil pressure regulating valve


Pos. 22

49A

Pointed screw

04 technical description.fm

The Oil suction strainer pos. 33A prevents dirt


particles in the oil of the crankcase from entering
the oil pump with a subsequent wear on the pump
bearings. The filter is of the full flow filter type.
The filter can be cleaned.
The oil pump, pos. 11A, Fig. 4.13, is built into the
compressor and driven by the crankshaft by
means of a coupling. The oil pump is a self-priming gear pump which takes the oil from the oil
sump through an oil suction strainer in the crankcase, pos 33A, Fig. 4.12 and forces it through the
full flow filter into the lubricating system.
The oil pressure regulating valve, pos. 22,
Fig. 4.11 regulates the oil pressure in the compressor lubricating system. It can be adjusted
from the outside by means of a screw driver when
the pointed screw, which locks the regulating
screw, has been loosened. For variable speed
driven compressors, the oil pressure has to be adjusted to the minimum oil pressure at minimum
speed. Due to rising pressure drop at high oil flow,
the pressure will rise when running at maximum
rpm.

0178-931 - ENG
Rev. 27.10.03

Fig. 4.12

oil suction strainer

Pos. 33A

External oil filter, pos. 9A. After the oil pump, the
oil is furthermore filtered in an external oil filter of
the full flow filter type, pos. 9A, before it is led into
the lubricating system. The filter element is a 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

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4. Technical Description

Fig. 4.13

Oil pump cover assembly

to the branch pos. 4F on the pump housing. After


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

4D

Fig. 4.14

Valves and filter on oil pump cover

4E
4Q

4F

4L

11B
4E
4D
4F

4K
9A

11A
4L

4k

9A

Shut-off valves, pos. 4K and pos. 4D are used


for dismantling the oil filter. The shut-off valves
must be completely open during operation to
avoid pressure drops in the oil system.
For additional information about function see oil
diagram Fig. 4.15.
The air purge valve, pos. 4E is used to reduce
the pressure in the oil filter before dismantling.
The valve pos. 4E further acts as a prelubrication valve.
Prelubrication of the compressor must always be
carried out before the initial start up and after a
long period of standstill.
This way the bearings and the oil system are lubricated and the oil pump is filled with oil. The hose
from the prelubrication pump must be connected

38/288

The shaft seal, pos. 10, is a sealing component


which prevents oil and refrigerant from the compressor interior from leaking into the atmosphere.
The shaft seal is of the slide ring type, consisting
of a plane, lapped cast iron slide ring which rotates with the crankshaft and seals against a stationary spring-loaded slide ring made of special
carbon. The shaft seal is of the balanced type and
consequently serves a universal purpose in view
of operating conditions, refrigerants and oil types
used for the compressor.
The design of the shaft seal and coupling of the
motor is such that the shaft seal can be removed
from the compressor without removing neither
compressor nor motor. This facilitates maintenance considerably.

0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

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

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SMC /TSMC 100 Mk4 - Engineering Manual

4. Technical Description

Fig. 4.16

Shaft seal

Fig. 4.17

SMC 100 block Pump end

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

Oil draining valve, pos. 23, for draining and


charging of oil. An inner socket at the draining
valve ensures that the oil sump is properly drained
so that the compressor does not have to be
opened when changing oil and filters.
The oil level glass, pos.1B, indicates the prescribed oil level in the crankcase. See Section 6,
Technical Data - Charging the Compressor with
Oil.
Evacuating valve, pos. 42, Fig. 4.18, for evacuating the compressor of refrigerant or air after
service.

0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

4. Technical Description

Fig. 4.18

SMC 104 - 108 Short Block

25-3

42
25-4

flanges for connection to ISO and ASME standard


pipes. Pipe dimensions are indicated on the dimension sketches in Section 5, Physical and Connecting data.

04 technical description.fm

Instrumentation: As standard equipment the


compressors are fitted with either an analogous
reading and safety system consisting of pressure
gauges, pressure switches and thermostat, or
with a SABROE microelectronic reading and control system, UNISAB II, as shown in Fig. 4.19.
Both systems are described in detail later in this
section.

The stop valves, pos. 25-3 and 25-4, are fitted on


the compressor discharge and suction flanges for
efficient blocking off of the compressor from the
refrigeration plant. The stop valves have welding

0178-931 - ENG
Rev. 27.10.03

Cooling of compressor and oil: On request the


compressor can be delivered with a built-in cooling system with either water or refrigerant as described in the section, Cooling Systems for Compressors.

41/288

42/288

Name plate

45J -- 1

D
D
45

39B -- 1

99

UNISAB II
31C -- 1

31A

Analogous control and


safety system

30A
31C -- 1

39A -- 1

D
45

39B -- 1

safety system

UNIS AB II
31C -- 1

Analogous control and

30A
31C -- 1

31A

99

Fig. 4.19

39

Name plate

45J -- 1

39

39A -- 1

SMC /TSMC 100 Mk4 - Engineering Manual

4. Technical Description

Instrumentation

0178-931 - ENG

Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

4. Technical Description

Two-stage Compressors Type TSMC 100


The TSMC compressors are so-called compound
machines in which the refrigerant gas is compressed in two stages. The compressor is divided
into a low-pressure section, LP, and a high-pressure section, HP. The cylinders in the low-pressure section compress the gas from evaporating
pressure, PE, to intermediate pressure, PI.
During the compression the gas is heated and
must consequently be cooled down in the intermediate cooling system before it reaches the
high-pressure stage.

04 technical description.fm

At the high-pressure stage, the gas is compressed


from PI to the condensing pressure PC.
The system is described in detail in Cooling of the
intermediate discharge gas on TSMC compressors later in this section.
The TSMC 100 compressors are available with 8
or 16 cylinders, divided as indicated:
TSMC 108:
6 low-pressure (LP) cylinder
2 high-pressure (HP) cylinder

TSMC 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

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Rev. 27.10.03

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SMC /TSMC 100 Mk4 - Engineering Manual

4. Technical Description

Piston Pin Bearing

Fig. 4.20

In the SMC and TSMC low-pressure stages the


piston pin bearing consists of slide bearings, pos.
17B, Fig. 4.20. In the connecting rods of the
high-pressure stage a needle bearing, pos.17B2, has been fitted. This is because HP pistons on
two-stage compressors - as opposed to single
stage and LP pistons - are often subject to uni-directional force.

TSMC 100 Cylinder Liner Complete

17B
TSMC HP
17A

17B
TSMC LP

17

Similarly, an O-ring, pos. 19M, is used to seal the


intermediate pressure chamber from the crankcase in which there is evaporating pressure.
Fig. 4.21

TSMC cylinder liner

19M

44/288

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Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

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.

In the high-pressure stage a suction filter of the


same size as the one for the LP stage has been
fitted, but this has round holes in the shell and is
closed at one end.

Fig. 4.22
TSMC 108

HP

04 technical description.fm

Closed end and O-ring


sealing

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

The by-pass system is described in detail later in


this section under Cooling of the Intermediate Discharge Gas on TSMC Compressors.
The TSMC 100 compressors can be delivered
with one or two oil separators depending on the
type of refrigerant and area of application. Otherwise, the terms of delivery are the same as the
ones described for one-stage compressors.

45/288

SMC /TSMC 100 Mk4 - Engineering Manual

4. Technical Description

Conversion of TSMC Compressors


from Two-stage to One-stage

3.

Changing the pipe connections on the


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

4.

Changing the HP stage connecting rods to


the single stage type (journal bearing in
small end). The piston pins must be
changed.

5.

Ensuring that the correct suction and discharge valves are fitted.

6.

Installing the correct by-pass valves.

7.

Adjusting the safety pressure controls.

If necessary, it is possible to convert a two-stage


compressor into a one-stage compressor.
The following variations are possible:
a.

Altering the compressor and using the same


refrigerant

b.

Altering the compressor and changing the 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

Generally, the conversion includes the following


points:
1.

Replacing the suction filter with a normal


one-stage suction filter on the HP side.

2.

Dismantling the pipe connection on the HP


suction side and installing a standard cover,
pos. 34 E.

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

SMC /TSMC 100 Mk4 - Engineering Manual

4. Technical Description

Oil Separator Type OVUR


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

Fig. 4.24

Oil Separator
A

The oil separator is mounted on the compressor


unit and connected to the discharge gas outlet of
the compressor as indicated in the drawing,
Fig. 4.23.

On some units the oil separator is not mounted.


Fig. 4.23

Standard Compressor Unit

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

Selecting an Oil Separator


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

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SMC /TSMC 100 Mk4 - Engineering Manual

4. Technical Description

Oil Return to the Compressor


The oil separated in the oil separator is usually
conveyed directly back to the compressor crankcase by means of the differential pressure between the pressure of the oil separator, PC, and
that of the crankcase, PE.
As the return of gas from the discharge side to the
suction side will have a negative effect on the
plant, it is desirable to lead only the separated oil
back to the crankcase. This is controlled by using
a thermodynamic liquid trap (TLT) combined with
a reliable solenoid valve which blocks the system
at standstill. Furthermore, it makes it possible to
delay the opening of the oil return after start up
and thus allowing condensed refrigerant, if any, in
Fig. 4.25

the oil separator to evaporate and not be led back


to the crankcase.
For plants which do not allow solenoid valves, a
reliable float valve controlled system can be delivered at an additional price.
A: Solenoid Valve Controlled Oil Return
As illustrated in the drawing, Fig. 4.25, the oil from
the oil separator is led to the compressor crankcase via valve block A and the TLT.
In the oil separator at position C the pipe is inserted 10 mm into the end plate whereby any sediment can settle at the bottom of the oil separator.

Solenoid Valve Controlled Oil Return


Compressor
Oil separator

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

SMC /TSMC 100 Mk4 - Engineering Manual

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

Valve Block, pos. A, Oil Return

Inlet

closed at dead coil whenever the compressor is


stopped. When the compressor is operating, the
solenoid valve is open, allowing the oil to flow to
the compressor.
As stated above it is recommended, however, to
keep the solenoid valve closed for 20 to 30 minutes after start-up by means of a time relay (which
may be ordered as an accessory part). Thus the
oil is not returned to the compressor before the oil
separator is warm and has evaporated any refrigerant which may have mixed with the oil at the bottom of the oil separator.
This time function is built into the UNISAB II system.

04 technical description.fm

Nozzle

Outlet

The solenoid valve seat is available with various


boring diameters and nozzle sizes. For this purpose 3.3 mm must be used.
The coil for the solenoid valve can be delivered as
a standard part with the following data:
Table 4.1

Wire mesh

From the stop valve the oil passes a wire mesh,


which can be removed and cleaned.The filtered oil
now passes the solenoid valve, which must be

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

SMC /TSMC 100 Mk4 - Engineering Manual

4. Technical Description

Thermodynamic Liquid Trap (TLT)


The purpose of the TLT valve is to ensure that
only oil is led back to the compressor as warm discharge gas mixed with the oil will cause the compressor capacity to decrease.
Fig. 4.27

Thermodynamic Liquid Trap TLT

If there are irregularities in the oil return, it may be


due to impurities in the oil. The problem can be
solved by unscrewing the cap, preferably using a
ring spanner, and turning over the disc so that the
plain side with a bleed scratch is towards the seating faces.

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

The TLT valve works in the following way:


A thermodynamic liquid trap uses a disc to control
the release of liquid and to trap gas. The trap cycles open and close to discharge liquid and closes
tightly between discharges. The disc, which is the
only moving part, rises and falls in response to dynamic forces produced by the gas flowing through
the trap.
Liquid and/or gas enters the trap through the central orifice, lifts the disc and is discharged through
the outlet orifice. The gas passes along the underside of the disc at high velocity and collects in the
control chamber above. The resulting pressure
imbalance forces the disc downward onto the
seating surfaces and stops the flow.

50/288

One side of the disc (3) is plain with a single


scratch towards the outer edge, whereas the other side of the disc has a machined circular groove.
The trap is supplied with the grooved side of the
disc towards the seating faces and is suitable for
clean operating conditions.

1 : Housing
2 : Cap
3 : Disc

The trap remains tightly closed until the loss of


heat through the trap body lowers the control
chamber pressure, allowing the inlet pressure to
raise the disc and repeat the cycle.

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

Principle piping diagram


Oil separator

TLT 15

Reciprocating
compressor

EVRB

245893

Nozzle 3.3 mm

0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

4. Technical Description

B: Float Valve Controlled Oil Return


The float valve is located in a separate float vessel, mounted on the side of the base frame and
connected to the oil separator and compressor as
illustrated on Fig. 4.29.
Fig. 4.29

Float Valve Control Oil Return

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

Oil Return in Connection with Parallel


Operation
If several compressors are running in parallel on
the same refrigeration plant, it is expedient to adjust their oil level in the crankcase by means of an
automatic system. This is particularly necessary
in the case of HFC and HCFC plants in which the
oil is returned to the compressors with the suction
gas as it is not distributed evenly on all the compressors.

04 technical description.fm

To the compressor

The separated oil is drained through stop valves A


and filter D to the float vessel C, and here the float
valve opens at an increasing oil level and returns
the oil to the crankcase.

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

SMC /TSMC 100 Mk4 - Engineering Manual

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, Fig. 4.30, is an example of a


plant with two compressors working in parallel on
the same suction and discharge line.

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.

Non-return valve,1 bar

3.

Filter

11.

Solenoid valve

4.

Stop valvet

12.

Nozzle, dia. 3.3 mm

5.

Oil separator

13.

Filter

6.

Solenoid valve incl. nozzle (Fig. 4.30)

14.

Heating cartridge

7.

Non-return valve

15.

Oil charging valve

8.

Float valve

16.

Oil level glass

52/288

0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

4. Technical Description

As illustrated in Fig. 4.31 a float valve, pos. 2, is


fitted on each of the compressors in front of the oil
level glass. This makes the oil level in the float
house equal to that in the crankcase. This can be
checked visually in the oil level glass. The complete float valve can be seen in Fig. 4.31.
Fig. 4.31

Float Valve Housing with Float Valve

Pipe
connection

Vent valve
Oil level glass
on compressor

The oil vessel, pos. 9, is illustrated by the principle


drawing, Fig. 4.32. Its size is calculated so that an
extra amount of oil is available to ensure the oil
level in the compressor.
The total volume of the vessel should be approx.
50% of the oil volume in all the compressors, and
the vessel should not be charged to more than
50%.
This means that the amount of oil in the vessel
corresponds to 25% of the total amount of oil in
the compressor.
The oil vessel must be equipped with:

04 technical description.fm

- heating rod, 240 W, pos. 14


- oil charging valve, pos. 15
- oil level glass, pos. 16
From the top of the oil vessel, pos. 9, a pipeline is
taken to the suction side of the plant.
The float controls a needle valve which opens at a
falling oil level, letting the oil flow from the oil vessel, pos. 9, return to the compressor. This ensures
a constant oil level in the compressor.
Fig. 4.32

Oil Vessel, pos. 9

To common
suction line
15

A non-return valve, pos. 10, Fig. 4.30, has been


inserted in the pipeline, and this valve opens at a
differential pressure of 1 bar. This way the pressure in the oil vessel will be 1 bar higher than the
suction pressure in the plant. This is sufficient in
order to squeeze the oil through the float valves,
pos. 2, without causing foaming in the float valve
houses.

16

14

240 W

Max. oil level

To float
valves

0178-931 - ENG
Rev. 27.10.03

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SMC /TSMC 100 Mk4 - Engineering Manual

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

Oil separator with float valve controlled oil return

Solenoid valve, pos. 6, closes whenever the actual compressor stops.

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.

This ensures a slight gas flow to the oil vessel,


pos. 9, and consequently overpressure that
presses the oil out to the compressors through

54/288

12

14
9

11

13

0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

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.

Principle diagram, Fig. 4.34, is an example of a


plant with two compressors working in parallel but
which do not have the same suction pressure,
PE+, PE-.

Fig. 4.34
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.

Non-return valve,1 bar

3.

Filter

11.

Solenoid valve

4.

Stop valve

12.

Nozzle, dia. 3.3 mm)

5.

Oil separator

13.

Filter

6a-6b.

Solenoid valve incl. nozzle (Fig. 4.34)

14.

Heating cartridge

7.

Non-return valve

15.

Oil charging valve

8.

Float valve

16.

Oil level glass

0178-931 - ENG
Rev. 27.10.03

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SMC /TSMC 100 Mk4 - Engineering Manual

4. Technical Description

To be able to press the oil from the oil vessel, pos.


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

above oil level. Any foaming that may occur will


soon be dissolved in the crankcase.

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

In case the oil return system is regulated by


means of a float valve as described under System
A, the same system as the one shown in Fig. 4.35
should be used.

56/288

The system has one further advantage as the oil


does not pass the level switch vessels 2a and 2b.
Should foaming occur, this is not going to interfer
with the working of the level switch.

0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

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.

The oil level in the crankcase is regulated by a


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

04 technical description.fm

Fig. 4.35

3a

10/8

1a

4a

2a

SNV8 CD

10/8

3b

1b

2b

4b

1a - 1b: Solenoid valve


2a - 2b: Float valve
3a - 3b: Connection to oil pump discharge
4a - 4b: Standard oil return system

0178-931 - ENG
Rev. 27.10.03

57/288

SMC /TSMC 100 Mk4 - Engineering Manual

4. Technical Description

Capacity Regulation of Compressor


All compressors have a built-in capacity regulating system which continually adjusts the compressor capacity to the cooling requirements of the
plant. Even at reduced capacity the compressor
works very efficiently. This makes it very well-suited for plants with reduced cooling requirements
for lengthy operating periods.
Fig. 4.36

Capacity Regulating Mechanism

13

sition and cannot be closed until the compressor


is in operation and the oil pump has built up the oil
pressure in the lubricating system. With an open
suction valve there is no compression resistance
in the compressor and this reduces its starting
torque considerably. Thus, a motor dimensioned
to suit the operating conditions of the compressor
can easily start up the compressor also by using
the star/delta starting system.
For compressors fitted with extra capacity stages
(extended unloading), one cylinder (SMC 104106-108) or two cylinders (SMC 112-116) will be
in operation all the time, also at start up.
See extended unloading.

Capacity Regulation and Unloading of


Compressor

The capacity regulating system including the


frame, pos. 13, is activated by the compressor oil
pressure and controlled by means of solenoid
valves fitted on the compressor. At a capacity reduction two suction valves are forced open at a
time. In this case no compression takes place in
the relevant cylinders as the sucked in gas in the
cylinders is pressed back to the suction chamber
through the suction valves.
The above forced opening of the suction valves is
also used when starting up the compressor. The
system works as follows: At compressor standstill
all the suction valves are forced into an open po-

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

SMC /TSMC 100 Mk4 - Engineering Manual

4. Technical Description

Fig. 4.37

Cylinder Liner Complete

19F

04 technical description.fm

19B

19A

The unloading frame, which is controlled by two


brackets with guiding pins, does always activate
two cylinders at a time. The unloading frame is
moving back and forth by means of the unloading
cylinder, pos. 12. If oil pressure is put on the cylinder during operation, the unloading frame will
move to the left as shown in Fig. 4.38. Thus the
angle of slope of the rocker arms is changed so
that the unloading, ring pos. 19F, is able to move
freely. Consequently, the cylinder is forced to
work.
If the oil pressure to the unloading cylinder closes,
the unloading frame, pos. 13, will move to the
right, thereby raising the rocker arms. The unloading ring with pins, pos. 19B, are pressed up under
the ring plate and the suction valve is forced open,
thereby unloading the cylinder.
Fig. 4.38

Unloading System
15A

13

12
15B

The unloading ring, pos. 19B, is activated by two


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

0178-931 - ENG
Rev. 27.10.03

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SMC /TSMC 100 Mk4 - Engineering Manual

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 can be seen from the starting torque curves,


in Section 6, Technical Data.
Solenoid Valves for Capacity Regulation
The unloading cylinders are controlled by solenoid valves, Fig. 4.39, which receive opening and
closing signals from a connected regulator. This
could e.g. be a programme device or the YORK
electronic control system, UNISAB II, as described later in this section under Instrumentation.

This unloading during start-up reduces the starting torque of the compressor considerably.
Fig. 4.39
12

3
1

The solenoid control valve is an electromagnetic


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

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


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

If the coil is energized, the valve will reverse so


that the passage of the oil flow from oil discharge

60/288

0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

4. Technical Description

Fig. 4.40

Solenoid Valve Block

04 technical description.fm

In the block there is a common supply of pressure


oil from the oil pump (pipe a) to the solenoid
valves as well as a common connection to the
crankcase (pipe c). Each solenoid valve has its
own oil connection to the relevant regulating cylinder (pipe b).

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

Standard compressors, however, with 2 cylinders


on the SMC 104, 106 or 108 compressors or 4 cylinders on SMC 112 and 116 will be set to work
when the compressor oil pump has worked up an
oil pressure in the lubricating system.
The cylinders mentioned are connected directly to
the oil system without any solenoid valve as
shown in . This makes it the lowest capacity stage
on the compressors.
The standard SMC 100 compressors can be regulated with the following capacity stages, represented by the hatched fields in Table 4.4.

61/288

SMC /TSMC 100 Mk4 - Engineering Manual

4. Technical Description

Schematic Drawings, Standard

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

SMC /TSMC 100 Mk4 - Engineering Manual

4. Technical Description

The electric regulating system should be


made in such a way that, after start-up, additional capacity cannot be loaded until the motor has reached its full torque.
The recommended run up time is 10 sec. The minimum speed according to the operating limit diagram is 5 sec (also applies to variable speed driven compressors).

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

The S solenoid valve makes the total unloading of


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

When total unloading is required until the


motor has reached its maximum torque moment.

When a refrigeration plant has sudden brief


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

The regulating sequence can be seen from the


schematic drawings in Fig. 4.41.
Capacity Stages:
The SMC 100 compressors can be regulated with
the following capacity stages, represented by the
hatched fields in Table 4.4.

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SMC /TSMC 100 Mk4 - Engineering Manual

4. Technical Description

Fig. 4.41

Schematic drawings, Additional Equipment

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

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0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

4. Technical Description

Table 4.4

Compressor
Type

Capacity per Stage in %


25

33

37

50

63

67

75

83

87

100

SMC 104
SMC 106
SMC 108
SMC 112
SMC 116
TSMC 108

04 technical description.fm

TSMC 116

As illustrated in Table 4.4, the SMC 100 standard


compressors can only be capacity regulated in
steps of two cylinders, which is sufficient in most
cases.
However, it will occasionally be required to feature
more stages and for this reason a system called
extended unloading has been developed to ca-

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).

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SMC /TSMC 100 Mk4 - Engineering Manual

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.

Type : SMC 100


Load
104

106

108

112

116

12.5%
16.7%
18.8%
25.0%
31.3%
33.3%
37.5%
41.7%
43.8%
50.0%
56.3%
58.3%
62.5%
66.7%
68.8%
75.0%
81.3%
83.3%
87.5%
91.7%
93.8%
100.0%

The system is optional and can be ordered when


an order for a new compressor is placed.
Already delivered SMC 100 compressors can be
converted for extended or totally unloaded sys-

66/288

tems by means of reconstructing kits supplied by


YORK Refrigeration's After Market Service Department.

0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

4. Technical Description

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


Table 4.6
Type : SMC 100
Load
104

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

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SMC /TSMC 100 Mk4 - Engineering Manual

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

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


15E-1.
The constantly connected cylinder is not mounted
with unloading ring pos. 19B, washer pos. 19C-1,
spring pos. 19D-1 and spring pos. 19E. It is
marked S on the guide ring for the discharge
valve pos. 19J-1. See the position of the cylinder
in Fig. 4.43.
Fig. 4.42

Cylinder Liner with Suction Valve


S

19J

104

106

108

112

116

25%

16.5%

12.5%

16.5%

12.5%

The change is obtained by removing the following


pos. nos. from the constantly connected cylinder:
both systems of rocker arms pos. 15A-1, bearing
cup pos. 15B-1, spring retainer pos. 15C-1, spring

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0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

4. Technical Description

Fig. 4.43

Position of cylinders in compressor frame

04 technical description.fm

SMC 106

SMC 108

12

15 11

16
9

3
2

11

10

14

1
13

SMC112

The valve body as for Total unloading is used to


regulate the capacity stages instead of the standard valve body and the corresponding connecting
pipes are mounted.
The increased starting torque must therefore be
taken into consideration when choosing motor
and start system.
For this purpose, the start up torque curves for
R717 compressors and for HFC/HCFC compressors might be useful. These figures can be seen
in Section 6, Technical Data, Starting torque of the

Rev. 27.10.03

SMC 104

0178-931 - ENG

12

2
5

6
4

S MC116

compressor. Please note that the max rpm is


shown in the Operating Limits Diagrams in section
6.
Please note that if the motor is started up by
means of a Y/ starter, the starting torque of the
compressor may exceed the starting torque of the
motor at a high differential pressure. In these cases the compressor must be equipped with a
by-pass system which makes the pressure on the
discharge side of the compressor equivalent to
the suction pressure as illustrated in Fig. 4.44.

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4. Technical Description

Fig. 4.44
Solenoid
valve

Nonreturn valve or
automatically controlled
stop valve

YORK Refrigeration's recommendations as to the


cooling of the compressor. These recommendations can be found in the Operating Limits diagrams.

Variable speed drive (VSD)

After long operating hours at minimum capacity,


the temperature of the compressor block and the
oil will exceed the normal operating temperatures.
It is therefore recommended to adhere to

70/288

Further, the compressor can be driven by VSD as


long as the rpm limits are not exceeded - see Operating limits. For the standard and total unloading
compressor, UNISAB II is able to control the VSD
combined with the mechanical capacity control in
the most efficient way taking into consideration
both energy consumption and wear.

0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

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

be mounted for the SMC compressors and two oil


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

Fig. 4.45

04 technical description.fm

SMC 100 Unit - Direct Couple

The compressors can be connected to an electric


driving motor or a combustion motor. The transmission can be either direct through a coupling
that is flexible in both radial and longitudinal direction but which is also rigid in its contorsion, thereby stabilising the compressor rotation. The transmission can also take place by means of a V-belt
drive, which, through the selection of standard
belt pulley diameters, is able to provide the compressor with the correct number of revolutions and
consequently, the desired compressor capacity.
For more information, read Section 6, Technical
Data.
Please note that the compressor must be modified
in order to change the direction of rotation: the oil
pump must be changed on Mk4.

SMC 100 Unit - V-belt Driven

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

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SMC /TSMC 100 Mk4 - Engineering Manual

4. Technical Description

Instrumentation
In the standard version the compressors are available with one of the following two systems:
A:

analogue reading and safety system

B:

UNISAB II reading, safety and capacity


regulating system

The compressors are designed so that either the


analogue system or the UNISAB II system can be
fitted without changing the compressor. They
each have their own characteristics, however, as
described in the following:
A: Analogue Reading and Safety System
The analogue system only has reading and
safety functions and cannot control the compressor capacity.
Capacity control is handled by an external
system built into the electrical switchboard
and connected to the compressor on the
mounting site. Some mounting costs must
be expected.

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

The control system can be one of many


types and makes. It must, however, be able
to send out opening and closing signals to
the solenoid valves of the compressor in the
prescribed unloading and loading sequence
as already described in this section, Capacity Regulation and Unloading of Compressor.
In special cases a manually operated switch
system can be used instead of the automatic one. This makes it possible to regulate the
compressor capacity by hand.

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0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

4. Technical Description

1.

High Pressure Cut-out KP15

The pressostat has a manual


reset function

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.

as well as a yellow indicator lamp which,


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

The pressostat has a manual


reset function.

04 technical description.fm

2.

Low Pressure Cut-out KP15

5.

Adjusted to stop the compressor if the suction pressure drops to a pressure corresponding to 5K lower than the lowest evaporating pressure.

Adjusted to stop the compressor if the


discharge gas temperature exceeds:

The pressostat has an automatic


reset function

This adjustment can, however, be set to


20C [68 F] above the normal discharge
gas temperature, once this is known from
experience. This makes it possible to safeguard the compressor against excessive
temperatures.

150 C [302 F] for R717


120 C [248 F] for HFC/HCFC

and will therefore restart the compressor


once the pressure rises again.
3.

Intermediate Pressure Cut-out KP5


Used only on TSMC compressors. Stops
the compressor if the intermediate pressure
has risen to 8 bar [116 psi].
The pressostat has a manual
reset function.

4.

Discharge Pipe Thermostat KP98

The thermostat has a manual


reset function.
6.

Adjusted to stop the compressor whenever


the oil temperature in the crankcase exceeds 80C [176 F].

Oil Differential Cut-out MP55


Adjusted to stop the compressor if the pressure in the lubricating system drops below
3.5 bar [51 psi] compared to the pressure in
the crankcase.
The pressure cut-out has a built-in time delay of 60 sec. which keeps it idle during the
start-up of the compressor until the correct
oil pressure has been established.

0178-931 - ENG
Rev. 27.10.03

Oil Thermostat KP98

The thermostat has a manual


reset function.
7.

Oil Filter Differential Pressostat


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

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SMC /TSMC 100 Mk4 - Engineering Manual

4. Technical Description

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

10.

Fig. 4.48
10

8.

9.

Low Pressure and Oil Pressure


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

8-9

This manometer has two manometer works


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

High Pressure Manometer

The manometers can be used with several


refrigerants.

High pressure manometer indicating the


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

High and Intermediate Pressure Manometer

HFC/HCFC manometers for R22, R134a,


R404A

R717 manometers

R410A, R744 (CO2) manometers

High and intermediate pressure manometer


indicating the discharge pressure for the HP
and LP stages on TSMC compressors,
Fig. 4.48.
This manometer has two manometer works
and two arrows, a red one for high pressure
and a black one for intermediate pressure.

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

SMC /TSMC 100 Mk4 - Engineering Manual

4. Technical Description

B: UNISAB II Reading, Safety and Capacity


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

04 technical description.fm

Fig. 4.49

Computerized Control and Monitoring

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

tion stops. In addition to efficient control and


monitoring of single compressors
UNISAB II is also designed for advanced
control and monitoring of any combination
of up to 14 compressors. It is thus possible
to centrally control and monitor up to 14
compressors by using a COMSAB or PC
COMSAB module.
Multi-lingual System
UNISAB II is available in 15 different languages, and it is possible to switch to the
English version at any time.
Easy to Operate
UNISAB II has a systematic and easily accessible user interface which does not require any special knowledge or education.
Operational data and status appear from the
distinct display which features four lines with
twenty characters each. The user interface
also has arrow keys for menu selection, set
key for parameter changing as well as keys
for selection of manual/automatic operation,
start/stop, manual capacity regulation and
resetting.

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4. Technical Description

Safety Monitoring and Control


UNISAB II provides safe monitoring by
means of warning and alarm values/settings
for all measuring points. If a set value is exceeded, a red diode will flash slowly in warning situations without stopping the compressor, and quickly in alarm situations with
compressor shut down. A display text will
show the cause of the alarm. In both warning and alarm situations separate relays are
activated for connection of a remote lamp,
bell or alarm panel.
It is easy to find all the set values and their
warning and alarm values through the
straightforward menu system.
Besides monitoring the compressor pressures and temperatures, the UNISAB II also
calculates the suction pressure vapour
overheating, monitors the capacity slide position and oil flow, and calculates the oil filter
differential pressure on screw compressors.
For correct fault diagnosis in case of a compressor shut down, the UNISAB II immediately stores the alarm situations in its memory which can be displayed and analyzed on
the display at any time.
Instrumentation
Depending on compressor type the
UNISAB II is equipped with a number of

76/288

pressure and temperature transducers as


well as position transmitters on the compressor. On one-stage reciprocating compressors three pressure and three temperature transducers are mounted while
two-stage reciprocating compressors are
equipped with four pressure and temperature transducers.
Screw compressors are fitted with four pressure and three temperature transducers as
well as one or two slide position transmitters.
Furthermore, a thermistor input is available
for motor protection.
Factory Test
Every UNISAB II is tested during the production process and when it is mounted on
the compressor. A computer test is performed including a test certificate before the
compressor leaves the factory.
Please note that UNISAB II cannot directly
combine the capacity of compressors with
extended capacity control; only SMC 104
can be controlled directly by UNISAB II
when it is equipped with a simple box
(this has to be configured as a HPC 108 or
SMC 108).

0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

4. Technical Description

Cooling of the Intermediate Discharge


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

04 technical description.fm

Common for these intermediate cooling systems


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

Fig. 4.50

Oil separator
Oil separator

In the intermediate cooler the liquid level of R717


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

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 drain off

TSMC 100 Compressor


Oil separator

Oil separator

CT

Intermediate Cooling System with


Intermediate Cooler Type DVEA, R717
The two-stage R717 plant may consist of two
compressors, one low-pressure compressor (LP)
and one high-pressure compressor (HP) as illustrated in Fig. 4.50 The plant may also consist of
one or more two-stage compressors as shown in
Fig. 4.51.
In both cases the compressors are connected to
an intermediate cooler in which the warm gas from
the LP-stage is cooled down before it flows on to
the HP-stage.

SMC 100 compressor

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.

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4. Technical Description

As a matter of precaution a solenoid valve


should be used in the liquid line to the float so that
it may shut off the liquid flow to the intermediate
cooler whenever the system is stopped.
At regular intervals the intermediate cooler must
be drained of oil through the oil drain valve.
Intermediate Cooling System with Liquid
Injection into the Intermediate Discharge Gas,
R22 and R717
Two-stage compressors type TSMC can be
equipped with a pipe connection from the LP
stage discharge branch to the HP stage suction
branch as shown in Fig. 4.52.
In the pipe connection the warm discharge gas
from the LP stage is cooled by injection of liquid
refrigerant into the intermediate pipe. This can be
achieved with the following two systems:

Connection, pos. B, pipe dimension OD 10 mm,


emerges from receiver or priority vessel as described in Cooling with thermopump - R717 later
in this section. The intermediate discharge pipe is
built onto the compressor on delivery as a block or
a unit. On delivery of a compressor block the liquid
system including the expansion valve must be
mounted on site.
2.

Intermediate Cooling with Thermostatic


Injection Valve Type:
TEAT (HCFC)

The intermediate cooling system is designed as 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.

Intermediate Cooling with Thermostatic


Expansion Valve Type:
TEA (R717) or TEX (R22)

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

In the system in Fig. 4.52 the liquid refrigerant


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

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

SMC /TSMC 100 Mk4 - Engineering Manual

4. Technical Description

Automatic Regulation of Intermediate


Pressure IP

Determining the Intermediate Pressure


IP

In two-stage plants with reciprocating compressors it should be pointed out that the intermediate
pressure is not allowed to drop excessively.

The intermediate discharge temperature of the


compressor is dependent on the evaporating temperature ET, the condensing temperature CT and
of the ratio between the capacity at the LP and HP
stages, corres-ponding to the number of cylinders
that is working at each stage.

A low intermediate pressure reduces the damping


effect of the gas on the valve plates in the LP
stage discharge valves. The danger is that a
breakdown may occur in the form of broken valve
plates.

04 technical description.fm

In order to prevent this it may be necessary to


mount a by-pass system between the HP side and
IP side. Thus a suitable amount of gas is led back
to the IP side. The system is illustrated in
Fig. 4.54.
The lower limits for IP have been fixed at:
-15C [5F] for R717 plants
- 25C [-13F] for HFC and HCFC plants.
The by-pass system is additional equipment and
is usually mounted by YORK Refrigeration directly on the internal pipe connections on the compressor block .
The diagrams, Fig. 4.50 to Fig. 4.53, do only show
the principle of the different systems and must not,
therefore, be used directly.
Fig. 4.54
TSMC
PM main valve
CVC pilot valve -0.75 -> 7 bar
Oil separator

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

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Rev. 27.10.03

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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

SMC /TSMC 100 Mk4 - Engineering Manual

4. Technical Description

Cooling Systems for Compressors


To preserve the optimum lubricating capacity of
the oil it may become necessary to cool during
compressor operation. Depending on the operating conditions and the type of refrigerant the plant
uses, a number of cooling systems are available.
See Section 6, Technical Data, Operating Limits
Diagrams.
The following standard cooling systems can be
delivered for the compressors, depending on
which type of refrigerant the compressor is operating with as well as the compressor type itself.

lease any surplus heat in the compressor into the


environment, see Fig. 4.55 and Fig. 4.56.
Fig. 4.55

Air-cooled Top Cover

Fig. 4.56

Air-cooled Side Cover

04 technical description.fm

Standard Cooling Systems for


Compressors
1.

R717
a.

2.

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

b.

Water-cooled top and side covers.

c.

SMC only:
Compressor cooling with thermopump

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

Air-cooled top and side covers.

b.

Air-cooled top covers and water-cooled


side covers.

There is therefore no need for forced cooling


air flow past the covers.
It is, however, necessary to cool the oil in the compressor by means of a built-in oil cooler, which is
cooled by the refrigerant in the plant. The cooling
system is built onto the compressor. It operates as
illustrated in piping diagram, Fig. 4.57, for a normal one-stage compressor and in Fig. 4.58 for a
booster compressor.

Description

The cooling system consists of an oil cooler


mounted on the oil pipe which connects the oil
pump with the shaft seal. The oil cooler is dimensioned to maintain the oil temperature at 50-70C
[122 - 158 F].

1a: Air-cooled Top and Side Covers with


Refrigerant-cooled Oil Cooler R717
Air-cooled top and side covers are covers without
cooling fins, but with a surface large enough to re-

The expanding gas is led through pipe, pos. 1,


Fig. 4.57, to the compressor suction side. On the
outside of the pipe the sensor for the thermostatic
expansion valve, type TEA, is fitted.

c.

Air-cooled top and side covers and


refrigerant-cooled oil cooler.

0178-931 - ENG
Rev. 27.10.03

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SMC /TSMC 100 Mk4 - Engineering Manual

4. Technical Description

The expansion valve, type TEA, is particularly


suited for R717. In the liquid line there is also a solenoid valve which closes when the compressor is
stopped.
Fig. 4.57

Normal One-stage Compressor R717


T
Oil separator

LP

HP

The pipe pos. 1 on the booster and two-stage


compressor is led to the IP side as illustrated in
Fig. 4.58 and Fig. 4.59. Thus the compressor capacity is not affected by the oil cooling system.
The liquid supply is regulated by a thermostatic injection valve of the TEAT type whose sensor is
placed on the discharge pipe of the compressor.
This gives the cooling system two cooling functions. One is to cool the oil in the crankcase the
other to cool the discharge gas and consequently
the discharge side of the compressor.

LP

Fig. 4.58

Booster Compressor R717

T
Liquid from
receiver
TEA

Oil cooler

Filter

Oil
separator

Stopvalve
LP

Solenoid valve

IP

The filter filters off any dirt particles in the liquid.


The filter element can be removed and cleaned.
The stop valve can block the cooling system from
the refrigeration plant.

Liquid from
receiver
Oil cooler

A thermostat T is connected to the cooling system


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

TEAT

Filter

Stopvalve

Solenoid valve

Fig. 4.59

Two-stage TSMC Compressor R717


IP

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

SMC /TSMC 100 Mk4 - Engineering Manual

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

Water-cooled Top Cover

The diagrams, Fig. 4.57 to Fig. 4.59, do only show


the principle of the different systems and must not
be used directly.

04 technical description.fm

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


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

Note: Do not use sea water as cooling water on


top covers.
Fig. 4.61

Water-cooled Side Cover

A system of canals is thus created between the


two covers in which the water is distributed evenly
and cools effectively.
As the water covers can be dismantled without removing the top covers and depressurizing the
compressor, the pipe system and the inner faces
of the water cover can easily be cleaned of any
impurities.
It is fairly easy to build this water cooling system
on an air-cooled compressor. Note, however, that
the air-cooled side covers must be replaced with
covers with cooling fins on the inside. This may be
seen by comparing Fig. 4.56 with Fig. 4.61.

0178-931 - ENG
Rev. 27.10.03

Mounting of Cooling Water Hoses


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

83/288

SMC /TSMC 100 Mk4 - Engineering Manual

4. Technical Description

Fig. 4.62

Mounting of water hoses on top and side covers.

Cooling of top and side covers


SMC 104-106-108 and TSMC 108
SMC 104 3185-230
Pos. No. Hose Type L (mm)

4
5

3
3
2

715

115

505

645

835

SMC 106 3185-231


Pos. No. Hose Type L (mm)
5

730

125

335

375

515

1100

6
3
3
2
1

SMC 108 TSMC 108 3185-232


Pos. No. Hose Type
4
4

3
3
2
1

84/288

L (mm)

760

150

340

255

230

1090

0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

4. Technical Description

Fig. 4.63
Cooling of side covers only
Side covers 3185-235 SMC 104106-108 and TSMC 108

SMC 104-106-108-112-116 and TSMC 108-116

Pos. No.

Hose Type

L (mm)

715

175

230

765

Side covers SMC 112 3185-246


3

Pos. No. Hose Type


4

04 technical description.fm

L (mm)
SMC 112

750

130

750

220

Side covers 3185-236 SMC 116


and TSMC 116
Pos. No

Hose Type

L (mm)
SMC 116
TSMC 116

740

160

770

215

0178-931 - ENG
Rev. 27.10.03

85/288

SMC /TSMC 100 Mk4 - Engineering Manual

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

SMC 188/TSMC 188 3185-243

Pos. no.

4
4

3
3
2
1

Hose type

L (mm)

335

1755

535

245

1175

340

Side covers only 3185-244


Pos. no.

Hose type

L (mm)

1165

245

1315

410

3
4

86/288

0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

4. Technical Description

Note:

The direction of the water flow is indicated in


Fig. 4.62.

The hose sections have been shortened to


the lengths indicated from factory.

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.

Necessary Water Consumption


To achieve satisfactory distribution of cooling water and hence proper compressor cooling, the following limiting values should be followed.
Min. Water Flow
5.5 litres per hour per kW motor output. On water
circulation plants greater water flow is recommended. See Fig. 4.65.
Max. permissible inlet temperature:
+40C [104F]
Min. permissible inlet temperature:
+10C [50F]
Max. permissible outlet temperature:
+55C [151F]
Max. permissible temperature rise from inlet
to outlet on compressor:
15C [59F]
Max. permissible cooling water pressure:
8 bar.

0178-931 - ENG
Rev. 27.10.03

87/288

SMC /TSMC 100 Mk4 - Engineering Manual

4. Technical Description

Pressure Loss in the Cooling System in SMC/TSMC Compressors


Fresh ground water

Totally for Side and Top Covers


Fig. 4.65 Pressure loss diagram

Water from cooling towers or condensers

TSMC 108
SMC 108
SMC 106
SMC 104

Pressure loss
p(mWc)

Closed water systems in which the water


is cooled and recirculated
SMC
112
T/SMC

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

Salt water (Brine)


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

0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

4. Technical Description

1c: Cooling with Thermo Pump - R717


The thermo pump is a compressor cooling system
which makes the compressor completely independent of the cooling water. The system is therefore very applicable in areas where there is a
shortage of water resources or where the water
quality is poor. The thermo pump system can only
be used with R717.
The purpose of the thermo pump is both to cool
the oil in the crankcase and to cool the compressor discharge gas in order to lower the temperature in the whole compressor.

04 technical description.fm

Fig. 4.66

Short Block with Thermopump

On TSMC compressors cooling only takes place


in the high pressure stage top covers and no oil
cooler is used in the crankcase.
The thermo pump works under the influence of
heat coming from the oil in the crankcase. In this
way it also regulates its own pump capacity. This
means that the thermo pump works slowly when
the oil is cold, e.g. right after start-up of the compressor, but as the oil temperature gradually rises,
the pump capacity will increase accordingly.
The thermo pump does not start, however, until
the discharge gas temperature exceeds 80C
[176 F].
The pumping cycle of the thermo pump, i.e. a filling and an evacuation period, lasts between 4 and
8 minutes depending on the number of cylinders
of the compressor, its capacity, the oil temperature in the crankcase and the operating pressure
and temperatures of the plant. The filling period
takes about 45 sec.

The thermo pump is mounted as a side cover on


the compressor and works by pressing the refrigerant into the canal system on the top covers and
into the oil cooler which - depending on the operating conditions - is built into the crankcase.

0178-931 - ENG
Rev. 27.10.03

The thermo pump has an important advantage,


namely that the refrigerant pumped by the thermo
pump is led directly into the discharge gas of the
compressor. Consequently, this will have no influence on the compressor capacity.

89/288

SMC /TSMC 100 Mk4 - Engineering Manual

4. Technical Description

The Structure of the Thermo Pump


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

from the oil bath in the crankcase. The cooling


cover is equipped with cooling fins in order to ensure a proper thermal contact with the oil.

Side Cover with Thermo Pump


98G

98D

98B

98A

A
98Q
C

98H

98C
98X

As indicated in the principle drawings of the SMC


108,Fig. 4.68, and a TSMC, Fig. 4.69, the thermo
pump has the following connections:

Connection pos. A, which is linked to the


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

90/288

Connection pos. B emerges from the plant


receiver or the priority tank (will be described later) and goes right to the valve
block pos. 80.

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

SMC /TSMC 100 Mk4 - Engineering Manual

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

The thermo pump is safeguarded by the following


systems as shown in Fig. 4.67, Fig. 4.68 and
Fig. 4.69:

98G

98T

98B
98M

98

a.

98H
C

B
98K
98V
98Y

98K
80

The thermostat is factory set to start up the


thermo pump once the discharge gas temperature is above 80C [176 F].

04 technical description.fm

Fig. 4.69

TSMC 108
b.
98M

98Z

IP

98X
2

Please, note that the pipe connection pos. D


to the plant evaporating side must be at a
place where there is suction pressure and no
risk of the liquid flowing back to the compressor through the suction line. Connection
should e.g. be made to the liquid separator or
the evaporator.

98G
98B
98

98H
C
98K
80

98K
98V
98Y

0178-931 - ENG
Rev. 27.10.03

An evacuation system emptying the pump


vessel through solenoid valve pos. 98V
whenever the thermo pump stops.

HP

A thermostat built into the control box pos.


98B with sensors pos. 98X fitted on the compressor discharge pipe.

c.

A safety circuit with a non-return valve, pos.


98Z, which opens for the flow in the pump
vessel at a pressure 3 bar [44 psi] higher
than the one in the compressor discharge
gas line.

91/288

SMC /TSMC 100 Mk4 - Engineering Manual

4. Technical Description

Description of the Pumping Cycle


Filling the Pump Vessel
As soon as the liquid leaves the bottom level sensor, the control box will activate the solenoid
valves pos. 98H in valve block pos. 80 and pos.
98G.
Thus solenoid valve, pos. 98G, opens in the pipe
connection to the compressor suction side and
the pressure in the pump vessel decreases slightly. At the same time solenoid valve pos. 98H
opens and refrigerant liquid starts flowing to the
pump vessel through pipe connection B.
Emptying the Pump Vessel
When the top sensor, pos. 98C, has registered
that the liquid has reached the top level, both solenoid valves will be closed by the control box.
The pressure in the pump vessel will now rise as
a consequence of the heat impact from the compressor oil and will - when it exceeds the pressure
on the compressor discharge side - make the refrigerant flow through the pipe connection C to the
top covers and the oil cooler.
At the top covers the refrigerant expands through
the nozzles, pos. 98M, directly into the hot discharge gas, resulting in immediate cooling of the
discharge gas.
The oil cooler OOSI (not always required) is a
heat exchanger in which the expanding refrigerant

92/288

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


Once the liquid in the pump vessel has returned to
its lowest level, it is registered by the bottom sensor and the control box opens the two solenoid
valves for a new pumping cycle.
Capacity Regulation of Thermo Pump
When reducing the compressor capacity, it will be
necessary to reduce the cooling effect of the thermo pump as well. This is done as follows:
SMC 104-106-108, TSMC 116
The pipe connection from the pump vessel to the
top covers is divided into two pipe lines. In one of
these pipe lines a solenoid valve, pos. 98U, is fitted.
This solenoid valve is wired to the capacity regulating system of the compressor and it closes
when the compressor capacity has been reduced
as indicated in the following table, Table 4.9.
Table 4.9
Compressor
Capacity
SMC 104
SMC 106
SMC 108
TSMC 116

Solenoid Valve pos. 98U


Open

Closed

100%
100 - 67%
100 - 75%
100 - 83 - 67%

50%
33%
50 - 25%
50 - 33%

On the SMC 112-116 two thermo pumps have


been mounted as shown in the principle drawings
Fig. 4.70, Fig. 4.71 and Fig. 4.72.

0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

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 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

SMC /TSMC 100 Mk4 - Engineering Manual

4. Technical Description

The total capacity of the thermo pumps is adapted


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

SMC 112
SMC 116

Thermo Pump at Compressor


Shaft End
Working

Not Working

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

50 - 33%
50 - 37 - 25%

When the compressor is stopped, the current to


the thermo pump is cut off, closing the solenoid
valves pos. 98H and pos. 98G. At the same time
solenoid valve pos. 98V opens and drains the liquid in the thermo pump back to the evaporating

94/288

Ensuring Liquid to the Thermo Pump


The thermo pump must always be ensured liquid
from the plant, irrespective of whether the plant
lacks liquid or if some other factor prevails.
Thus, the thermo pump must also be ensured liquid during a possible pump down by means of the
compressor.
In other words: During operation the compressor
must never be short of cooling.

Table 4.10
Compr.
Capacity

side of the plant. See the previously mentioned


point b.

This safety is achieved either by taking the liquid


directly from the receiver, pipe connection B, or by
building a priority tank into the liquid line of the
plant, Fig. 4.73.
The liquid volume A of the priority vessel must be
minimum 10 litres per thermo pump.
The liquid tube from the priority vessel to the thermo pump must be dimensioned to prevent the formation of flash gas along the way.

0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

4. Technical Description

Fig. 4.73
1

Receiver

3
B
B

04 technical description.fm

1:
2:
3:
B:

Power Connection

Refrigerant liquid from condenser/receiver


Refrigerant liquid to evaporator
Refrigerant liquid reserve for oil cooling
Refrigerant liquid for oil cooling

Fig. 4.74
K1

The control box is geared for the 3 voltages listed


below.
Voltages:
110V - 50/60Hz
220V - 50/60Hz
240V - 50Hz
The control box contains a terminal strip as shown
in Fig. 4.74.

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

Lower level sensor

Main voltage selector


VS1
230
115

0178-931 - ENG
Rev. 27.10.03

95/288

SMC /TSMC 100 Mk4 - Engineering Manual

4. Technical Description

2a: Air-Cooled Top and Side Covers


R22 - R134a - R404A - R507
Use the same cover mounting as described in paragraph 1a. As indicated in the Operating Limits Diagrams in Section 6, Technical Data, there is no
need for oil cooling.

Table 4.11

2b: Air-Cooled Top Covers and Water


Cooled Side Covers
R22 - R134a - R404A - R507
If water is available and a need for cooling exists
according to the Operating Limits Diagrams, Section 6, Technical Data, this system is an excellent
solution.
The water-cooled side covers are mounted as described in paragraph 1b, Fig. 4.63.
Fig. 4.75

Cooling of Side Covers only

Pos No

Hose type

Length (mm)

715

175

230

765

2c: Air-Cooled Top and Side Covers


and Refrigerant-Cooled Oil Cooler
R22 - R134a - R404A - R507
Use the same cover mounting as the one described in paragraph 1a.
In principle, the oil cooling system is constructed
as illustrated in Fig. 4.57 for one-stage compressors, in Fig. 4.58 for booster compressors and in
Fig. 4.59 for two-stage compressors.

3
4

96/288

0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

4. Technical Description

fCompressor Accessories

Extended set of tools. Besides the


normal set of tools, this set contains all
necessary standard hand tools.

Spare parts set in various sizes.

Following an order, the accessories listed below


can be delivered for compressors or units:

Explosion-proof instrumentation instead of


the standard equipment.
Explosion-proof heating cartridge for oil
heating in the crankcase.

Explosion-proof solenoid valves for


capacity regulation.

Vibration dampers to be inserted


between unit and machine floor dimensioned to fit the unit in question.

Normal set of tools, comprising special


tools for dismantling and assembling the
compressor.

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

SMC /TSMC 100 Mk4 - Engineering Manual

4. Technical Description

Types of Spare Parts Set:

For the different compressor blocks:

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

Extended spare parts set: In addition to


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

Certificate spare parts set: In addition to


the parts from the extended spare parts
set this set contains a major number of
components and wearing parts selected by
the classification societies.

98/288

Special spare parts set: This is a more


comprehensive set than the extended
spare parts set as almost all O-rings and
gaskets are included and for the most wearing parts the number of parts have been extended.

For the Different Compressor Units:

Standard spare parts set: This is a set


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

Certificate spare parts set: In addition to


the parts from the standard spare parts set
this set contains other components selected
in accordance with the requirements of the
classification societies.

0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

5. Physical and Connection Data

5. Physical and Connection Data


The purpose of this document is:

to describe the physical data of the equipment,

to give complete information concerning the


requirements of the surrounding
system.

The safety precautions are intended for all user


categories.

05 physical and connection data.fm

This document was produced by:


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 start. Failure to comply with safety precautions may cause death or in-

0178-931 - ENG
Rev. 27.10.03

jury to personnel. It may also cause damage to or


destruction of the equipment.

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

SMC /TSMC 100 Mk4 - Engineering Manual

5. Physical and Connection Data

Physical Data
Dimension Sketches
Dimension sketches of all compressor blocks and
units are included in a separate binder Dimensions and Piping Diagrams.

tion is welded on the connecting branch of the


valve. See Table 5.1

Connection Data

Note: Be aware of the measures which must be


taken in order to avoid damaging the valve and
other parts of the unit when welding. See Section
7, Installation Instructions.

Refrigerant Suction Side


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

Connections to the Compressor


The tables in Table 5.1 and Table 5.2 show the
pipe connection on standard compressors. On delivery from YORK Refrigeration the compressors
are fitted with standard welding nipples on suction
as well as discharge side.

Note: Be aware of the measures which must be


taken in order to avoid damaging the valve and
other parts of the unit when welding. See Section
7, Installation Instructions.

The tables Table 5.3 to Table 5.5 include a list of


applicable welding nipples.

Refrigerant Discharge Side


On the compressor discharge side the pipe connection is made to the stop valve pos. 2 - see Dimensions and Piping Diagrams. The pipe connec-

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

SMC /TSMC 100 Mk4 - Engineering Manual

5. Physical and Connection Data

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

Nominal diameters for standard welding connections (in inch.)


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

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

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


32

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

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

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SMC /TSMC 100 Mk4 - Engineering Manual

5. Physical and Connection Data

+)
++)

HPS: High pressure suction side


PD: Low pressure discharge side

FP

The first value: connection for the low


pressure Oil Separator.
The second value: connection for the high
pressure Oil Separator.

ANSI Pipe according to ANSI B31.5 schedule 80


and 40 (DN 32 and 40 ~ schedule 40).

Fixed connection

FS

Fixed connection, delivered separately

102/288

Fixed pipe

R-KB Boiler pipe according to DIN 2448

Note: In this connection two types of standard


welding nipples are available. This should be
specified when ordering.

0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

5. Physical and Connection Data

Standard welding nipples are available from


YORK Refrigeration under the designation of RKB nipples, following the standard of DIN 2448
and with pipe dimensions as indicated in the table
in Fig. 5.1 (OD, s, ID1).

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.

The welding nipples are universal as their welded


ends have dimensions according to DIN 2448.

Fig. 5.1

Welding Nipples for R-KB Pipes

305

05 physical and connection data.fm

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

1) Smallest inner diameter = ANSI B31.5


Material:
1: RST 37-2 DIN 17100
2: SIS 2142/SKF 280

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Rev. 27.10.03

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SMC /TSMC 100 Mk4 - Engineering Manual

5. Physical and Connection Data

Instead of the welding nipples for R-KB


pipes, it is possible to order welding nipples solely used for standard pipes in accordance with ANSI B31.5, schedules
80 and 40.
Fig. 5.2

The welding nipples are shown in


Fig. 5.2 and must be specified when ordering a compressor.

Welding Nipples for ANSI Pipes


305

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

SMC /TSMC 100 Mk4 - Engineering Manual

5. Physical and Connection Data

Connections on SMC / TSMC Mk4


Fig. 5.3

Standard connections for both SMC / TSMC 10X and 11X


AC

AF

N
T

G
U

C
V

05 physical and connection data.fm

D
Fig. 5.4

SMC 112-116 Mk4


1
4

Z
AF

H
AE
AH
AK
AJ

0178-931 - ENG
Rev. 27.10.03

AD
Y

AA

105/288

SMC /TSMC 100 Mk4 - Engineering Manual

5. Physical and Connection Data

Fig. 5.5

TSMC 108 Mk4


1

AC

AF

M
H
4
R
3

Fig. 5.6

TSMC 116 Mk4


1
AF

H, AL

AG
AD

Y
AK

Fig. 5.7

Top cover

Fig. 5.8

Top cover w. flange

X, AN
S
Z, AL

106/288

0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

5. Physical and Connection Data

05 physical and connection data.fm

Fig. 5.9

BE

Fig. 5.10

Pump end

BT

BD

BL

BX

BB

BP

BN

BJ

BS

BA

BQ

Shaft seal end

F
K
AB

0178-931 - ENG
Rev. 27.10.03

AM

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SMC /TSMC 100 Mk4 - Engineering Manual

5. Physical and Connection Data

Connections for T/SMC104-116


Numbers at position are referring to

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

Oil charging valve

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

Oil pressure to unloading


cylinder

Fig. 5.10

FIG. NO.

THREAD
(ISO228/1-G)

NORMAL
APPLICATION

POS
(COMP. TYPE)

Table 5.6

G (1)

1/2

Suction

Gas

Plugged

Return from built-in oil cooler

Fig. 5.3

G (3)

1/2

Suction

Gas

Plugged

Plugged

Return from built-in oil cooler

Fig. 5.3

G (2+4)

1/2

Suction

Gas

plugged

Plugged

Plugged

Available

1)

1/4

Discharge

Gas

High pressure connection

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

1/4

Suction

Gas

Oil return from solenoid valves

Fig. 5.3

1/4

Oil

Oil

Oil pressure to solenoid valves

Fig. 5.10

1/4

Suction

Gas

Low pressure connection

Fig. 5.3

Intermediate pressure
connection
Oil return from oil separator

M1) (3+4)

1/4

Intermediate

Gas

Fig. 5.5 and Fig. 5.6

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

Return from built-in oil cooler

Fig. 5.3

Q (1+2+4)

1/4

Discharge

Gas

Plugged

Plugged

Return from oil cooler


(thermopump)

Fig. 5.3

Q (3)

1/4

Discharge

Gas

Plugged

Plugged

Plugged

Available

Fig. 5.3

Suction pressure to unloading


cylinder

Fig. 5.3

R (3+4)

1/4

Suction

Gas

1/4

Discharge

Gas

Plugged

Plugged

Refrigerant cooled top cover

Fig. 5.7

Equalization to suction end of


thermo pump

Fig. 5.3

Gas

Not included Not included

Fig. 5.5 and Fig. 5.6

1/4

Suction

1/4

Discharge

Liquid supply to top covers

Fig. 5.3

1/2

Suction

Oil

Plugged

Connection to built-in oil cooler

Fig. 5.3

1/2

Discharge

Gas

Discharge gas temperature

Fig. 5.8
Fig. 5.5 and Fig. 5.6

Liquid Not included Not included

Y (2+4)

3/4

Suction

Gas

Plugged

Plugged

Plugged

Plug for fixing intermediate


bearing

AN (3)

1/2

Intermediate

Gas

Plugged

Plugged

Plugged

Available

Fig. 5.8
Fig. 5.4

Z (2)

3/4

Discharge

Gas

Purge valve (discharge pressure)

Z (4)

1/2

Discharge

Gas

Purge valve (discharge pressure)

Fig. 5.8

Z (1+3)

1/2

Discharge

Gas

Purge valve (discharge pressure)

Fig. 5.8

AA (2+4)

1 1/4

Suction

Oil

AB

3/8

Suction

Oil

Plugged

Plugged

Plugged

108/288

Heating rod
Available

Fig. 5.4 and Fig. 5.6


Fig. 5.10

0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

05 physical and connection data.fm

OIL, GAS
OR LIQUID

AIR-COOLED
wATER-COOLED

1/2

Suction

Gas

Used in connection with UNISAB

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

5. Physical and Connection Data

Suction temperature (superheat)

Fig. 5.3, Fig. 5.4,


Fig. 5.5 and Fig. 5.6
Fig. 5.4 and Fig. 5.6

AD (2+4)

1/4

Suction

Gas

Return from solenoid valve

AE (2)

1/4

Suction

Gas

Plugged

Return from built-in oil cooler

Fig. 5.4

AF (1+2)

1/4

Discharge

Gas

Plugged

Plugged

Return from built-in oil cooler

Fig. 5.3 and Fig. 5.4

AF (3+4)

1/4

Discharge

Gas

Plugged

Return from built-in oil cooler

Fig. 5.5 and Fig. 5.6

Equalization from thermopump


for intermediate pressure

Fig. 5.6

Equalization to suction end of


thermo pump

Fig. 5.4

AG (4)

1/4

Intermediate

Gas

Plugged

Plugged

AH (2)

1/4

Suction

Gas

Not included Not included


Not included Not included

AJ (2)

1/4

Suction

Gas

Liquid supply to top covers

AK (2+4)

1/2

Suction

Gas

Plugged

Return from built-in oil cooler

AL (3)

1/2

Intermediate

Gas

Purge valve
(intermediate pressure)

Fig. 5.8

AL (4)

1/2

Intermediate

Gas

Purge valve
(intermediate pressure)

Fig. 5.6

AM

1/4

Suction

Oil

Plugged

Plugged

Plugged

Available

Fig. 5.10

BA

3/8

Oil

Oil

Plugged

Plugged

Plugged

Not recommended for use

Fig. 5.9

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

Not recommended for use

BE

1/2

Suction

Oil

Plugged

Plugged

Plugged

Not recommended for use

Fig. 5.9

BJ

1/8

Oil

Oil

Plugged

Plugged

Plugged

Not recommended for use

Fig. 5.9

BL

1/4

Suction

Oil

Plugged

Plugged

Plugged

Not recommended for use

Fig. 5.9

BN

1/4

See
application

Oil

BP

1/8

See
application

Oil

Oil pressure after oil filter


Oil pressure before oil filter

Fig. 5.9
Fig. 5.9

BQ

1/4

Oil

Oil

Plugged

Plugged

Plugged

Not recommended for use

Fig. 5.9

BX

1/8

Oil

Oil

Plugged

Plugged

Plugged

Not recommended for use

Fig. 5.9

BS

1/4

Oil

Oil

Oil pressure

Fig. 5.9

1/4

See
application

BT
1

Oil

Used in connection with UNISAB Q

Low pressure suction stop valve

Oil pressure before oil filter

Fig. 5.9
Fig. 5.3, Fig. 5.4,
Fig. 5.5 and Fig. 5.6

2 (3+4)

Low pressure discharge stop valve

Fig. 5.5 and Fig. 5.6

3 (3+4)

Connection from intermediate pressure

Fig. 5.5 and Fig. 5.6

High pressure discharge stop valve

Fig. 5.3, Fig. 5.4,


Fig. 5.5 and Fig. 5.6

1) Positioning

on the different block types may vary

0178-931 - ENG
Rev. 27.10.03

109/288

SMC /TSMC 100 Mk4 - Engineering Manual

5. Physical and Connection Data

Electrical Connections
Fig. 5.11
TT7

Electromechanical Control

Computer Control, UNISAB II

TT5

PT2
7
PT1

PT3

TT6

1+2

High and low pressure cut-out KP15

PT1

Suction pressure

High pressure cut-out (intermediate pressure) KP5

PT2

Discharge pressure

Differential oil pressure cut-out MP55

PT3

Oil pressure

Discharge gas thermostat KP98

TT5

Discharge gas temperature

Oil thermostat KP98

TT6

Oil temperature

Computer control, UNISAB II

TT7

Suction gas temperature

Heating element

Oil filter differential pressure

UNISAB II:

MOTOR

Supply voltage:

115 VAC
230 VAC
24 VAC
Permissible variation: +10%/-15%
Frequency:
45-65 Hz
Power:
50 VA

Connection data for


supply voltage:
Permissible variation:
Frequency:
Power:

Where UNISAB II is supplied with 24 VAC, the


connecting terminals supplying the heating elements must be supplied with 115 or 230 VAC, see
Installation Manual for UNISAB II.

Supply voltage and motor power appear from the


order sheet.

110/288

VAC
+10%/-15%
45-65 Hz
kW

0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

5. Physical and Connection Data

Control of the Unit


The compressors are available with
a.

analogue reading and safety system, electromechanical control.

b.

UNISAB II reading, safety and capacity regulating system.

05 physical and connection data.fm

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.

1. Pressure Transmitters marked PT1,


PT2 and PT3
As standard, the product is delivered with pressure transmitters of the type: AKS32 and
AKS2050 from Danfoss - see data sheet in Section 21, Appendices.
Connection data: Connect a three-wire cable to
the terminals of the plug fitted at the end of the
pressure transmitters.
Supply voltage: 5 VDC
Output signal: 4-20 mA
Pressure transmitters are used for measuring:
1.1 Suction Pressure, PT1
The measurement is used to protect against
too low suction pressure. Low suction pressure must stop the compressor. The control
system can be adjusted in such a way that
the compressor starts automatically at too
high suction pressure. The set values must
be within the permissible working range for
compressors as stated in Section 6, Technical Data.
1.2 Discharge Pressure, PT2
The measurement is used to protect the
compressor against too high discharge
pressure. Too high discharge pressure must
stop the compressor without automatic restart. The set values must be within the per-

111/288

SMC /TSMC 100 Mk4 - Engineering Manual

5. Physical and Connection Data

missible working range for compressors as


stated in Section 6, Technical Data.
1.3 Oil Pressure across Mechanical Oil Pump
Is calculated as oil pressure after oil pump
PT3 minus suction pressure PT1. Too low
oil pressure (< 0.5 bar) must stop the compressor without automatic restart. However,
this alarm must be delayed 45 sec when
starting the compressor.
2. Temperature Sensors marked TT5, TT6 and
TT7
As standard, the unit is delivered with Pt100 temperature sensors of the type P2208. See data
sheet in Section 21, Appendices.
Connection data: The sensor is fitted with a plug
of the type IEC 947-5-2 with four conductors. The
connection is carried out by means of a
PG9-screw-joint.
The sensors are used for measuring:

112/288

2.1 Suction Gas Temperature,


TT7 measuring range: -50C to +180C
[-60F to +356F]
2.2 Discharge Gas Temperature,
TT5 measuring range: -50C to +180C
[-60F to +356F]. The measurement is
used to protect the compressor against a
too high temperature in the discharge gas
pipe. Too high a temperature in the discharge gas pipe must stop the compressor
without automatic restart. The set values
must be within the permissible working
range for the compressor as stated in Section 6, Technical Data.
2.3 Oil Temperature,
TT6 measuring range: -50C to +180C
[-60F to +356F]. The measurement is
used to protect the compressor against too
high an oil temperature. Too high an oil temperature must stop the compressor without
automatic restart.

0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

5. Physical and Connection Data

Heating Element for Oil Heating


Fig. 5.12

Dimension Sketch for Heating Element


Marking: Prod. no.
Watt
Volt
Manu. date

NV 50

30

30

50

G 1 1/4

L1
L2

80

Table 5.7

Table of Power and Application

05 physical and connection data.fm

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

* Can be delivered with UL approval.


All heating rods are executed in Degree of Protection IP54

Coils for Solenoid Valves1)


220/230 Volt 50/60 Hz 10 Watt
115 Volt

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

SMC /TSMC 100 Mk4 - Engineering Manual

5. Physical and Connection Data

114/288

0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

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:

Selecting lubricating oil

Data for compressor

Data for unit

This document was produced by:

Working range

Handling the compressor

Area of application

Laying the foundation

Copyright 2003 YORK Refrigeration

Noise level data

Vibration data

Test pressure for compressors

Assessing the oil

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.

06 technical data.fm

This document is primarily intended for


designers, service engineers, sales personnel
and prospective customers.

0178-931 - ENG
Rev. 27.10.03

YORK Refrigeration
Chr. Xs Vej 201
DK-8270 Hoejbjerg
Denmark

115/288

SMC /TSMC 100 Mk4 - Engineering Manual

6. Technical Data

Technical Data for the SMC 100 Series


Table 6.1
Compressor type

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

LP = Low pressure cylinder


HP = High pressure cylinder
Permitted max. speed varies with operation conditions- and refrigerant.
See the Operating Limit Diagrams

116/288

0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

6. Technical Data

Table 6.2

Weight of Compressor Units

Compressor Type

Direct driven

Belt driven

Remarks

Kg

lb

Kg

lb

SMC 104
SMC 106
SMC 108
SMC 112
SMC 116

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

Excl. intermediate cooler Incl. intermediate cooler

TSMC 116
TSMC 116

1900
2350

4189
5181

2080
2530

4586
5578

Excl. intermediate cooler Incl. intermediate cooler

06 technical data.fm

The weight is exclusive of electric motor

0178-931 - ENG
Rev. 27.10.03

117/288

SMC /TSMC 100 Mk4 - Engineering Manual

6. Technical Data

Weight of Electric Motors


Sizes

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

SMC /TSMC 100 Mk4 - Engineering Manual

6. Technical Data

Compressor Capacity

06 technical data.fm

Compressor capacity is calculated by means of


the COMP 1 program in the YORK Match Master
suite of programs.

Alternatively, contact your local dealer who can


help dimensioning the compressor.

0178-931 - ENG
Rev. 27.10.03

119/288

SMC /TSMC 100 Mk4 - Engineering Manual

6. Technical Data

Dimension Sketches of Compressor Block


As standard execution the compressor block can
be delivered with either an analog display and
safety system, i.e. with pressure gauges, pressure sentive and thermostats, or with a UNISAB II
system with display and safety facilities as well as
capacity regulation of the compressor.
To illustrate the structure of the dimension sketches, three examples have been included, Fig. 6.1,

120/288

Fig. 6.2 and Fig. 6.3. Moreover, reference is


made to Dimension and Piping Diagram, which includes dimension sketches of all compressors
and units.
However, during the final planning the latest dimension sketches from YORK Refrigeration are
required.

0178-931 - ENG
Rev. 27.10.03

0178-931 - ENG

FOR WITHDRAWING CRANKSHAFT

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

FOR UNITS WITH UNISAB

DISCHARGE

SUCTION

COMPR.

WELDING CONNECTIONS

(COMPR. WITH WATER COOLING ONLY)

WATER INLET AND OUTLET G3/8

G1/4

G1/4

R717 THERMOPUMP.SYSTEM

G1/4

LIQUID REFRIG.

CONNEC.FOR

710

650

R717 OIL COOLER (BOOSTER)

R22 OIL COOLER

FOR WITHDRAWING V--BELT GUARD

COOLING SYSTEM

FOR OPERATING STOP VALVES

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

FOR EXACT LENGTH USE

OF MOTOR AND TYPE

VARIES ACCORDING TO MAKE

OVERALL LENGTH AND WIDTH

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

SMC 100, V-belt Driven, Anolog System

121/288

C (OVERALL HEIGHT)
D

122/288

FOR WITHDRAWING CRANKSHAFT

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

(COMPR. WITH WATER COOLING ONLY)

WATER INLET AND OUTLET G3/8

R717 THERMOPUMP.SYSTEM

R717 OIL COOLER (BOOSTER)

R22 OIL COOLER

FOR WITHDRAWING V--BELT GUARD

COOLING SYSTEM

FOR OPERATING STOP VALVES

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

FOR EXACT LENGTH USE

OF MOTOR AND TYPE

VARIES ACCORDING TO MAKE

OVERALL LENGTH AND WIDTH

80

III

II

1455

900

1500

1100

5
200

141

200

4833--011_0

205

32
MIN 400

Fig. 6.2

A (OVERALL LENGTH)

SMC /TSMC 100 Mk4 - Engineering Manual

6. Technical Data

SMC 100, V-belt Driven, UNISAB II System

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

FOR EXACT LENGTH USE

OF MOTOR AND TYPE

VARIES ACCORDING TO MAKE

OVERALL LENGTH AND WIDTH

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.

WATER INLET AND OUTLET

R717 THERMOPUMP.SYSTEM

R717 OIL COOLER (BOOSTER)

R22 OIL COOLER

COOLING SYSTEM

FOR WITHDRAWING CRANKSHAFT

FILTER

FOR WITHDRAWING PISTONS AND SUCTION

FOR OPERATING STOP VALVES

Fig. 6.3

205

06 technical data.fm
SMC /TSMC 100 Mk4 - Engineering Manual

6. Technical Data

SMC 100, Direct Driven, UNISAB II System

123/288

510

SMC /TSMC 100 Mk4 - Engineering Manual

6. Technical Data

Planning the Machine Room


When planning the machine room, make sure that
there is enough space around the compressor.
The minimum spacing is indicated below, see
Fig. 6.4, Fig. 6.5 and Fig. 6.6.

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

Compressor Block with


Analog System

Enough room must be left around the compressor


to allow the operating personnel to operate the
compressor and carry out service work on the
compressor . Space should be considered as

124/288

Fig. 6.6

Compressor Block with


UNISAB II System

sufficient space to make it possible to take out the


crankshaft without dismounting the compressor
from the base frame.

0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

6. Technical Data

Operating Limits Diagrams

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

The operating limits are specified in the following


Operating Limits Diagrams. YORK Refrigeration
is only liable in so far as the operating limits conditions of the compressor are kept within the limitation of the curvas. Similary, the recommendation concerning the number of revolutions and
cooling of the compressor must be observed.

Max Permissible Differential Pressure


across the Pistons:

Fig. 6.8
TC
2

TE

The limitation curves have been determined on


the basis of both constructional and operating
conditions.

Permissible Compression Ratios :


The compression ratio is calculated into the
diagram with the following values:
Max. value or for:

1.

- R717

8 (7 for SMC 100 E)

- R134a

12

- R22

10

- R207C

10

- R404A

14

- R507

14

3.

Max Permissible Condensing Pressure:


The pressure limit corresponds to the test
pressure which is applied to all compressors
and as indicated under Test Pressure in this
section.

Fig. 6.7
TC
1

Fig. 6.9
TC

TE
TE

3a.

0178-931 - ENG
Rev. 27.10.03

Limitation of the Compressor rpm:


The limitation has been introduced in order
to avoid excessive discharge gas and oil
temperatures.

125/288

SMC /TSMC 100 Mk4 - Engineering Manual

6. Technical Data

Fig. 6.10

Fig. 6.12

TC

TC
3a

5
TE

4.

The Lowest Permissible Suction


Pressure:
The limit has been fixed at approx 0.5 bar
and 5.6 bar for R744 (CO2 triple point).

TE

6.

Fig. 6.11
TC

Minimum Difference between Condensing and Evaporating Temperature:


If there is less difference than specified, the
compressor will not get sufficiently warm.
Lubrication problems may occur when the
refrigerant content in the oil is too high with
a subsequent risk of oil foaming in the compressor.
It should also be noted that some of the
equipment in a refrigeration plant requires a
certain pressure difference in order to function properly.

TC

TE

5. The Lowest Permissible Condensing


Pressure:
At condensing pressures lower than the
ones specified, the dampening effect from
the gas on the valve plates against the valve
retaining plate is reduced. This increases
the risk of valve breakdown.

TE

7.

126/288

The Highest Permissible Evaporating


Pressure:
In the crankcase there will always be an
evaporating pressure. An increase in the
evaporating pressure will increase the load
on the thrust bearing at the crankshaft as
well.

0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

6. Technical Data

Furthermore, the refrigerant content in the


oil is going to increase, primarily refrigerants
used with soluble oil, and this may cause lubrication problems. The HFC and HCFC refrigerants, which are relatively heavy, will
raise the pressure drop through the discharge and suction valves and this will impede the proper functioning of the valves.

7a.

The Highest Permissible Evaporating


Pressure:
The limitation curves represent the highest
permissible suction pressure without reducing the number of revolutions.

Fig. 6.14
TC
7a

Fig. 6.13
TC
7

06 technical data.fm

TE

TE

The following Operating Limits diagrams include


the refrigerants: R717, R134a, R22, R407C,
R404a, R410A, R507 and R744.
The cooling systems for compressors which are
mentioned in the Operating Limits Diagrams below are described in detail in Section 4, Technical
Description - Cooling Systems for Compressors.

0178-931 - ENG
Rev. 27.10.03

127/288

SMC /TSMC 100 Mk4 - Engineering Manual

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

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


-76

-58 -40 -22

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

Air cooled top- and side covers # or water-cooled


Thermopump or water-cooled

1)

Air cooled top - and side covers # or water-cooled


Thermopump or water cooled

1)

Water-cooled

* SMC 188: 840 - 920 RPM not allowed.


# Included refrigerant cooled oil cooler.
Thermopump: Top and side covers are cooled by injected refrigerant.
Oil cooling is included in the system.
Water-cooled: Top and side covers are water-cooled.
Oil cooling is included in the system.
Discharge temperature must not exceed 150C (302F) at full load and at part load.
1) Discharge temperature at part load has to be checked.

128/288

0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

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

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

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

Thermopump or water cooled

NOTE

1)

Thermopump: Top and side covers are cooled by injection refrigerant.


Oil cooling is included in the system.
Water-cooled: Top and side covers are water-cooled.
Oil cooling is included in the system.
Discharge temperature must not exceed 150C (302F) at full load and at part load.
1) Discharge temperature at part load has to be checked.

0178-931 - ENG
Rev. 27.10.03

129/288

SMC /TSMC 100 Mk4 - Engineering Manual

6. Technical Data

TC

0177128_0 VIEW 3,1

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)

Oil cooling is always necessary.


Thermopump: Only the HP Stage top covers are cooled by a thermo pump.
Oil cooling included in the system
Water-cooled: Top and side covers. Oil cooling included in the system.
Part-load operation: 1) Depending on the operating conditions and the pressure on the compressor, a
by-pass system may be required.
See section: By-pass system for two-stage compressors.

130/288

0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

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

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


-76

-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

OIL COOLING REQUIRED1)


No

1500
900
1800

No
At less than 50% capacity
Yes

1000

No

1200

No

3
4

700

1800

At less than 50% capacity


Yes

1
2

SMC100L

3
4

2)
1000
1200

No
700

At less than 50% capacity yes


Yes

1-2
SMC180

3
4

REMARKS

MIN.

2)
750

450

At less than 50% capacity yes


Yes

Top covers: Air-cooled only


1) When required, choose freely between A or B
- except SMC180 where only A may be selected.
A: Water-cooled side covers
B: Built in refrigerant cooled oil cooler with thermostatic expansion valve.
2) Discharge temperature at part load has to be checked.

0178-931 - ENG
Rev. 27.10.03

131/288

SMC /TSMC 100 Mk4 - Engineering Manual

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)

Top covers: Air-cooled only.


1)

When required, choose freely between A or B


- except TSMC180 where only A may be selected.
A: Water cooled side covers
B: Built in refrigerant cooled oil cooler with thermostatic expansion valve.

2)

By-pass equipment required to maintain intermediate temperature at minimun load.


(see price list specification).

3)

Not applicable.

132/288

0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

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

At less than 50% capacity


No
At less than 50% capacity

1000
1200

No
700

No
No

1500

At less than 50% capacity

1
SMC100L

2
3

NOTE

MIN.

2)
1000
1200

No
700

No
At less than 50% capacity

Top and side covers: Air-cooled


1)

2)

When required, choose freely between A or B


A: Water-cooled side covers
B: Built in refrigerant cooled oil cooler with thermostatic expansion valve.
Not applicable.

0178-931 - ENG
Rev. 27.10.03

133/288

SMC /TSMC 100 Mk4 - Engineering Manual

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)

Oil cooling: Not required.


Top- and side covers: Only air-cooled.

2)

Part-load operation:
By-pass equipment required to maintain intermediate temperature at minimum load.

134/288

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Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

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

--58 --40 --22

--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

Top covers: Air-cooled design only.


1)

When required, choose freely between A or B


A: Water-cooled side covers.
B: Built-in refrigerant-cooled oil cooler with thermostatic expansion valve.

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SMC /TSMC 100 Mk4 - Engineering Manual

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

Top and side covers: Air-cooled only.


1) Part-load operation:
By-pass equipment required to maintain intermediate temperature at minimum load.

136/288

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Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

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

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

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

Top covers: Air-cooled only.


1)

When required, choose freely between A or B


A: Water-cooled side covers.
B: Built-in refrigerant-cooled oil cooler with thermostatic expansion valve.

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SMC /TSMC 100 Mk4 - Engineering Manual

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

Top- and side covers: Air-cooled only.


1) Part-load operation:
By-pass equipment required to maintain intermediate temperature at minimum load.

138/288

0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

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

Top covers: Air-cooled design only.


1)

When oil cooling is required, choose freely between A or B however, for SMC 180, only A may be selected.

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Rev. 27.10.03

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SMC /TSMC 100 Mk4 - Engineering Manual

6. Technical Data

Direction of Rotation of the Compressor


The normal direction of rotation for the compressors is anti-clockwise when looking at the compressor from the shaft end.
Fig. 6.15

Direction of rotation for compressor


seen from A

pressor is connected to a combustion motor with


a specified direction of rotation.
In such cases the oil pump must be changed as it
is uni-directional.
The direction of rotation for the pump is indicated
by a guide pin.

Counterclockwise compressor rotation:


Marking in cover to the right of the logo.

Fig. 6.17
Guide pin
An arrow cast into the bearing cover indicates the
direction of rotation as shown in the picture.
Fig. 6.16

At times it may be necessary that the crankshaft


rotates in the opposite direction, e.g. if the com-

140/288

Clockwise compressor rotation:


Marking in cover to the left of the logo.

Fig. 6.18

Guide pin

0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

6. Technical Data

Choice of Electric Motor

B.

The IEC electric motors type IP23 or IP54 (55)


(IP= Index of Protection) are normally used to
drive the compressors, and the base frames are
standard design for these motors.
Fig. 6.19

IP23 Drip-proof Motor

Do consider, however, which type of plant the


compressor is going to work on, and then dimension the motor in accordance with the following rules:
a: For plants in which a higher ET may be
expected, and consequently also a higher
CT in the start-up phase, the motor must be
dimensioned to meet the higher operating
temperatures. Usually, this does not incorporate factor 1 and 2.
Likewise, special consideration should be
given concerning the booster compressors.

06 technical data.fm

When selecting an electric motor, the following


factors must be taken into consideration:

Motor Dimension
The size of the motor is determined on the basis
of the power demands of the compressor under
the current operating conditions calculated by
means of the 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

2: Other refrigeration plants:

Factor 1.15

3: For V-belt drive:

Factor 1.05

0178-931 - ENG
Rev. 27.10.03

b: Alternatively, the motor can be connected


to a system for Ampere limitation which reduces the compressor capacity until the
planned operating temperatures have been
reached. This element is found in
UNISAB II, which must be linked to the
Amp. signal, however. In this case, factor 1
and 2 should also be omitted.
Note: YORK Refrigeration would like to point out
that when using a motor with a class F insulation
(105K) for operating conditions like for class B
(90K), approx. 10% continual overloading of the
motor will be acceptable in connection with the
nominal effect.
As mentioned previously, all compressors are as
standard completely unloaded during the
start-up phase. This reduces the power consumption of the compressor considerably as may be
seen from the starting torque curve, Fig. 6.20.
As standard, the SMC 100 can only be capacity
regulated in steps of two cylinders, which is usually satisfactory. If required, extended unloading
can be ordered when the order is placed or it can
be mounted at a later time.
For more information on this subject, see Section
4, Technical Description - Extended unloading of
the Compressor.

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SMC /TSMC 100 Mk4 - Engineering Manual

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.

The maximum time for reaching minimum rpm


(TSMC 100 : 750 rpm.) is 5 sec. and nominal
speed should be reached after max. 10 sec.
For more information on this, see Section 4, Technical Description - Capacity Regulation and Unloading of the Compressor.

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

STARTING TORQUE FOR COMPRESSOR SMC/TSMC/HPC100

142/288

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Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

6. Technical Data

Starting Torque of the Compressor


The motor size is usually selected as described in
the previous section. With all cylinders unloaded
during the starting-up phase the motor generally
has sufficient starting power in order to bring the
compressor at full speed before the cylinders are
loaded. Read more in Section 4, Technical Description - Capacity Regulation and Start Unloading of the Compressor.
At times, however, it may be a good idea to compare the starting torque curve of the compressor
Fig. 6.21

to the starting curve of the motor (this information


can be obtained from the motor manufacturer).
Especially, when the compressor starts at a plant
pressure below normal and when power limiting
systems are used to start up the motor, e.g. a Y/
starter, it may be necessary to work out a diagram as the one shown in Fig. 6.21. The hatched
area represents the torque moment available to
the motor when speeding up the compressor.

Starting Torque Curve for Electromotors

06 technical data.fm

Kpm
[Lb.ft.]

Motor

starters

Motor Y starters

Compressor

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Rev. 27.10.03

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SMC /TSMC 100 Mk4 - Engineering Manual

6. Technical Data

Start up torque SMC 100 R717 25% load

144/288

0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

6. Technical Data

Fig. 6.22

Start up SMC 100 - HFC/HCFC - 25% load

06 technical data.fm

Dp

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Rev. 27.10.03

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SMC /TSMC 100 Mk4 - Engineering Manual

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

Moment of Inertia (kgm2) for SMC/HPC/TSMC 100 Compressors

Type

SMC 100 S (80 mm stroke)

No of cylinders:
SMC/TSMC 100

HPC 100

0.154

0.189

Compressor with
free shaft end

SMC 100 L (100 mm stroke)

SMC 100 E (120 mm stroke)

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

Direct driven compressor with complete AMR coupling

0.262

0.297

0.326

0.559

0.610

0.304

0.342

0.377

0.647

0.762

0.362

0.429

0.448

0.776

0.888

Table 6.4

Moment of Inertia (Ib.ft2) for SMC/HPC/TSMC 100 Compressors

Type

SMC 100 S (80 mm stroke)

No of cylinders:
SMC/TSMC 100

HPC 100

3.66

4.49

Compressor with
free shaft end

SMC 100 L (100 mm stroke)

SMC 100 E (120 mm stroke)

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

Direct driven compressor with complete AMR coupling

6.22

7.05

7.74

13.28

14.49

7.22

8.12

8.95

15.37

18.10

8.60

10.19

10.64

18.43

21.09

146/288

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Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

6. Technical Data

Direction of Rotation of Electric Motor


Sometimes the motor is equipped with specially
designed ventilation wings to reduce the noise
level. These motors have a specified direction
of rotation which must be considered when connecting them to a compressor. If the motor is connected by means of a coupling, it must rotate
clockwise when looking at it from the shaft end,
Fig. 6.23.

SMC 104-106-108 and TSMC 108


Anti-clockwise, Fig. 6.24.
Fig. 6.24

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:

Note: The driving part of the V-belts must always


be closest to the base frame.

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SMC /TSMC 100 Mk4 - Engineering Manual

6. Technical Data

Handling of Compressor and Unit


When lifting the compressor, only use the lifting
eyes M20, Fig. 6.26, which are fitted in the threaded holes at the top of the block. The weight of the
compressor block is indicated in Table 6.1 in the
beginning of this section.

the wires do not get stuck and thus damage the


pipes or any other components on the unit.
Fig. 6.27

Note: It is only the compressor block which may


be lifted in the lifting eye. The same applies to the
motor.
Fig. 6.26

Alternatively, the unit can be lifted with a forklift


truck.
It is recommended to make the distance "x" as
wide as possible yet still keeping it within the supports as illustrated in the Fig. 6.28. Be careful that
the unit does not tip sideways as the point of gravity is rather high.
Fig. 6.28

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

The weight of the unit can be seen in the shipping


documents or in Table 6.2.

0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

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

AMR Coupling Flange to Motor Shaft


C

Max. 0.02 mm

Alignment must be kept within the values


stated in Table 6.5.

149/288

SMC /TSMC 100 Mk4 - Engineering Manual

6. Technical Data

Table 6.5

Fig. 6.31

Max. axial untruth measured at


point A

0.02 mm

Max. radial untruth measured at


point B

0.02 mm

Boring is carried out to the immediate motor


shaft diameter with an H8 tolerance. Please,
note that the max. boring diameter is 95 mm
and that two key grooves must be engraved
in the key of the motor shaft in order to maintain balance.
The width of the key grooves is made with
an H7 tolerance, and the depth must be
such as to create a distance between key
and hub of 0.2-0.3 mm, Fig. 6.31

H7

+0.2/0.3 mm

H8

Max. dia. 95 mm

As seen in the above drawing, Fig. 6.30, the


coupling hub is slit up axially and clamped to
the motor shaft with two screws.
Read more about the coupling in the following section.

150/288

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SMC /TSMC 100 Mk4 - Engineering Manual

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

provided that the motor comes from


YORK Refrigeration. Intermediate piece and parcels with laminas are delivered separately and
must be mounted on site. Remember that compressor and motor must be aligned as described in Section 7, Installation Instructions.
Intermediate piece B also makes it possible to remove the shaft seal of the compressor without
having to move motor or compressor. The length
C of the intermediate piece (Fig. 6.33) and the
lamina parcels cover a distance - after they have
been dismantled - that makes it possible to dismount the coupling flange and the shaft seal of the
compressor.

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

HPC/SMC 104 - 106 - 108


TSMC 108

102

SMC 112 - 116


TSMC 116

113

The compressor unit is delivered with coupling


flanges mounted on the compressor and motor,

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SMC /TSMC 100 Mk4 - Engineering Manual

6. Technical Data

The procedure for alignment of compressor and


motor is described in Section 7, Installation Instructions.
Balancing must be made before the key groove is
engraved.

After boring, the coupling flanges are balanced.


This is characterized by one or more holes on the
side of the flange. Max. permissible imbalance
can be seen from the table, Table 6.7.

Table 6.7
Compressor
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

SMC /TSMC 100 Mk4 - Engineering Manual

6. Technical Data

V-Belt Drive for SMC/TSMC 100


Fig. 6.34

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

By letting the electro motor drive the compressor


through a V-belt drive, the speed of the compressor can be selected so that the max. capacity corresponds to the capacity requirements of the
plant.
The V-belts are referred to as SPB Red Power.
Their cross section dimensions are shown in
Fig. 6.35
Fig. 6.35

S = C plus SPB 2650


16.3

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.

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SMC /TSMC 100 Mk4 - Engineering Manual

6. Technical Data

Table 6.8

Standard Programme for V-Belts and Pulleys for SMC/TSMC 100

Standard V-belt pulley


Diameter mm
Compressor

400

Motor

Compressor speed compared


to Motor speed
50 Hz 1460 rpm

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

* SMC 104 - 108 and TSMC 108 only

154/288

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SMC /TSMC 100 Mk4 - Engineering Manual

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.

Max. Power Transmission SMC104-106-108 and TSMC108

Number of
V-belts

06 technical data.fm

of V-belts which must be used to transmit the


maximum power of the motor to the V-belt drive in
question, thus indicating how many V-belts must
be fitted.
The compressor pulleys, however, are only delivered with the number of grooves shown below.
Thus it may occur that there are more grooves on
the compressor pulley than on the motor pulley.

Motor speed 1460 rpm (50 Hz)


730

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

Motor speed 1760 rpm (60 Hz)


792

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

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SMC /TSMC 100 Mk4 - Engineering Manual

6. Technical Data

Table 6.10

Max. Power Transmission (kW) SMC112, 116 and TSMC116

Number of
V-belts

Motor speed 1460 rpm (50 Hz)


730

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

Motor speed 1760 rpm (50 Hz)


792

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

SMC /TSMC 100 Mk4 - Engineering Manual

6. Technical Data

Construction of V-Belt Drive

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

SMC 104-106-108, TSMC 108


Nominal center distance

06 technical data.fm

900 mm

Fig. 6.38

SMC 112-116, TSMC 112-116


II

The compressor pulley is bored with a cylindrical


hole and is fitted to the crankshaft with a clamping
unit. The end of the crankshaft and the outer face
of the clamping unit must be aligned. Thus the belt
pulley can be mounted on the crankshaft without
previous adjustment. It must be tightened with the
nine screws on the clamping unit, see fig. 6.41.
The screws are tightened with a torque wrench.
Fig. 6.40

III

Nominal
center
distance
500 mm

Align these faces

The driving part of the V-belts must always be


closest to the base frame as shown with A in
Fig. 6.39.
Fig. 6.41

When dismounting the belt pulley, loosen the


screws on the clamping unit.

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Rev. 27.10.03

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SMC /TSMC 100 Mk4 - Engineering Manual

6. Technical Data

The motor pulley is tightened to the motor shaft


by means of a conical bushing, pos. 1 in Fig. 6.42,
which fits the conical boring of the belt pulley. The
bushing is bored and equipped with a key, which
fits the motor shaft in question. When mounting
the pulley, first place the belt pulley and the bushing on the motor shaft, then fix the pulley to the
bushing by means of two or three screws, pos. 2
in Fig. 6.42. Mount the screws in the holes where
the thread faces the belt pulley. Thus the conical
bushing is pressed around the motor shaft so that
it both holds and centers the belt pulley. Before
tightening, the belt pulley is placed on the motor
shaft so that it is flush with the compressor belt
pulley. Tighten the screws, pos. 2, with the torque
moment as indicated in Section 21.

Tightening and Adjusting the V-Belt Drive


When the necessary number of belts have been
mounted - corresponding to the number of
grooves on the motor pulley (max. 8) - the
V-belt drive is tightened by moving the motor
away from the compressor. For this purpose, use
two washers which are part of the base frame and
mounted at the feet of the motor.

Fig. 6.42

The motor pulley is delivered balanced and with


a conical bushing, which is ready bored for direct
fitting on the motor shaft in question.

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

When dismounting the belt pulley, first dismount


the two or three screws, pos. 2, and then mount
one or two of the screws in the free hole/s where
there is only a thread in the side which faces the
bushing. By tightening the two screws evenly, it is
now possible to press the belt pulley off the bushing. The bushing and the belt pulley can now be
dismounted manually.
The V-belts must only be mounted and dismounted when the motor is placed close to the compressor to avoid damage of the belts.

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

SMC /TSMC 100 Mk4 - Engineering Manual

6. Technical Data

Laying the Foundation


When erecting a compressor unit, it is important
that the bed plate upon which it is placed is as
plane as possible as the rigidity of the base frame
depends on whether the base frame is supported
correctly under all its "feet".

Fig. 6.44

Unit mounted on vibration dampers

The base frame should therefore be stress-free


and rest evenly on all its "feet" when positioned on
the foundation.
In the following paragraphs a distinction is made
between stationary plants and marine plants.

Fig. 6.43

Unit mounted directly on concrete


foundation

The most preferred form of mounting today is the


one on vibration dampers as the unit can be positioned directly on the machine floor without any
clamping and without the laying of a concrete
foundation. This reduces the plant costs considerably both during the initial installation and later on
during a potential rearrangement of the units in
the machine room.
Further, the use of vibration dampers is a way to
ensure that vibrations from the unit are not propagated to the construction itself via the foundation.
In return, this form of mounting requires a plane
and horizontal machine floor within narrow limits
as specified in the following.

300

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

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SMC /TSMC 100 Mk4 - Engineering Manual

6. Technical Data

Mounting Directly on Foundation:


Mounting directly on the foundation or the floor of
the machine room. The base plates of the unit are
clamped down by means of foundation bolts, cast
into the foundation as shown in the drawing.
Fig. 6.45

Fig. 6.46

Moulding of Foundation Bolts

Foundation plate

Example of Foundation Drawing

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.

Foundation bolts, nuts and foundation plates are


delivered together with an order. Following a specific order a foundation drawing will be forwarded
and the holes poured into the foundation as indicated in this drawing.

The foundation plates are tightened under the


base plates of the base frame by means of steel
wire. The foundation bolts are suspended in the
holes with the nut screwed down flush with the
end of the foundation bolt as illustrated in the
drawing.

As shown in the drawing, Fig. 6.45, the unit is


placed on a concrete foundation which is usually
300 mm high. During the concreting the holes are
moulded into the concrete as indicated in the forwarded drawing, Fig. 6.46.

The concrete poured round the foundation bolts


should only contain very little water in order that it
may be stamped down properly round the bolts. A
low water content does not cause contraction of
the setting concrete.
10-14 days should be allowed to pass before the
joists are removed and the nuts of the foundation
bolts tightened. Remember to remove the steel
wire and check that no space is left between base
frame and foundation plates. Otherwise, place the
liners between the plates before tightening.

160/288

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Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

6. Technical Data

Mounting of Vibration Dampers


By placing the compressor unit on vibration dampers, Fig. 6.44, calculated and delivered by
YORK Refrigeration, an optimum damping of vibrations from the unit to the foundation and consequently to the construction will be achieved.
As already mentioned, the unit with the vibration
dampers is usually placed directly on the floor
which must be strong enough to be able to carry
the weight of the unit.

06 technical data.fm

The vibration dampers need not be clamped to the


floor as the bottom side has a rubber coating, the
friction of which prevents them from sliding around
on the floor.
This makes it easy and quick to align the units on
a plane floor and they are easily moved during a
potential later rearrangement of the machine
room.
Vibration Dampers:
From the table in Fig. 6.48 it is possible to read
how much the damping of a vibration damper depends on its deflection when loaded.
YORK Refrigeration recommends that vibration
dampers be selected and loaded to a deflection of

0178-931 - ENG
Rev. 27.10.03

nominally 2 mm. A good and rigid support of the


unit is thereby achieved as well as a proper damping coefficient.
The rotating parts in the compressor are completely balanced for forces of the 1st order and
consequently, damping is primarily necessary for
forces of the 2nd order, which rotates at double
speed.
In the table in Fig. 6.47 the normative values for
damping can be read in relation to the number of
revolutions:
Fig. 6.47

Guide for Selection of Suitable Deflection

rpm

Suitable deflection order

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%

In the diagram in Fig. 6.48 the vibration damping


with various vibration speeds can be read in dependence of the deflection of the vibration
dampers:

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SMC /TSMC 100 Mk4 - Engineering Manual

6. Technical Data

Fig. 6.48

Diagram for Damping of Vibrations

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

1.2 1 0.8 0.6

mm

Deflection of vibration dampers

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

SMC /TSMC 100 Mk4 - Engineering Manual

6. Technical Data

Fig. 6.49

5
Vibration absorber type

Compressor

Compressor

Motor

Unit A

Unit B

06 technical data.fm

Motor

Vibration dampers can be adjusted in height by


means of screw, pos.1, Fig. 6.50 which is finally
locked by tightening nut, pos. 2. The height H can
now be changed within the limits stated in the table and are thus able to even out any minor differences in the planeness of the floor.
Fig. 6.50
1

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

After this equalizing a further tightening of screws


will lead to a deflection of the vibration damper.
This reduces the measure h from an unloaded to

0178-931 - ENG
Rev. 27.10.03

Make sure, however, that the pipes are supported


so that they do not start oscillating, thereby affecting the unit.
After alignment of the unit as described above,
compressor and motor must be aligned in relation
to each other.

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SMC /TSMC 100 Mk4 - Engineering Manual

6. Technical Data

Specific Requirements to Vibration Damping


In places where particularly strict requirements
are set up in order to prevent vibrations from being
propagated to the building construction itself and
causing noise nuisance, specific measures
should be taken.

In case of questions, please contact


YORK Refrigeration whose employees are always ready to place their expertise at your disposal.

This could be in connection with housing and office buildings or e.g. hospitals.

Units in marine refrigeration plants are always


placed on vibration dampers as they serve a twofold purpose in so far as they dampen both the vibrations of the marine engines as well as those of
the compressor.

In such cases the best results are achieved by


fastening the whole unit on a sufficiently large
concrete foundation which is placed on vibration
dampers with a large bearing capacity or on a rubber mat adapted to the purpose.

Marine Installations

Fig. 6.53

Vibration dampers for marine installations

At the same time flexible vibration eliminators


should be used in the pipe connection to the unit
in order to avoid transmission of noise through the
piping. Very often it will be necessary to insulate
the machine room against noise or to use a noise
absorbing lining on the unit, Fig. 6.52, in order to
prevent noise from spreading to the environment.
Fig. 6.52

Noise absorbing shielding of compressor unit

Liner plate

164/288

0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

6. Technical Data

The illustrated type of vibration dampers,


Fig. 6.53, which is standard equipment on
YORK Refrigeration's Sabroe reciprocating compressors, is fixed to the unit feet and foundation.
This keeps the unit fixed to the foundation under
all kinds of load conditions when the ship is exposed to the sea. It is not possible to adjust the
height of the vibration dampers. This makes it
necessary to machine the steel foundation as
evenly as possible (max. deviation approx. 1 mm).

In case of a larger tolerance on the planeness or


where vibration dampers of different heights are
used due to the fact that the base frame loads differently on the surfaces of support, this must be
compensated with liner plates as shown on the
drawing, Fig. 6.53
Vibration dampers are selected by
YORK Refrigeration for a particular unit and
delivered together with a drawing indicating the
position of each damper.

Fig. 6.54

06 technical data.fm

It is very important to observe these positions as


the unit does not rest with the same weight on all
feet.

0178-931 - ENG
Rev. 27.10.03

Vibration absorber type


Pos.

Unit A

Unit B

The vibration dampers are selected to a deflection


of 3 to 5 mm. A damping of the forces of the 2nd
order is thereby achieved as indicated in the diagram in Fig. 6.54. Read more on this subject in
this section under Vibration Dampers.

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SMC /TSMC 100 Mk4 - Engineering Manual

6. Technical Data

Noise from Compressors and Units


Noise is inevitable when a compressor or unit is
working. However, by taking this into consideration during the project phase, it is possible to reduce noise pollution of the environment considerably.

Fig. 6.55

Unit covered with a measuring grid

Through the years YORK Refrigeration has been


aware of this problem. As a consequence, we
have designed the compressors and units with a
view to meeting market demands concerning
maximum noise levels.
Of course, modern compressor units are loud and
must be expected to make noise, and this makes
it the more important that the sound data stated
for a compressor or unit should be evaluated correctly.
The above issue will be discussed in the following.
In this connection YORK Refrigeration would like
to point out that at a fairly low cost it is possible to
make the machine room a pleasant work place.
The use of noise absorbing materials could be
one solution to the problem.

1.

Sound Power and Sound Pressure

As seen in Table 6.12 sound data is indicated as


sound power level LW or sound pressure level
LP. It is essential to distinguish between these two
values as they are stated in dB (decibel) and
should be read as follows:
1.1. Sound Power Level LW
According to ISO 9614-2 LW is measured directly
at the unit, Fig. 6.55, by installing a measuring grid
as close to the unit as possible.

166/288

The measuring grid is divided into fields of


max.1 sq. m each. The measuring is carried out
by moving the sound level meter in a kind of back
and forth movement, as illustrated in Fig. 6.55.
The sound level meter now calculates the total
sound power level LW for the entire unit.
The sound power level LW is, however, dependent
on the surroundings of the noise source. Consequently, it is a somewhat theoretical value. Here,
the sound pressure level Lp becomes of interest.

0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

6. Technical Data

1.2. Sound Pressure Level Lp

1.3. Frequency

It is actually the sound pressure level Lp that is


measured by the sound meter. In the sound meter
this is then automatically converted to the sound
power level LW by means of its built-in calculation
programs.

Sound is fundamentally a pressure wave in the air


at a given wave length (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

The arrangement of the room as well as building


materials have a considerable influence on the results of the measuring.
This is why the measured values of the manufacturers for sound pressures are based on standard
measures according to ISO 3989 which refers
sound pressure level LP to a free field above a reflecting plane at a distance of 1 meter from the
measuring grid, as described in pt. 1.1.
Above facts should be taken into consideration
during a check measuring on the plant in question
as mentioned in points 2.1 and 2.3.

0178-931 - ENG
Rev. 27.10.03

From a compressor unit sound waves are emitted


at many different frequencies due to the different
movable parts.

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.

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SMC /TSMC 100 Mk4 - Engineering Manual

6. Technical Data

2.

Assessing the Measured Values

Fig. 6.56

Curve for adding of


logarithmic levels

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

SMC /TSMC 100 Mk4 - Engineering Manual

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

separator etc. which have all been covered by the


measuring grid.
Thus, on assessing the measure results it is essential to know the extent of the measured surface
area in the surrounding measuring grid.
2.5.
If the compressor is working at part load, this will
generally lead to higher measured values than the
ones indicated in the tables.

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SMC /TSMC 100 Mk4 - Engineering Manual

6. Technical Data

3.

How to Check Sound Data

Table 6.12

3.1.

Compressor block

LW

Lp

The only correct method is the measuring of


sound power LW on the site itself and this requires
the setting up of a measuring grid as well as the
use of sound intensive equipment.

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!

Noise Data for Reciprocating


Compressors
Single-stage
LW and Lp values are measured at the following
conditions:

Two-stage
LW and Lp values are measured at the following
conditions:
Evaporating temperature ET= 35C [-31F]
Condensing temperature CT= +35C [+95F]

Evaporating temperature ET = 5C [5F]

Refrigerant=

R22/R717

Condensing temperature CT = +35C [95F]

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

Condensing temperature CT = +70C

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

SMC /TSMC 100 Mk4 - Engineering Manual

6. Technical Data

4.

Damping Acoustic Noise in


a Machine Room

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

Reflected sound power


Incident sound power

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6. Technical Data

Subjective Perception of Noise Damping


With reference to table, Table 6.14, indicating
how the human ear perceives the effect of noise
insulation in a machine room, the following should
be noted:

By investing in a sensible noise insulation of


the ceiling of the machine room this usually
means reducing the reverberation time by

half in the machine room with a subsequent


great subjective effect.

When using a pre-fabricated noise baffle


board from YORK Refrigeration, the sound
pressure in the machine room will typically
be reduced by 20 dB. Naturally, this must be
considered a great improvement - subjectively perceived.

Table 6.14
Reduction of sound pressure
by noise insulation of
compressor unit

Reduction of the average


sound pressure level
by noise insulation

Subjective perception of
the improved acoustic quality
of the room

dB

dB

Relative
reverberation time

0,5

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

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SMC /TSMC 100 Mk4 - Engineering Manual

6. Technical Data

Vibration Data for Compressors - All Compressor Types


Vibration data for YORK Refrigeration's Sabroe
reciprocating compressors comply with: the ISO
10816, standard, Part 6, Annex A, group 4, AB,
which fixes max. permissible operating vibrations
at 17.8 mm/s.

standard, part 1, Annex B, Class III, C, which


fixes max. permissible operating vibrations at 11.2
mm/s.
The measurements are made as illustrated in the
figure below (points A-D).

Vibration data for YORK Refrigeration's Sabroe


screw compressors comply with: ISO 10816
Fig. 6.60
CV

DV

AV
BV
AA
xAH

BH

DHx

DA

06 technical data.fm

BA
CA

x
CH

Pay attention to the following, however:

Motors comply with EN 60034-14 (CEI/IEC


34-14) Class N.

When placing the unit on the vibration


dampers supplied by YORK Refrigeration
(additional), the vibrations against the foundation are reduced by:
85-95% for screw compressor units
80% for reciprocating compressor units

However, higher vibration level may occur if:


motor and compressor have not been
aligned as described in the Instruction
Manual.

0178-931 - ENG
Rev. 27.10.03

the compressor runs at an incorrect Vi


ratio. This applies to screw compressors.
the piping connections have been executed in a way that makes them force
pull or push powers on the compressor
unit or transfer vibrations to the unit
caused by natural vibrations or connected machinery.
the vibration dampers have not been fitted or loaded correctly as indicated in
the foundation drawing accompanying
the order.

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6. Technical Data

Fig. 6.61

Specification of Compressor Materials

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-

sistance to the refrigerants and oils approved for


the compressors.
The following table,Table 6.15, lists the most important components.

Table 6.15
Designation

Material

Form

Compressor frame SMC and TSMC


Compressor frame HPC 100
Oil pump housing HPC 100, SMC and
TSMC100
Bearing cover pump end HPC 100, SMC
and TSMC100
Water covers HPC 100, SMC and TSMC100
All other covers SMC and TSMC
All other covers HPC
Crankshaft HPC108
Crankshaft all other compressors
Connecting rod
Piston pin bushing
Half section of bearings for
Connecting rod
Bolts for connecting rod
Piston
Piston rings and oil scraper ring
Piston pin
Cylinder liners

Cast iron
Ductile cast iron
Cast iron

EN-GJL-250, EN 1561
EN-GJS-500-7, EN 1563
EN-GJL-250, EN 1561

Ductile cast iron

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

Cl, 12.9, DIN 898


BS 1490/LM13
BS 1452 (W.CI7)
17Cr3, DIN 17210
EN-GJL-250, EN 1561

Suction and discharge valve


plates
Suction valve retaining plate
Safety head spring
Main bearings
Shaft seal carbon ring
Shaft seal steel ring
Suction filter
Oil level glass
Oil strainer
By-pass valve
Buffer springs
Gaskets
O-ring seals

Special steel

174/288

Ductile cast iron


Steel spring
White metal on a steel base
Special carbon
Special steel
Stainless steel wire-mesh
Glass in steel flange
Filter cartridge
Various steel
Spring steel
Non-asbestos
CR Rubber (standard)

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

SMC /TSMC 100 Mk4 - Engineering Manual

6. Technical Data

Test Pressure Levels for Standard Compressors and Components


All components for refrigeration plants which are
under the influence of gas pressure must be pressure tested to prove their strength and tightness.

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-

tional price. Please, contact YORK Refrigeration


for further information.
When pressure testing compressors and vessels,
components must first prove their strength by resisting the test pressure of the strength test.
This test is carried out with air. Afterwards, the
leak test is carried out, also with air, at the prescribed pressure and with the component soaked
in a water basin for 30 minutes.
Units consist of components which have been
pressure tested as described in the following table. This means that it is only necessary to leak
test the unit. Dwelling time is 20 minutes. Leak
testing is carried out with pressurized air at the
pressure stated in the table. All weldings and connections are covered with a frothing liquid
which will start foaming in case of a leak.

Table 6.16
Standard Test Pressure Levels
Compressor Type

Compressor Side

CMO

High pressure side

SMC 100
SMC 180

Low pressure side


High pressure side

Strength
Testing

Leak Testing with


Pressurized Air

bar

[psi]

bar

[psi]

42

[609]

25

[363]

27

[392]

14

[203]

42

[609]

25

[363]

TCMO
TSMC

Low pressure side

27

[392]

14

[203]

Intermediate pressure side

42

[609]

25

[363]

HPO

High pressure side

80

[1160]

40

[580]

HPC

Low pressure side

45

[653]

22

[319]

SAB 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.

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SMC /TSMC 100 Mk4 - Engineering Manual

6. Technical Data

Charging the Compressor with Oil


Usually, the compressor is delivered without any
oil in the crankcase. As a principal rule, the
amount of oil indicated in the table, Table 6.17,
should be charged to the compressor.
Table 6.17

Fig. 6.62

Oil level glass

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

After some hours of operation the compressor


must be recharged with oil, however, as part of the
oil has been absorbed by the refrigerant. This is
especially the case for HFC and HCFC refrigerants.
The amount of oil to be recharged depends on the
size of the refrigeration plant and the amount of
refrigerant. Oil is charged to the middle of the oil
level glass and the amount of oil needed in order
to increase the oil level 10 mm is indicated in the
table, Table 6.18.

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.]

A manually operated pump connected to the oil


charging valve pos. B can be used for the first as
well as the following oil charges.
See Section 5, Physical and Connection Data.
Note: On HPC 100 compressors with R717, the
pressure must be relieved before oil charging.
Fig. 6.63

Manually Operated Oil Pump


Optional hand-operated oilpump

To compressor

Gasket
B

Cap

176/288

T0177131_0V

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SMC /TSMC 100 Mk4 - Engineering Manual

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.

will consequently continue into the plant, in which


it is condensed in the condenser.
In HFC and HCFC as well as in compact R717 refrigeration plants this oil will return to the compressor together with the suction gas.

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

Oil consumption kg/h =

Circulated amount of refrigerant Q (kg/h) x Oil consumption (ppm)


10

The normal oil consumption is between 20 and 30


ppm for an SMC/HPC 100 compressor.

Selecting Oil Separator


As the velocity through the oil separator affects
the ability of the oil separator to separate the oil
from the discharge gas, an oil separator size has
been designed for each compressor. See
Table 6.19.
The maximum oil consumption for this oil separator is 35 ppm. Depending on the choice of lubricating oil, the oil consumption is normally much lower.

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6. Technical Data

Table 6.19

Oil Separators

Code no.

Part no.

Type

SMC 104S - B301


SMC 104L - B301
SMC 104E - B301
SMC 104S - B302
SMC 104L - B302
SMC 104E - B302

4241.280
4241.280
4241.280
4241.280
4241.280
4241.280

OVUR 3206D
OVUR 3206D
OVUR 3206D
OVUR 3206D
OVUR 3206D
OVUR 3206D

SMC 106S - B301


SMC 106L - B301
SMC 106E - B301
SMC 106E - B314
SMC 106S - B302
SMC 106L - B302
SMC 106E - B302
SMC 106E - B315

4241.280
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

SMC 108S - B301


SMC 108L - B301
SMC 108E - B301
SMC 108E - B314
SMC 108S - B302
SMC 108L - B302
SMC 108E - B302
SMC 108E - B315

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

SMC 112S - B301


SMC 112L - B301
SMC 112E - B305
SMC 112E - B314
SMC 112S - B302
SMC 112L - B302
SMC 112E - B308
SMC 112E - B315

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

SMC 116S - B301


SMC 116L - B301
SMC 116E - B301
SMC 116E - B305
SMC 116E - B314
SMC 116S - B302
SMC 116L - B302
SMC 116E - B302
SMC 116E - B308
SMC 116E - B315

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.

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Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

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.

For the E - version the following special conditions apply


(TE = evaporating temperature):
SMC 104E:

OVUR 3206D

SMC 106E:

OVUR 3206D (TE<+15C) [+59F]


OVUR 4107D (TE>+15C) [+59F]

SMC 108E:

OVUR 3206D (TE<+5C) [+41F]


OVUR 4107D (TE>+5C) [+41F]

SMC 112E:

OVUR 4107D (TE<+10C) [+50F]


OVUR 5008D (TE>+10C) [+50F

SMC 112E:

OVUR 4107D (TE<0C) [+32F]


OVUR 5008D (0C<TE<+20C) [+32F<TE<+68F]
OVUR 6006D (TE>+20C) [+68F]

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6. Technical Data

Selecting Lubricating Oil for SABROE


Reciprocating Compressors
Refrigerant: R717
In a period from 1990 to 1995 YORK Refrigeration
experienced a rising number of problems with the
use of mineral oils, especially in R717 plants. The
problems can be divided into two groups:
c.
d.

The oil changes viscosity within a few operating hours.


The oil dissolves (becomes very black).

The problems have been observed in connection


with several different types of mineral oil and often
occur within only a few operating hours. The consequences have been severe for both compressors and plants.
On the basis of the thorough investigation subsequently carried out by YORK Refrigeration, it was
decided to introduce a series of synthetic oils
complying with the requirements of modern refrigeration plants.
Mineral oils can, however, still be used in refrigeration plants, provided the lubricating quality is
carefully monitored. For modern high-capacity refrigeration plants where a long service life for both
lubricant and moving parts is expected,
YORK Refrigeration recommends the use of synthetic oils.
Areas of application and specifications for the synthetic oils mentioned are described in the following pages. Supervisors and/or users of plants are
at liberty to choose between
YORK Refrigeration's own oil brands and alternative oil brands, provided they comply with the
specifications required.

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:

possess the correct viscosity under all


operating conditions.

possess acceptable viscosity at start-up.

possess sufficient oxidation stability (the oil


must be free of moisture when charged to
the system).

possess sufficient chemical stability when


used together with R717.

Moreover, the extent to which different 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

SMC /TSMC 100 Mk4 - Engineering Manual

6. Technical Data

If you consider changing the type of oil, please


read the section Oil Changing on SABROE Compressors carefully.
Selecting Lubricating Oil
The correct oil is selected by means of the following diagrams. When the general conditions concerning the lubrication of the compressor have
been considered, the specific conditions of the
plant must be taken into account.
Use the oil recommendation diagrams to select
the correct oil code number.
The oil code number consists of letters indicating
the oil type and viscosity number.
Table 6.20

06 technical data.fm

Code
design

Oil types

Mineral oil

Synthetic oil based on Alkylbenzene

PAO
AP
E

Synthetic oil based on Polyalphaolefin


Mixture of A and PAO oils
Synthetic ester-based lubricants

In the oil recommendation diagrams it is possible


to find the code number best suited for the operating conditions in question. With the code number
it is possible to select the correct Sabroe oil for the
application in question.
Oil Types and Oil Companies
Due to the large number of oil companies offering
oil for refrigeration plants, it has not been possible
for YORK Refrigeration to test all the different oil
brands on the global market.
It is our experience that certain oil brands can
change character during use and thus no longer
correspond to the specifications stated by the oil
companies on delivery. We have thus experienced changes in specifications as well as formula and performance without having received infor-

0178-931 - ENG
Rev. 27.10.03

mation on this beforehand from the oil company.


This makes it extremely difficult for
YORK Refrigeration to give a general approval of
other oil brands.
In co-operation with a large, respected oil company YORK Refrigeration has therefore developed
a series of three different oils covering most demands. Furthermore, a list of the oils which can be
supplied through YORK Refrigeration has been
prepared. Data for these oils is included in the table Data for Sabroe Oils. We recommend that you
use these oils, which can be delivered in 20 litre
pails or 208 litre drums. When ordering, use the
part no. stated in List of Part Numbers for Available Sabroe Oils.
It is of course possible to use similar oils from other oil companies. If this is the case, use the table
Data for Sabroe Oils.
Please note that YORK Refrigeration has not tested other oils than our own brand. Thus we cannot
guarantee the quality, stability or suitability of other oils. The respective oil companies are thus responsible for the quality and suitability of the oil
delivered, and if there are any problems with
these oils in the compressor or the refrigeration
plant, contact the oil supplier directly.
When selecting oils from other oil companies,
special attention should be paid to the suitability of
the oil in the compressor and the refrigeration
plant as a whole.
Please note in particular the following points:

Oil type

Compressor type

Miscibility between refrigerant and oil

Operating data for the compressor


Discharge gas temperature
Oil temperature

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6. Technical Data

Normal oil temperature in crankcase is


50-60C

Max. permitted viscosity = 100 cSt

Max. permitted oil temperature =


set point for alarm

Max. permitted viscosity during startup of the compressor = 500 cSt

Min. permitted oil temperature =


set point for alarm - if there is any

Max. refrigerant concentration in the


oil during operation: 25% - also in
case the viscosity requirements have
been met.

The viscosity of the oil in the compressor


during operation:
Type of refrigerant and solubility of refrigerant in the oil
Operating temperatures
Vapour pressure in the oil reservoir
Suction pressure and oil temperature in
the crankcase
Compatibility with neoprene O-rings:
The aniline point indicates how the Oring material reacts to the oil.
At an aniline point less than approx.
100C the material has a tendency to
swell, and at an aniline point higher than
approx. 120C it has a tendency to
shrink
Thus it cannot be recommended to
change the oil type from M to PAO without changing the O-rings at the same
time as a leak may otherwise easily occur in the compressor or the plant.
YORK Refrigeration recommends therefore the use of the Sabroe AP68 oil since
this type of oil in this case reduces considerably the risk of leaks. YORK Refrigeration can supply a list of operating
data on request.

Please note the viscosity limits during operation:


Optimum viscosity limits =
20 to 50 cSt

182/288

Min. permitted viscosity = 10 cSt

Use of Mineral Oil


As described in the introduction, mineral oil in particular causes serious problems especially in
R717 plants.
When using mineral oil, it is important to monitor
the plant closely. The condition/colour of the oil
must therefore be checked on a weekly basis and
for each 1,000 to 2,000 operating hours oil samples must be taken for further analysis.
YORK Refrigeration recommends therefore
only to use M oil under moderate operating
conditions - see the following oil recommendation diagrams.
YORK Refrigeration is aware that several customers have used mineral oils for many years without
any problems. The customers who wish to continue using mineral oil in existing as well as new
compressors can do so, provided that the compressor type and the operating conditions are similar to the existing ones.
YORK Refrigeration has thus decided to market
one brand of mineral oil which has been tested
and found suitable for most of the general refrigeration purposes.
In case another brand of mineral oil is used, follow
the specifications on the data pages in this recommendation as a guideline.
Mineral oil can be used in refrigeration plants, provided the lubricating quality is carefully monitored.
YORK Refrigeration recommends, however, that

0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

6. Technical Data

you use synthetic oils for modern high-capacity


plants where a long service life for both lubricant
and moving parts is expected.
The advantage of using synthetic lubricating oils is
a much lower oil consumption and longer oil
changing intervals. Improved viscosity at low temperatures facilitates furthermore drainage at the
cold parts of the plants.

06 technical data.fm

How to Use the Diagrams in the Oil


Recommendation:
To find the correct code number, select refrigerant and compressor type in the oil recommendation diagram. Then insert the estimated operating
conditions in the diagram.
Example (reciprocating compressors):
R717
Refrigerant
Condensing temperature: TC +35 C
Evaporating temperature: TE -20 C
Note: Sometimes plants operate under different
conditions, e.g. different evaporating temperatures due to variations in the plant, or different
condensing temperatures as a result of seasonal
changes. By inserting TC and TE in the oil recommendation diagram, the recommended area is
found. In this case it is oil area 1. If the intersection
is outside the area, contact YORK Refrigeration
for a detailed calculation by means of the calculation program COMP1.

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

By using the table which is situated next to the oil


recommendation diagram, select the recommended code number and thus the recommended oil. In
the example above there are thus 3 possibilities:
PAO3, AP1 or M1. However, M1 is only recommended for moderately loaded compressors.
Table 6.21
Code no.
PAO3
AP1
M1

Area no. 1

/
See note

Oil Change on Sabroe Compressors


Never change to another oil type without contacting the oil supplier. Nor is it advisable to recharge
a compressor with another oil type than the one
already used for the plant or compressor in question.
Mixing different oils may result in operating problems in the refrigeration plant or damage to the
compressor. Incompatibility between different oil
types may reduce the lubricating properties considerably and may cause oil residues to form in
the compressor, oil separator or plant. Oil resi-

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6. Technical Data

dues may block filters and damage the moving


parts of the compressor.
Changing the oil type or brand should only be
done following a thorough procedure involving
drainage and evacuation of the refrigeration plant.
Information on a suitable procedure can be 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.

Make sure that the original oil container is sealed


properly during storage so that moisture from the
air is not absorbed by the oil. Many oils, particularly polyolester oils, are extremely hygroscopic. It is
therefore recommended only to buy the oil in containers whose size correspond to the amount to
be used.
In case all of the oil is not used, make sure that the
rest of the oil is sealed in the original container
and stored in a warm, dry place. It is recommended to charge nitrogen to keep the water content
below 50 ppm.
Ideally, oil containers should be equipped with a
barrel tap to ensure an effective, airtight seal.

184/288

0178-931 - ENG
Rev. 27.10.03

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6. Technical Data

Oil Changing Intervals


A list of the recommended oil changing intervals is
included in the instruction manuals of the compressors. This list is for guidance only. The actual
oil changing intervals are often determined by a
number of operating parameters in the plant.

It is strongly recommended to monitor the quality


of the oil by performing oil analyses on a regular
basis. This will also give an indication of the condition of the plant. This service can be supplied by
YORK Refrigeration or the oil supplier.

Oil recommendation diagram symbols:

In case of a new plant. Very suitable.

In case you wish to change from mineral oil

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

Max oil concentration in liquid phase: contact YORK Refrigeration

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

06 technical data.fm

Dry expansion systems only. Flooded systems to be considered individually: contact


YORK Refrigeration

SH

Suction gas superheat, K (Kelvin)

Zone in which both oils are useable

Calculation must be performed using COMP1

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Rev. 27.10.03

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SMC /TSMC 100 Mk4 - Engineering Manual

6. Technical Data

Data Sheet for Listed Sabroe Oils


Typical data for lubricating oils for Sabroe compressors
Sabroe

Viscosity

Viscosity

Spec.

Flash p.

Pour p.

Anilin

Acid no.

code

cSt
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

SMC /TSMC 100 Mk4 - Engineering Manual

6. Technical Data

List of Part Numbers for Available Sabroe Oils


Oil brand

Part no.
20 litre pail

208 litre barrel

Mobil Gargoyle Arctic 300

M1 (M68)

1231-264

1231-296

Sabroe Oil A100

A3 (A100)

1231-263

1231-262

Sabroe Oil AP68

AP1 (AP68)

1231-257

1231-260

Sabroe Oil PAO68

PAO3 (P68)

1231-256

1231-259

Mobil Gargoyle Arctic SHC 228

PAO5 (P100)

1231-282

1231-283

Mobil Gargoyle Arctic SHC 230

PAO9 (P220)

1231-284

1231-285

Mobil EAL Arctic 68

E3 (E68)

1231-272

1231-273

Mobil EAL Arctic 100

E5 (E100)

1231-274

1231-275

Mobil EAL Arctic 220

E9 (E220)

Sabroe H oil

E11 (E370)

1)

06 technical data.fm

Oil code no.

1231-279
3914 1512 954

1)

9415 0008 000

18.9 litre pail (5 US gallons)

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

Mobil Gargoyle Arctic 300 - M1 (M68)

Sabroe Oil PAO 68 - PAO 3 (PAO 68)

Mobil Gargoyle Arctic SHC 230 - PAO 9 (PAO 220)

Sabroe H oil - E 11 (E 370)

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Sabroe oil

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SMC /TSMC 100 Mk4 - Engineering Manual

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:
:

Very suitable in case of a new plant.


In case you wish to change from mineral oil.

188/288

0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

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:
:

Very suitable in case of a new plant.


In case you wish to change from mineral oil.

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Rev. 27.10.03

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SMC /TSMC 100 Mk4 - Engineering Manual

6. Technical Data

R717

TC
F

HPO and HPC


reciprocating
compressors

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:

Very suitable in case of a new plant.

190/288

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Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

6. Technical Data

List of Major Oil Companies


The oil from the companies listed below are not tested by YORK Refrigeration and are therefore not approved by YORK Refrigeration. The following list includes the information provided by the oil companies.
The oil companies are responsible for the information concerning the durability and suitability of their oils
for specific purposes. Oils tested and approved by YORK Refrigeration are included in the "List of Part
Numbers for Available Sabroe Oils".
Oil Company

Oil Types

06 technical data.fm

PAO

AP

Aral

Avia

BP

Castrol

Chevron (UK: Gulf Oil)

CPI Engineering Services

DEA

Elf / Lub Marine 1

Esso/Exxon

Fina

Fuchs

Hydro-Texaco

ICI

Kuwait Petroleum (Q8)

Mobil

Petro-Canada

Shell

Statoil

Sun Oil

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SMC /TSMC 100 Mk4 - Engineering Manual

6. Technical Data

Selecting Lubricating Oil for SABROE Reciprocating Compressors


Refrigerant: HFC/HCFC
In a period from 1990 to 1995 YORK Refrigeration
experienced a rising number of problems with the
use of mineral oils, especially in R717 plants.
The problems can be divided into two groups:
e.

The oil changes viscosity within a few operating hours.

f.

The oil dissolves becomes very black).

The problems have been observed in connection


with several different types of mineral oil and often
occur within only a few operating hours. The consequences have been severe for both compressors and plants.
On the basis of the thorough investigation subsequently carried out by YORK Refrigeration, it was
decided to introduce a series of synthetic oils
complying with the requirements of modern refrigeration plants.
Mineral oils can, however, still be used in refrigeration plants, provided the lubricating quality is
carefully monitored. For modern high-capacity refrigeration plants where a long service life for both
lubricant and moving parts is expected, YORK
Refrigeration recommends the use of synthetic
oils.
Areas of application and specifications for the synthetic oils mentioned are described in the following pages. Supervisors and/or users of plants are
at liberty to choose between YORK Refrigeration's own oil brands and alternative oil brands,
provided they comply with the specifications required.
General
This recommendation will only deal with the lubrication of the compressor. The performance of the

192/288

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:

possess the correct viscosity under all operating conditions.

possess acceptable viscosity at start-up.

possess sufficient oxidation stability (the oil


must be free of moisture when charged to
the system).

possess sufficient chemical stability when


used together with HFC/HCFC.

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

SMC /TSMC 100 Mk4 - Engineering Manual

6. Technical Data

areas, the oil concentration must not exceed 5%.


For area B, please contact YORK Refrigeration.
Plants with Several Different Compressor
Types/Makes
In plants where several different compressor
types/makes are connected, it is strongly recommended to use the same type of oil in all the compressors. This is very important where automatic
oil return systems are used.

06 technical data.fm

If you consider changing the type of oil, please


read the section Oil Changing on SABROE Compressors carefully.
Selecting Lubricating Oil
The correct oil is selected by means of the following diagrams. When the general conditions concerning the lubrication of the compressor have
been considered, the specific conditions of the
plant must be taken into account.
Use the oil recommendation diagrams to select
the correct oil code number.
The oil code number consists of letters indicating
the oil type and viscosity number..
Table 6.22
Code
design

Oil types

Mineral oil

Synthetic oil based on Alkylbenzene

PAO

Synthetic oil based on Polyalphaolefin

AP

Mixture of A and PAO oils

Synthetic ester-based lubricants

In the oil recommendation diagrams it is possible


to find the code number best suited for the operating conditions in question. With the code number
it is possible to select the correct Sabroe oil for the
application in question.

0178-931 - ENG
Rev. 27.10.03

Oil Types and Oil Companies


Due to the large number of oil companies offering
oil for refrigeration plants, it has not been possible
for YORK Refrigeration to test all the different oil
brands on the global market.
It is our experience that certain oil brands can
change character during use and thus no longer
correspond to the specifications stated by the oil
companies on delivery. We have thus experienced changes in specifications as well as formula and performance without having received information on this beforehand from the oil company.
This makes it extremely difficult for
YORK Refrigeration to give a general approval of
other oil brands.
In co-operation with a large, respected oil company YORK Refrigeration has therefore developed
a series of three different oils covering most demands. Furthermore, a list of the oils which can be
supplied through YORK Refrigeration has been
prepared. Data for these oils is included in the table Data for Sabroe Oils. We recommend that you
use these oils, which can be delivered in 20 litre
pails or 208 litre drums. When ordering, use the
part no. stated in List of Part Numbers for Available Sabroe Oils.
It is of course possible to use similar oils from other oil companies. If this is the case, use the table
Data for Sabroe Oils.
Please note that YORK Refrigeration has not tested other oils than our own brand. Thus we cannot
guarantee the quality, stability or suitability of other oils. The respective oil companies are thus responsible for the quality and suitability of the oil
delivered, and if there are any problems with
these oils in the compressor or the refrigeration
plant, contact the oil supplier directly.
When selecting oils from other oil companies,
special attention should be paid to the suitability of

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SMC /TSMC 100 Mk4 - Engineering Manual

6. Technical Data

the plant. YORK Refrigeration recommends


therefore the use of the Sabroe AP68 oil
since this type of oil in this case reduces
considerably the risk of leaks.

the oil in the compressor and the refrigeration


plant as a whole.
Please note in particular the following points:

Oil type

Refrigerant type

Compressor type

Miscibility between refrigerant and oil

Operating data for the compressor

Please note the viscosity limits during operation:

Discharge gas temperature

Optimum viscosity limits


= 20 to 50 cSt

Oil temperature

Max. permitted viscosity = 100 cSt

Normal temperature in the crank case is


50-60C

Min. permitted viscosity = 10 cSt

Max. permitted oil temperature =


set point for alarm.
Min. permitted oil temperature =
set point for alarm - if there is any

YORK Refrigeration can supply a list of operating data on request.

The viscosity of the oil in the compressor


during operation and under the influence of:
Type of refrigerant and solubility of refrigerant in the oil
Operating temperatures
Vapour pressure in the oil reservoir
Suction pressure and oil temperature in
the crankcase
Compatibility with neoprene O-rings:
The aniline point indicates how the
O-ring material reacts to the oil.
At an aniline point less than approx. 100C
the material has a tendency to swell, and at
an aniline point higher than approx. 120C it
has a tendency to shrink.
Thus it cannot be recommended to change
the oil type from M to PAO without changing
the O-rings at the same time as a leak may
otherwise easily occur in the compressor or

194/288

Max. permitted viscosity during startup of the compressor = 500 cSt


Max. refrigerant concentration in the
oil during operation: 25% - also in
case the viscosity requirements have
been met.
Use of Mineral Oil
As described in the introduction, mineral oil in particular causes serious problems especially in
R717 plants.
When using mineral oil, it is important to monitor
the plant closely. The condition/colour of the oil
must therefore be checked on a weekly basis and
for each 1,000 to 2,000 operating hours oil samples must be taken for further analysis.
YORK Refrigeration recommends therefore
only to use M oil under moderate operating
conditions - see the following oil
recommendation diagrams.
YORK Refrigeration is aware that several customers have used mineral oils for many years without
any problems. The customers who wish to continue using mineral oil in existing as well as new
compressors can do so, provided that the compressor type and the operating conditions are similar to the existing ones.

0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

6. Technical Data

YORK Refrigeration has thus decided to market


one brand of mineral oil which has been tested
and found suitable for most of the general refrigeration purposes.

Fig. 6.65

In case another brand of mineral oil is used, follow


the specifications on the data pages in this recommendation as a guideline.

140 60

06 technical data.fm

The advantage of using synthetic lubricating oils is


a much lower oil consumption and longer oil
changing intervals. Improved viscosity at low temperatures facilitates furthermore drainage at the
cold parts of the plants.
How to Use the Diagrams in the Oil
Recommendation:
To find the correct code number, select refrigerant
and compressor type in the oil recommendation
diagram. Then insert the estimated operating conditions in the diagram.
Example (reciprocating compressors):
R134a
Refrigerant
Condensing temperature: TC +35 C

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

By using the table which is situated next to the oil


recommendation diagram, select the recommended code number and thus the recommended oil. In
the example above an oil with code number E5
can be used.
Table 6.23
Code no.

Area no.
1

E5
E9

Evaporating temperature: TE -3C


Note: Sometimes plants operate under different
conditions, e.g. different evaporating temperatures due to variations in the plant, or different
condensing temperatures as a result of seasonal
changes. By inserting TC and TE in the oil recommendation diagram, the recommended area is
found. In this case it is oil area 1. If TC should
change, e.g. from -3C to +7C, use oil area 2. As
+7C is within the marked area, oil area 1 can,
however, also be used at this TE.

0178-931 - ENG
Rev. 27.10.03

Oil Change on Sabroe Compressors


Never change to another oil type without contacting the oil supplier. Nor is it advisable to recharge
a compressor with another oil type than the one
already used for the plant or compressor in question.
Mixing different oils may result in operating problems in the refrigeration plant or damage to the
compressor. Incompatibility between different oil
types may reduce the lubricating properties considerably and may cause oil residues to form in

195/288

SMC /TSMC 100 Mk4 - Engineering Manual

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

Make sure that the original oil container is sealed


properly during storage so that moisture from the
air is not absorbed by the oil. Many oils, particularly polyester oils, are extremely hygroscopic. It is
therefore recommended only to buy the oil in containers whose size correspond to the amount to
be used.
In case all of the oil is not used, make sure that the
rest of the oil is sealed in the original container
and stored in a warm, dry place. It is recommended to charge nitrogen to keep the water content
below 50 ppm.
Ideally, oil containers should be equipped with a
barrel tap to ensure an effective, airtight seal.

0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

6. Technical Data

Oil Changing Intervals


A list of the recommended oil changing intervals is
included in the instruction manuals of the compressors. This list is for guidance only. The actual
oil changing intervals are often determined by a
number of operating parameters in the plant.

It is strongly recommended to monitor the quality


of the oil by performing oil analyses on a regular
basis. This will also give an indication of the condition of the plant. This service can be supplied by
YORK Refrigeration or the oil supplier..

Oil recommendation diagram symbols:

In case of a new plant. Very suitable.

In case you wish to change from mineral oil

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

Max oil concentration in liquid phase: contact YORK Refrigeration

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

06 technical data.fm

Dry expansion systems only. Flooded systems to be considered individually: contact


YORK Refrigeration

SH

Suction gas superheat, K (Kelvin)

Zone in which both oils are useable

Calculation must be performed using COMP1

0178-931 - ENG
Rev. 27.10.03

197/288

SMC /TSMC 100 Mk4 - Engineering Manual

6. Technical Data

Data Sheet for Listed Sabroe Oils


Typical data for lubricating oils for Sabroe compressors
Sabroe

Viscosity

Viscosity

Spec.

Flash p.

Pour p.

Anilin

Acid no.

code

cSt
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

SMC /TSMC 100 Mk4 - Engineering Manual

6. Technical Data

List of Part Numbers for Available Sabroe Oils


Oil brand

Oil code no.

Part no.
20 litre pail

208 litre barrel

Mobil Gargoyle Arctic 300

M1 (M68)

1231-264

1231-296

Sabroe Oil A100

A3 (A100)

1231-263

1231-262

Sabroe Oil AP68

AP1 (AP68)

1231-257

1231-260

Sabroe Oil PAO68

PAO3 (P68)

1231-256

1231-259

Mobil Gargoyle Arctic SHC 228

PAO5 (P100)

1231-282

1231-283

Mobil Gargoyle Arctic SHC 230

PAO9 (P220)

1231-284

1231-285

Mobil EAL Arctic 68

E3 (E68)

1231-272

1231-273

Mobil EAL Arctic 100

E5 (E100)

1231-274

1231-275

Mobil EAL Arctic 220

E9 (E220)

Sabroe H oil

E11 (E370)

1231-279
3914 1512 954

1)

9415 0008 000

06 technical data.fm

1) 18.9 litre pail (5 US gallons)

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

Mobil Gargoyle Arctic 300 - M1 (M68)

Sabroe Oil PAO 68 - PAO 3 (PAO 68)

Mobil Gargoyle Arctic SHC 230 - PAO 9 (PAO 220)

Sabroe H oil - E 11 (E 370)

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Rev. 27.10.03

Sabroe oil

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SMC /TSMC 100 Mk4 - Engineering Manual

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

Very suitable in case of a new plant.


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

200/288

0178-931 - ENG
Rev. 27.10.03

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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:

Very suitable in case of a new plant.


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

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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

-76 -58 -40 -22

32

50

68

86 F

-4

14

TE

Evaporating temperature
Code no

Area no
1

E5

E9

L:

Very suitable in case of a new plant.


Zone in which both oils are applicable.:

202/288

0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

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

Very suitable in case of a new plant.

0178-931 - ENG
Rev. 27.10.03

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SMC /TSMC 100 Mk4 - Engineering Manual

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

: :

Very suitable in case of a new plant.

b:
c:

Max oil concentration in liquid phase: contact YORK Refrigeration


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

204/288

0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

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

: :

Very suitable in case of a new plant.

b:
c:

Max oil concentration in liquid phase: contact YORK Refrigeration


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

0178-931 - ENG
Rev. 27.10.03

205/288

SMC /TSMC 100 Mk4 - Engineering Manual

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

: :

Very suitable in case of a new plant.

c:
L:

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


Zone in which both oils are applicable.

206/288

0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

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

: :

Very suitable in case of a new plant.

c:

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

0178-931 - ENG
Rev. 27.10.03

207/288

SMC /TSMC 100 Mk4 - Engineering Manual

6. Technical Data

R410A

TC

HPO and HPC


reciprocating
compressors

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

: :

Very suitable in case of a new plant.

a:

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

208/288

0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

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

: :

Very suitable in case of a new plant.

c:

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

0178-931 - ENG
Rev. 27.10.03

209/288

SMC /TSMC 100 Mk4 - Engineering Manual

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

: :

Very suitable in case of a new plant.

c:

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

210/288

0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

6. Technical Data

List of Major Oil Companies


The oil from the companies listed below are not tested by YORK Refrigeration and are therefore not approved by YORK Refrigeration. The following list includes the information provided by the oil companies.
The oil companies are responsible for the information concerning the durability and suitability of their oils
for specific purposes. Oils tested and approved by YORK Refrigeration are included in the "List of Part
Numbers for Available Sabroe Oils".
Oil Company

Oil Types

06 technical data.fm

PAO

AP

Aral

Avia

BP

Castrol

Chevron (UK: Gulf Oil)

CPI Engineering Services

DEA

Elf / Lub Marine 1

Esso/Exxon

Fina

Fuchs

Hydro-Texaco

ICI

Kuwait Petroleum (Q8)

Mobil

Petro-Canada

Shell

Statoil

Sun Oil

0178-931 - ENG
Rev. 27.10.03

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6. Technical Data

212/288

0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

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.

how to install the equipment in a safe and effective way.

The safety precautions and instructions pertaining


to the individual sections of this document must
also be read and followed.

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

SMC /TSMC 100 Mk4 - Engineering Manual

7. Installation Instructions

Preparing the Installation

Safety shoes

This section describes the preparations which


must be carried out before commencing the installation.

Gloves

Tools and Accessories

Salt water solution for eye rinsing

The list below shows the tools, accessories and


materials which are necessary in order to carry
out the installation correctly.

Oxygen equipment

Ordinary Hand Tools


Tools for installing pipes, including welding tool
Tools for wiring
Special tools
Small tool set for compressor.
See Document no. 0662-061-EN.
Accessories
Lifting eye
Shakles
Hand-operated oil charging pump, spare
part no. 3141-026,
see description in Section 6, Technical Data
- Charging the compressor with oil.

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.

Preparing the Mounting Site


Safety Equipment

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 installing the unit, the following must be


carried out:
1.

The foundation for the unit must be ready.


Check that the foundation is level and has
the necessary strength.

2.

Check that the access roads are wide


enough for the unit to pass through - see the
dimension sketches.

3.

Block the mounting site.


The mounting site must be blocked to prevent unauthorised personnel from being injured or causing damage.

4.

The mounting site must be cleared.

When installing the equipment, use the following


safety equipment which must be in good condition:

214/288

0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

7. Installation Instructions

Lifting Accessories and Equipment


See Section 14, Transport Instructions.

Cooling water hoses for cooling of top


and side covers.

Preparing Lifts

Vibration dampers as well as drawing indicating the position of the dampers.

See Section 14, Transport Instructions.

Lifting and Loading Instructions


See Section 14, Transport Instructions.

07 installation instructions.fm

Unpacking and Inspection


On receipt the unit is wrapped in PE plastic film.
After unpacking the unit, check for transport damage. Check also whether the delivered goods correspond to the specification. Check in particular
that the control system and valves fitted on the
outside of the unit are not damaged. It must also
be checked whether the following parts are included:
Intermediate piece for coupling, inner
and outer screen and perhaps loose
coupling hub for motor.

0178-931 - ENG
Rev. 27.10.03

Disposal of Materials which are not


Reusable
Materials from the packing of the unit which cannot be reused must be disposed of according to
local regulations.

Moving the Equipment to the Mounting


Site after Unloading and Unpacking
After unloading and unpacking the unit, it must
only be lifted in the lifting eyes welded on the
frame. If the unit is moved with e.g. a forklift truck,
it must be placed on a pallet intended for the purpose. Secure the unit so that it does not tip over
when starting, turning and braking the forklift
truck. Do not lift directly under the unit.

215/288

SMC /TSMC 100 Mk4 - Engineering Manual

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:

Distortion between compressor unit and


foundation.

Distortion between compressor and base


frame.

Distortion between motor and base frame.

Strains from pipe connections between


compressor and plant.

Incorrect alignment of coupling between


compressor and motor.

Compressor or motor shafts are untrue.

Coupling is untrue.

Imperfect balancing of coupling.

Imbalance in compressor and motor.

216/288

The supervisor who sets up the unit is responsible


for the points up to and including alignment of the
coupling. The other points must be checked by the
compressor and motor manufacturer before delivery. The following sections will deal with the individual points concerning the supervisor.

1. Alignment of Unit against


Foundation
When the unit has been moved to the site where
it is to be installed, an alignment must be carried
out before the piping can be laid.
When mounting the unit on the foundation or the
machine floor, it must rest evenly on all its supporting surfaces.
The unit can be mounted in the following ways:

on vibration dampers.

directly on the foundation with foundation


bolts.

With both methods the unit must be set up before


the pipes are connected to the plant.
Depending on whether the unit is to be used on
land or on a ship, vibration dampers are supplied
as shown in the drawing Fig. 7.1.
The purpose of the vibration dampers is to dampen the vibrations from the unit to the foundation.
Moreover, the marine vibration dampers must
dampen the vibrations from the foundation to the
compressor unit and at the same time secure the
unit to the foundation.
It is very important that the vibration dampers are
placed correctly as illustrated in the drawing forwarded to the customer or the dealer. This drawing applies only to the unit in question.

0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

7. Installation Instructions

Mounting on Vibration Dampers


Fig. 7.1

1
A1

A2
H

Hmax

07 installation instructions.fm

A1
A2

T0177040_0

The vibration dampers supplied are marked with a


code, e.g. LM6-60. LM6 indicates the size whereas 60 indicates the rubber hardness and is thus an
expression of bearing and damping capacity.
When using vibration dampers, the foundation is
assumed to have the necessary bearing strength
and to be level enough to enable adjustment of
the vibration dampers to be made within the adjusting measurements stated on the drawing submitted.
In order for the individual vibration damper to
dampen properly, a sufficient load must be imposed: Measure A1 and H (unloaded position)
and A2 (loaded position) as shown in drawing
Fig. 7.1.

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

The flexion of a damper is adjusted by increasing


or decreasing the load in relation to the other supports. The foot can be raised by lowering the adjusting rod or inserting more disks between damper and foot (marine design), thereby increasing
the load and hence also the flexion.
Once the installation has cooled down, check during operation that the flexion of the dampers is still
correct!

0178-931 - ENG
Rev. 27.10.03

217/288

SMC /TSMC 100 Mk4 - Engineering Manual

7. Installation Instructions

Mounting Directly on Foundation


When mounting the unit directly on a concrete
foundation, the foundation must be cast in accordance with the foundation drawing forwarded.
When the foundation has been cast - with the
holes shown for the foundation bolts - and has
cured, place the unit in a position allowing it to rest
on beams levelled at a suitable height so that the
foundation plates are recessed slightly into the
foundation.
Check that the foundation plates are right next to
the base frame. This can be achieved by binding
them to the resting surfaces of the base frame by
means of steel flex.
The concrete which is cast down around the foundation bolts should only have minimal water content to allow it to be rammed well down around the
bolts. Low water content does not cause the hardening concrete to shrink.
10-14 days should pass before removing the
beams and tightening the nuts for the foundation

218/288

bolts. Before that, however, remove the steel flex


and check that there is no space between the
base frame and the foundation plates. If there is,
place shims between the plates before tightening.

2. Alignment of Compressor on Base


Frame
Check that the entire footing of the compressor
makes full contact against the faces of the base
frame.
Perform this check with the bolts loosened. If slip
occurs at one or more resting surfaces, shim up
before tightening. If unaligned, there is a risk of
stresses occurring in the compressor frame,
which will damage the bearings.

3. Alignment of Motor on Base Frame


Check the contact faces of the motor against the
base frame in the same way as for the compressor.

0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

7. Installation Instructions

Fitting and alignment of coupling type AMR


4. Installation and alignment

Important!

In principle, alignment involves manoeuvring the


motor to make the shaft form an extension of the
crankshaft.

Before performing any work on the coupling,


make sure that the compressor motor cannot start
inadvertently.

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

* See final installation

0178-931 - ENG
Rev. 27.10.03

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SMC /TSMC 100 Mk4 - Engineering Manual

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.

Degrease the compressor shaft and hub


bore surfaces. Any lubricant here will reduce the transferred torque.

Place the hub at the compressor side, observing the measurement "F".

Tighten the screws "D" crosswise in two or


three steps of torque. Assembly is completed when no screw can be tightened any further (one by one) with tightening torque D.

Place the hub at the motor side. Tighten the


bolts "A" and the pointed screw loosely.

Mount the retaining plate from the coupling


screen onto the compressor and insert a
support ring for the coupling screen over the
motor flange.

Assemble the intermediate piece and the 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.

Line up the motor so that the free holes in


the motor feet are right above the threaded
holes in the base frame.

Shift the motor coupling flange to make up


distance "C" in table. See Table 7.1.

Tighten the two bolts and the pointed screw


in the hub.

Tighten the measuring pin on the coupling


flange of the compressor, as shown in the
drawing.

0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

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.

Insert shims of thickness "y" either under


both front feet or both rear feet, thereby tilting the motor in the direction required.

Shim thickness "y" is calculated by using the


following formula (see also Fig. 7.3):

07 installation instructions.fm

Achieving parallel shafts in horizontal plane

Turn the coupling so that the alignment


gauge is in upper position. See Fig. 7.2.

Guide the measuring pin (pos. 2) towards


the coupling flange, using a 1.0 mm feeler
gauge, and fix the pin. Remove the feeler
gauge.

Rotate the coupling 180 and measure the


change in distance from the measuring pin
to the flange, using feeler gauges. This
change is called "x".

Measure the distance b between the motor


feet as shown in Fig. 7.3. Measure the distance a from the centre of the pin pos. 2 to
the centre of the motor as illustrated in
Fig. 7.2

y= X

b
2xa

Fig. 7.3

After tightening the motor bolts, repeat the


measurement and compare the result with
the values in the table below:

Table 7.2
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

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SMC /TSMC 100 Mk4 - Engineering Manual

7. Installation Instructions

Achieving correct centre height

Turn the coupling so that the alignment


gauge faces vertically down.

Guide the measuring pin (pos. 1) towards


the coupling flange, using a 1.0 mm feeler
gauge, and fix the pin. Remove the feeler
gauge.

Rotate the coupling 180 and measure the


increase in distance "z" from one millimetre
using feeler gauges.

Then lift the motor by placing shims of a


thickness equal to half value of "z" under all
four feet.

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.

Achieving parallel shafts in vertical


plane

Turn the coupling 180 and by using feeler


gauges measure deviations from one millimetre at both pins.

Move and turn the motor and repeat this


measurement, align the motor in accordance with pos. 1 horizontal and pos. 2 in the
table. Remember that the motor must be
firmly secured during any measurements.

Final installation

Tighten the foundation bolts on the motor


(see torque table).

Fit four bolts into the motor coupling flange


so that thin shims are placed between the
flange and the lamellae, with the rounded
side facing lamella.

Tighten the bolts to torque specified in the


table.

Readjust the flange distance "C" so that the


lamellae are aligned, by moving the motor
flange on the shaft and fastening the motor
flange.

The motor is now positioned at its correct


height. What remains is to push and turn the
motor at the level on which it is already lined
up.

Check the alignment of the coupling in horizontal and vertical planes for pos. 1 and
pos. 2.

Dismantle the measuring pin and tighten the


screw to the prescribed torque.

Turn the coupling so that the alignment


gauge faces out to one side horizontally.

Fit the coupling guard.

Guide both measuring pins towards the coupling with a 1.0 mm feeler gauge in between.

Once normal operating temperature has


been achieved, double-check the coupling
alignment.

222/288

0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

7. Installation Instructions

Preliminary Installation

Check tightening of coupling flange on compressor.


Tighten 8 coupling bolts securing lamellar
segments to intermediate piece to prescribed moment stated in table. It is worthwhile doing this before placing the intermediate piece in position.
Mount retaining plate from coupling screen
onto compressor and insert support ring for
coupling screen over motor flange.

Alignment
Check that the motor with loose bolts stands with
all four feet on the base frame. If necessary, insert
any liner plates where there is an air gap beneath
the feet. Tighten the bolts slightly.

Achieving Parallel Shafts in Horizontal


Plane

Turn coupling so that alignment gauge is in


upper position, Fig. 7.2

Insert coupling intermediate piece. Create


space between flanges either by shifting entire motor or just motor coupling flange.
The intermediate piece should only be
secured to the compressor flange. Do
not insert the last four bolts in the motor
flange until the coupling has been
aligned.
As the compressor shaft rotates during the
alignment procedure, the motor must turn
with it, as the bolts in the intermediate piece
engage in the free holes in the motor coupling flange.

Guide measuring pin (Pos. 2) towards coupling flange by means of a 1.0 mm feeler
gauge and fix pin. Remove feeler gauge.

Rotate coupling 180 and measure change


in distance from measuring pin to flange by
means of feeler gauges. This change is
called "x".

Measure the distance b between the feet of


the motor as shown in Fig. 7.4. Measure the
distance a from the centre of the pin pos. 2
to the centre line of the motor as illustrated
in Fig. 7.2

Line up motor so that free holes in motor


feet are right over threaded holes in base
frame.

Shift motor coupling flange to achieve distance "C" in table, Fig. 7.2.

Insert shims of thickness "y" either under


both front feet or both rear feet, thereby tilting motor in direction required. Shim thickness "y" is calculated using the following formula (see Fig. 7.4):

Tighten two bolts in coupling hub. On


CMO-HPO units, the motor flange must be
correctly positioned before putting the motor
into place.

Tighten alignment gauge on coupling flange


of compressor as shown in drawing.

07 installation instructions.fm

0178-931 - ENG
Rev. 27.10.03

y = X

b
2xa

223/288

SMC /TSMC 100 Mk4 - Engineering Manual

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.

Turn coupling 180 and measure deviations


from one millimetre at both pins by means of
feeler gauges.

By moving and turning motor and by


repeating this measurement, align motor in
accordance with pos. 1 horizontal and pos.
2, Fig. 7.2.

2.

Remember that the motor must be firmly secured when measuring.

y
b

After tightening motor bolts, repeat measurement and compare result with values in
table under Pos. 2, Fig. 7.2

Achieving Correct Centre Height

Turn coupling so that alignment gauge faces vertically downwards.

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

Rotate coupling 180 and measure increase


in distance "z" from one millimetre by means
of feeler gauges.

Tighten foundation bolts on motor (see table


showing the torque for screws and bolts).

Fit four bolts into motor coupling flange so


that thin shims are placed between flange
and lamellae with rounded side facing lamella. There are no thin shims on couplings
for CMO and HPO.

Tighten bolts to torque specified in table.

Readjust flange distance "C" so that lamellae are aligned by moving motor flange on
shaft and securing motor flange.

Check alignment of coupling in horizontal


and vertical planes for pos. 1 and pos. 2,
Fig. 7.2

Dismantle alignment gauge and tighten


screw to prescribed torque.

Fit coupling guard.

Once normal operating temperature has


been achieved, double-check coupling
alignment.

Then lift motor by placing shims of thickness


equal to half value of "z" under all four feet.

After securing motor, repeat measurement


and compare result with table values in pos.
1 vertical, Fig. 7.2

1.

Remember that the centre line of the motor


shaft must be at least 0.05 mm higher than
the centre line of the compressor, corresponding to a minimum of 0.1 mm distance
less at the top position of the alignment
gauge.

Achieving Parallel Shafts in Vertical


Plane
The motor is now positioned at its correct height.
What now remains is to push and turn the motor
at the level on which it is already lined up.

224/288

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Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

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

The connecting pipe is to be welded onto a


connecting branch on a stop valve. In order
to protect the stop valve when welding, remove the insides of the valve. Do not put the
insides back into the valve until the weld has
cooled off - see the instructions from the
valve manufacturer in Section 21, Appendices.
The welding must be carried out according
to the specifications and standards applying
to the plant in question.

> 1.5 m

07 installation instructions.fm

5.1 Refrigerant Connection to Compressor

5.2 Refrigerant Connection to Oil Cooler


(OOKH og OSSI)

The connection to the oil cooler is indicated


on the compressor with V for water supply
and Q for return. See section 5, Physical
and Connection Data.
T0177057_0

Final alignment of compressor and motor can be


performed once all piping has been connected to
the unit.
Section 5, Physical and Connection Data includes
data concerning dimensions and descriptions of
piping connections. The piping connections which
must be made are outlined below:

0178-931 - ENG
Rev. 27.10.03

5.3 Connection to Water-Cooled Top


and Side Covers
The water cooling hoses are delivered separately and connected to top and side covers according to enclosed mounting instructions. Connect water supply to the inlet of
the water system and establish return to
drain or the like, e.g. cooling tower for reuse
of the water. Connection dimensions are included in Section 5, Physical and Connection Data. The system is described in detail
in Section 4, Technical Description.

225/288

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7. Installation Instructions

6. Connecting Electricity Supply


Data for the electrical components of the unit and
their supply is included in Section 5, Physical and
Connection Data.

WDanger!
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

Opening the Cabinet

6.1 Connecting the Motor


Installation and connection instructions for the
chosen motor type is order specific and delivered
together with the unit by YORK Refrigeration.
These data sheets include descriptions of how to
connect the motor. Where another motor type is
used, data sheets containing this information
must be obtained.
Motor data appear from the name plate on the motor.
Important!
Always follow the instructions from the manufacturer concerning connection.

226/288

Connecting Supply Voltage


The supply voltage 230 VAC, 115 VAC is led
through the screwed cable entry and connected to

0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

07 installation instructions.fm

7. Installation Instructions

the terminals marked L (phase) and N (zero) - see


page 010 in diagram 2347-003. Check that the
jumper for 220/115 VAC corresponds to the supply voltage used.

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.

As standard UNISAB II is prepared to be supplied


by 230/115 VAC, but UNISAB II can also be supplied by 24 VAC. If this is the case, another transformer must be used. Check that the correct transformer 24/24 VAC (YORK Refrigeration product
no. 1556.043) has been fitted. Check,
moreover, that the jumper for 220/115 VAC has
been removed and that components, e.g. solenoid valves, are designed for 24 VAC.

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

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7. Installation Instructions

7. Pressure Testing

The entire plant must be pressure tested


in accordance with the local regulations
for pressure testing.

The test pressure must never exceed


the pressure for which the unit was designed.

If it is required that the compressor


should be pressure tested together with
the unit or with the plant, the testing
pressure must not exceed:

After installing the unit, it must be pressure tested


and pumped down.
7.1 Pressure Testing of the Refrigeration Plant
Before charging the plant with refrigerant, it
must be pressure tested and pumped down.
Pressure test the plant with one of the following:
dry air - pressurized cylinders containing dry atmospheric air may be used but never oxygen cylinders;

For reciprocating compressors:


- HT side 24 bar
- LT side 17.5 bar

air compressor for high pressure;

Please observe that manometers, pressure controls, pressure transmitters and


other control equipment are not exposed to testing pressure.

Afterwards, reduce pressure to 10 bar


for a period of 24 hours - as an initial
tightness test - as a tightly sealed plant
will maintain this pressure throughout
the period.

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.

During the tightness test, it is permitted to


enter the room and approach the plant.

Plant safety valves must normally be


blanked off during pressure testing, as their
opening pressure is lower than the testing
pressure. Shut-off valve pos. 4K-1 must be
closed during pressure testing.

When pressure testing, prepare a pressure


test report containing the following points:

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.

date of pressure testing,

person carrying out the test,

comments.

7.2 Pumping Down the Refrigeration Plant


Following pressure testing, the refrigeration
plant must be evacuated in order to eliminate atmospheric air and moisture. Evacua-

0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

7. Installation Instructions

tion must be carried out on all types of


plants, regardless of the type of refrigerant
with which the plant is to be charged.
Note that HCFC and HFC refrigerants mix
only minimally with water and it is, therefore,
necessary to effect evacuation of such systems with particular care.

07 installation instructions.fm

The boiling point of a fluid is defined as the


temperature at which the steam pressure
equals atmospheric pressure. For water the
boiling point is 100C. If the pressure is lowered, the boiling point of the water will also
be lowered.

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:

The table sets out the boiling point of water


at very low pressures:

Evacuate to a pressure lower than 5 mm


Hg.

Table 7.3

Blow dry air or nitrogen into the system


to a pressure corresponding to atmospheric pressure. Never use OXYGEN
cylinders.

Repeat evacuation to reduce pressure


to less than 5 mm Hg.

Shut off the vacuum pump from the


refrigeration plant and check that the
pressure does not rise for the next couple of hours. If the system still contains
water, this will evaporate and cause the
pressure to rise, thereby indicating unsatisfactory evacuation, which means
that the above procedure must be repeated.

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

For evacuation, use a vacuum pump which


empties the plant of air and steam.
The vacuum pump must be able to lower the
pressure to approx. 0.1 mm Hg (mercury
column) and must be fitted with a gas ballast
valve. This valve should be used wherever
possible to prevent water vapour condensing in the vacuum pump.

0178-931 - ENG
Rev. 27.10.03

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SMC /TSMC 100 Mk4 - Engineering Manual

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

accordance with the oil recommendation before


start-up.

0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

7. Installation Instructions

Final Check of the Installation


After the installation has been completed, go
through the following check list.

WWarning!
It is of vital importance that all security systems
and their functions are checked before start-up.
Failure to comply with safety precautions may
cause death, personal injury or damage to the
equipment.

Table 7.4

07 installation instructions.fm

Check list for the installation

OK

Level foundation

Measure whether the foundation is level

Position of vibration dampers

Measure flexion

Position of motor on foundation

Check that the motor rests on all four supporting


surfaces

Position of compressor on foundation

Check that the compressor rests on all four supporting surfaces

Tightness of pipe connection

Pressure testing: After putting the unit under pressure, paint with soapy water around welds, thread
connections and union nuts.

Coupling between motor and compressor

Check that the alignment is in order - must be


checked again after 5 hours of operation while the
coupling is warm.

Torque

Check that all bolts are tightened to the torque indicated.

Electrical connection

Check all electrical connections e.g. by measuring.

Oil charging

Check that the oil in the crankcase goes up to the


middle of the sight glass.

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Rev. 27.10.03

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7. Installation Instructions

232/288

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Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

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

Oil charging valve

Purge valve

Thermostatic expansion valve for intermediate cooling (TSMC)

Thermostatic expansion valve for oil


cooling

Solenoid valves for oil cooling and intermediate cooling

Solenoid valve block for capacity regulation

08 components.fm

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.

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

Electromechanical control (analogue


reading and safety system).
Computerized reading, safety and
capacity regulating system.

0178-931 - ENG
Rev. 27.10.03

Oil separator

Oil cooler

Float valve for oil return

Intermediate cooler (TSMC)

Heat exchanger for intermediate cooling


(TSMC)

Heating element

For further information regarding dimensions and


location, please see the binder Dimensions and
Piping Diagrams as well as Section 5, Physical
and Connection Data.

233/288

SMC /TSMC 100 Mk4 - Engineering Manual

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.

Makes: Schorch and Leroy-Somer

Supply voltage: 3x380V 50 Hz or


3x440V 60 Hz

Enclosure class: IP 22/23 or IP 54/55

Size: IEC 160 - 355

The necessary motor power depends on the operating conditions of the unit. The motor size can be
determined on the basis of the calculations in the
calculation program COMP1.

a belt pulley diameter of 400 mm. The required


transmission of speed between motor and compressor is achieved by choosing the right standard
belt pulley for the motor.
See, moreover, Section 6, Technical Data where
both systems are described in detail.

Oil 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

SMC 104-106-108 and TSMC 108 are available


either directly driven or belt driven.

See Section 4, Technical Description - Cooling


Systems for Compressors where the oil cooling
principles are described in detail.

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-Cooled Oil Cooler

Oil Cooler Model

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

SMC /TSMC 100 Mk4 - Engineering Manual

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

High and low pressure cut-out

High pressure manometer:

KP5

Intermediate cut-out

MP55

Oil difference cut-out

KP98

Discharge pipe thermostat

KP98

Oil thermostat

KZD4/M3

Oil filter differential pressostat

Indicating discharge pressure.


High and intermediate pressure:
Indicating discharge pressure for
HP and LP Stages (TSMC).
Low pressure and oil pressure:

08 components.fm

Indicating suction pressure and oil pressure.

0178-931 - ENG
Rev. 27.10.03

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SMC /TSMC 100 Mk4 - Engineering Manual

8. Components

UNISAB II
The UNISAB II control receives its impulses from
pressure transducers and temperature sensors.

Pressure Transducers, marked PT1,


PT2, PT3
For plants with UNISAB II control the unit is delivered with pressure transducers from Danfoss of
the type:
PT1: AKS32R and
PT2 and PT3: AKS2050 see data sheet in Section 21, Appendices.
For plants with another control the unit is delivered
with pressure transducers from Danfoss of the
type:
PT1: AKS3000 and
PT2 and PT3: AKS3050 see data sheet in Section 21, Appendices.

Temperature Sensors, marked TT5,


TT6 and TT7
As standard the unit is delivered with Pt100 temperature sensors of the type: P2208 G"B L80.

236/288

This type has a replaceable sensor insert placed


in a protective pocket made of stainless steel,
which makes it possible to replace the insert while
the unit is under pressure, see data sheet in Section 21, Appendices.
The regulating systems are described more closely in Section 4, Technical Description - Instrumentation.

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

SMC /TSMC 100 Mk4 - Engineering Manual

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

Copyright 2003 YORK Refrigeration


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

Safety Precautions

WDanger!
Risk of injury to personnel and damage to 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

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SMC /TSMC 100 Mk4 - Engineering Manual

9. Settings

Table 9.1

Pressure and Temperature Settings for Compressor Type SMC/TSMC

Analogous control and safety


system
R22

R 134

R 404A

R 507

R 717

SafetyEquipment
ControlEquipment

Min. setting
(own setting)

24 bar (standard)

22 bar (special)

MT

12 bar

High and intermediate-pressure cut-out

KP5
(KP15)

Set so that the compressor stops at a


pressure 2 bar lower than the safety
valve set- ting.

Low-pressure cut-out

KP1
(KP15)

Set to a pressure with saturation


temp. 5 K lower than the lowest
evaporating temperature.

Oil pressure cut-out

MP55

3.5 bar

Discharge pipe thermostat

KP98

Oil thermostat

KP98

Thermostat for compressor cooling

KP77

T (E) X
T (E) N
T (E) S

Safety valve on
compressor

Thermo valve for compressor cooling

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

Normally set at 4 C su- perheat


Change to min. 10 C superheat
Factory setting 45 C. See NB
X

Factory setting 75 C. See NB


Set at min.10 C superheat

PMC+ CVC

Max. setting (own


setting)

Set at min.10 C superheat

-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

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9. Settings

UNISAB II Reading, Safety and Capacity Regulating System


Table 9.2

Measured and Calculated Pressure Levels

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

Measured and Calculated temp. - Reciprocating Compressors

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

Suction gas superheat


[C]

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

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9. Settings

4-20 mA Auxiliary input Signal


Measuring

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

Alarm monitoring 15 sec delayed after compressor start.

Note 2

The alarm can be switched off immediately (RESET key).

Note 14

Delay of 60 sec, regardless of when


the limits are exceeded.

Note 3

The alarm is switched off automatically.

Note 15

Only applies to HPO and HPC compressors.

Note 4

The safety limits can be entered in


bar or C/R at your choice.

Note 16

Alarm monitoring 20 sec delayed after compressor start.

Note 5

Alarm monitoring active when digital


output "compressor starting signal"
has been chosen.

Note 17

Note 6

Alarm monitoring always active - except when "BLOCKED" has been selected in the picture COMPRESSOR
CTRL MODE.

Note 7

Alarm monitoring 300 sec delayed


after compressor start.

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

The limits are not active until AUX.


INPUT SIGNAL has been selected in
the CALIBRATION 4-20 mA menu.

Note 19

For SAB 80 the differential pressure


across the oil filter is calculated as
follows below: Oil filter diff. pressure
= Discharge pressure 2 - Oil pressure 4 (after oil filter).

Note 8

Alarm monitoring 180 sec delayed


after compressor start.

Note 9

Alarm monitoring 45 sec delayed after compressor start.

Note 10

A setting of 0.0 impedes monitoring.

Note 11

Delay of 300 sec, regardless of when


the limits are exceeded.

Note 12

240/288

The compressor must have been


above 5% capacity. Below 5% capacity monitoring is impeded.

The shown oil filter pressure will thus


be 0.1 to 0.7 bar higher than the actual pressure loss across the filter
due to the pressure loss across the
oil separator and the oil cooler.

0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

9. Settings

sure 3 (after pump) - Suction pressure 1 .

The maximum allowed pressure


drop across the oil filter is 1.2 bar.
Consequently, the warning limit
should be set between 0.8 and 1.4
bar or lower. The alarm limit should
be set between 1.1 and 1.7 bar or
lower.
Note 20:

Table 9.4
09 settings.fm

No.

Set points 1 and 2 are used for alarm


monitoring of the mechanical oil
pump. Cf. the description of the
alarm under "Oil pump error" in the
section Other Alarms. For SAB 80,
the oil pressure is calculated as follows below: Oil pressure = Oil pres-

Min.

Set point 1/ oil temp.


Difference
Oil cooling

+35

Set point 2/ oil temp.


Difference
Oil heating

Set point 1/ discharge pipe


temp. Difference
Water cooling

-20

Set point 2/ discharge pipe


temp. Difference
Intermediate pressure
liquid injection

-20

Change af factory settings, see Instruction Manual, UNISAB II Control.

0178-931 - ENG
Rev. 27.10.03

The set points are used to control the


oil pump. When the pressure falls
below set point 1, the oil pump will
start. When the pressure exceeds
set point 2 for 60 seconds, the oil
pump will stop.

Note 22:

The set points are used to control the


full flow pump. When the pressure
falls below set point 1, the full flow
pump will start. When the pressure
exceeds set point 2 for 60 seconds,
the full flow pump will stop.

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)

Fig. 9.1 - Expected Discharge Gas Temperatures


- shows the values recommended when setting
operational and safety functions.

241/288

242/288

Suction gas superheat C

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

90 100 112 126 20.5 65


88 103 11.0 50
95 110 12.5 54

96 109 123 16.2 64

91 105 120 12.5 64

76
84

98 109 121 133 20.5 75


83

68

92 103 115 128 18.2 69

111 125 14.3 69

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

Discharge gas temp. C

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

95 113 133 151

83 102 121 142

71

89 106 123 141 160

77

65

53

+10

9.1

7.6

95 114 132 153

83 103 122 143

9.1

96 115 134 153

99 14.6 123 138 155

Discharge gas temp. C

95 12.6 112 128 146 163

90 106 126 144 163

78

91 10.7 102 118 136 154

87

7.6

93 16.9 121 136 154 171

89 14.6 111 127 144 162

82

89 106 125 142 162

77

65

85 12.6 100 116 134 152

81 10.7

77

72

83 16.9 110 126 143 161

79 14.6 101 117 133 151 170

75 12.6

71 10.7

67

62

40

or
intermediate temperature

Evaporating temperature

R717

97 103 16.9 132 148 165

92

87

83

78

73

87

82

77

73

68

63

77

72

67

63

58

53

30

Discharge gas temp. C

16.5 99 108 117 128 139 20.5 85


94 102 16

Discharge gas temp. C

83

82

14.5 92 101 111 123 135 18.2 79


99 14

89

83

79

40 10.1 77

45 11.5 81

76

95 106 118 131 16.2 74

12.7 84
94 12

84

78

74

73

35 8.8

62

94 106 120 18.2 59

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

Condensing pressure bar

20

10

Condensing pressure bar

+10

Evaporating temperature
or
intermediate temperature

R404A/R507

Condensing pressure bar

10

30

20

10

Condensing pressure bar

Evaporating temperature
or
intermediate temperature

R22

Fig. 9.1

Evaporating temperature
or
intermediate temperature

Condensing temp. C

+10

R134a

HFC HCFC

SMC /TSMC 100 Mk4 - Engineering Manual

9. Settings

Expected Discharge GasTemperatures

0178-931 - ENG

Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

10. Operating Instructions

10. Operating Instructions


The purpose of this document is to describe:

Safety Precautions

WDanger!

Dangers resulting from failure to comply


with safety precautions when operating the
equipment.

How to start, operate and stop this equipment in a safe way.

How to act when problems occur during operation.

This document is primarily intended for operators


and service engineers.

10 operating instructions.fm

This document was produced by:


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 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

A number of safety considerations which must be


read before operating the unit in question are presented in the following. General safety instructions/regulations must be studied carefully. Failure to do so may result in personal injury or even
death. Moreover, the equipment may be damaged
or destroyed.

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

SMC /TSMC 100 Mk4 - Engineering Manual

10. Operating Instructions

Hot and Cold Surfaces

Qualification Requirements

A compressor unit contains both hot and cold system parts. Always wear and use the re-commended safety items.

Before carrying out the measures set forth in this


document, all personnel must have carefully studied the instructions issued for the compressor unit.

Never use your hands or other parts of the body to


search for leaks.

The personnel must also fulfil all national requirements for authorization.

244/288

0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

10. Operating Instructions

Compressor Control and Alarm


Functions
The reciprocating compressors can be equipped
with either analogue reading and regulating system or UNISAB II reading, safety and regulating
system.

Alarms and Warnings

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:

KP 15: High and low pressure cut-out


Stops the compressor at too high or too low
pressure in the refrigeration system.

KP 5: Intermediate pressure cut-out


(only on TSMC compressors)
Stops the compressor at too high intermediate pressure.

MP 55: Oil differential cut-out


Stops the compressor at too low oil pressure in the lubricating system.

KZD4/M3 Oil differential cut out


Oil differential pressure across oil filter. A
warning is given if the pressure drop
through the external oil filter is too high.
KP 98: Discharge pipe thermostat
Stops the compressor at too high discharge
gas temperature.

0178-931 - ENG
Rev. 27.10.03

KP 98: Oil thermostat


Stops the compressor at too high oil temperature.

The safety equipment stops the compressor if the


max. or min. values are exceeded. If this happens,
correct the error before restarting the plant. To
prevent accidents the plant cannot be started before the function of the safety cut-out has been activated.
Cut-outs and thermostats are not factory set on
delivery. The set values are included in Section 9,
Settings - Analoque Control and Safety Function.
However, always check the set values before
starting the plant.
As regards adjustment and setting of the equipment, see Section 21, Appendices, which includes instructions for the individual components.

UNISAB II Reading, Safety and


Capacity Regulating System
UNISAB II is a Computerized Control System, the
purpose of which is to monitor and control the
compressor.
The signals to the control and safety automatics
come from the pressure transmitters and temperature sensors mounted on the compressor. It is
possible to connect UNISAB II to a superior monitoring device- MULTISAB.
On delivery UNISAB II is preset with a number of
factory values, e.g. safety and alarm functions. A
battery backup makes sure that preset values are
not lost in case of power failure.
All control operations for the reciprocating compressor unit are carried out from the operator's
panel and its keys. The following page in this document gives a brief explanation of what the keys
on the operator's panel are used for.

245/288

SMC /TSMC 100 Mk4 - Engineering Manual

10. Operating Instructions

A detailed description of the control system, its


functions and its use is included in the Instruction
Manual for UNISAB II Control.

Carefully read the Instruction Manual UNISAB II


Control to get a thorough knowledge of how to operate the control system.

The following are for normal daily operation of the


reciprocating compressor unit.

UNISAB II is operated exclusively by means of the


keys as shown in Fig. 10.2. Reading of operating
conditions as well as changing limit values and set
points is done via the display, which contains a
number of pictures.

1.

The emergency stop button on the side of


the control cabinet can always be used to
stop the compressor unit quickly.

2.

When voltage is applied to UNISAB II, the


following main picture will appear on the
display, and UNISAB II is ready for operation.
SUCT. PRESS.

0.0 BAR

DISCH. PRESS.

0.0 BAR

MOTOR CURR.

0A

STOPPED

0%

Values for warning limits, alarm limits and set


points, etc. are programmed into UNISAB II.
This makes it possible to start the compressor
immediately.

The control panel is normally closed and locked


with a screw at each end of the panel.
By turning the screws half a turn the control panel
is loosened and can be lifted to an open position.
Here it is fastened to the cabinet as shown in
Fig. 10.1.
Fig. 10.1

Opening the Cabinet

UNISAB II

UNISAB II

However, some of the values must always be


adapted for the actual operating situation. For this
purpose use the table Quick Reference, see
Fig. 10.6, Fig. 10.7, Fig. 10.8 and Fig. 10.9.

246/288

0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

10. Operating Instructions

Display
Pos. 1

Has a constant background illumination and displays 4 lines, each with


20 characters. The contrast has
been factory set, but can be adjusted
if required.
See subsection Contrast (display) in
the section Languages in the
UNISAB instruction manual.
In the display pressure levels, temperatures as well as all set points,
warning and alarm limits can be
read.

"STARTING" (lamp flashes) and


"OPERATING" (lamp light steady )
can be seen in the bottom line of an
operating picture.
Pos. 3

Yellow lamp indicating whether the


state of operation is automatic or
manual. Yellow light = manual
operation.

Pos. 4

Red lamp indicating warning or


alarm.
Slow flashes = warning
Quick flashes = alarm

Pos. 5

A Compressor start at manual operation by pressing the key once.


Works only if yellow lamp pos. 3
is lit.

Pos. 6

B Compressor stop at manual operation by pressing the key once.


Works only if yellow lamp pos. 3
is lit.

Pos. 7

C A change between manual


(yellow lamp on) and automatic
(yellow lamp off) takes place by
pressing the key once.
Please note that if manual was selected from the CONTROL menu, it
is not possible to change to automatic. See section Control Mode in the
UNISAB instruction manual.

Pos. 8

D Key used to acknowledge alarms.

10 operating instructions.fm

Front Panel
The UNISAB II front panel is divided into two
sections:

the control section, pos. 2-10, by means of


which the compressor is controlled.

the recording section, pos. 11-15, by


means of which menu pictures are selected
and values changed.

Control Section
Pos. 2

Green lamp indicating whether the


compressor is running. At start-up
this lamp will flash until UNISAB II
has received feedback from the motor starter. At the same time the text

0178-931 - ENG
Rev. 27.10.03

247/288

SMC /TSMC 100 Mk4 - Engineering Manual

10. Operating Instructions

Fig. 10.2

Front Panel of UNISAB II


10

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

E Loading of capacity during


manual operation.
By pressing the E key once one
capacity level is loaded on a reciprocating compressor with fixed rpm.
On variable speed drive (VSD) compressors, the capacity is increased
continuously by pressing the key.
F Unloading of capacity during
manual operation.
By pressing the F key once one
capacity level is unloaded on a reciprocating compressor with fixed rpm.
On variable speed drive (VSD) compressors, the capacity is decreased
continuously by pressing the key.

Recording Section
Pos. 11

G This key has several functions.

When pressing the G key, a change


will take place between Bar (PSI) and
C/R (F/R) for saturated vapours when
the display shows a suction or discharge
pressure.
Changing the set values can only be carried out by using the password shown
on page 1 in the UNISAB instruction
manual. As to the encoding of a password, see section Changing Set Values
in the UNISAB instruction manual.
Pos. 12

H Used for moving left in the menu


system. Used for selecting pictures
or a digit when changing a value.

Pos. 13

I Used for moving right in the menu


system. Used for selecting pictures
or a digit when changing a value.

0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

10. Operating Instructions

Pos. 14

K Used for moving downwards in a


picture in order to point at a certain
value, or when changing to a lower
value.

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

SMC /TSMC 100 Mk4 - Engineering Manual

10. Operating Instructions

Preparations for Starting


Check the following points before starting the
compressor for the first time after the installation.

This is the case for both analogue control


and UNISAB II control.

1.

Check that the oil goes up to the middle of


the sight glass. If this is not the case, recharge with oil.

3.

The heating element in the crankcase must


be energized 6-8 hours before starting-up
the compressor.

2.

Check that the safety equipment is set correctly. All safety functions are factory set.

4.

Check that the valves are open according to


Table 10.1.

Table 10.1

Position during Operation

Pos no

Qty

Suction stop valve

Open

Discharge stop valve

Open

Air purge valve

Closed

Oil charge valve

Closed

Stop valve - after oil seperator

Open

Stop valve - receiver

Open

Stop valve - liquid line

Open

Fig. 10.3

Designation

In operation position

Remarks
Must be opened by only a
couple of turns.

To be opened after start-up

Principle Drawing - Position during Operation


3
2

To Conderser

From Condenser

Note!
Other valves may occur. See
Dimensions and Piping Diagram

6
Open
Closed

Receiver

To Evaporator

5.

Switch on the pilot voltage. Check that the


emergency stop button, see Fig. 10.4, is in
ON-position (the button must be in its outer-

250/288

most position). If the plant does not start,


check that the fuses are intact. See
Fig. 10.5.

0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

10. Operating Instructions

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.

Start the compressor on the control board or


by means of A on UNISAB II (on compressors with analogue/digital control the start
button is often mounted as an ON/OFF
service cut-out on the compressor).

Check suction and oil pressure. For compressors with variable speed drive (VSD),
the oil pressure has to be adjusted at min.
rpm and checked at max. rpm.

Check if the oil is foaming in the sight glass.

Check that the time relay keeps the solenoid


valve in the oil return line shut for 20-30 minutes after the compressor has been started.
Solenoid valve controlled oil return only.

Open the suction stop valve slowly until it is


completely open.

Open the main shut-off valve in the liquid


line.

Starting

Before starting up the plant, carefully read the


section Preparations for Starting. Reset any
alarms.

The compressor is now operating. Gradually increase the capacity to 100%.

Do not leave the plant unattended the first


15 minutes after start-up.

Emergency
stop button

Fig. 10.5

Drawing of Fuses and their Position

10 operating instructions.fm

3 Amp

U N IS AB II

When the plant is to be started for the first time, it


is recommended to choose a manual starting-up
procedure.

After start up, carry out the final regulation of the


plant and set the plant to automatic operation.

Operating Mode UNISAB II

Open the suction stop valve a couple of


turns. Open all other valves except from the
main shut-off valve in the liquid line.
Start condenser cooling, brine pumps, ventilators at air coolers and maybe compressor cooling.

0178-931 - ENG
Rev. 27.10.03

The compressor can be adjusted to different


forms of operation. These are found in SETUP H
CONTROL I.

251/288

SMC /TSMC 100 Mk4 - Engineering Manual

10. Operating Instructions

COMPRESSOR CTRL. MODE


STOPPED

When selecting this picture, the cursor will be in


the top line. Press G and the cursor moves to the
second line.

temperatures. These forms of regulation are


found in CONFIG CONTROL ON.
If you place the cursor on CONTROL ON and
press G until the cursor moves to the right side
of the picture, you can now select different types
of regulation with the keysJ K.
Among the following:

It is now possible to select the desired form of operation with the keys J K.

SUCTION SIDE

BRINE

The possibilities are:

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).

STOPPED means that the compressor is blocked


and thus cannot start.
MANUAL means that the compressor only operates manually, i.e. you cannot change to another
form on UNISAB II by means of the key C.
However, the compressor can be started with
A and stopped with the B key and capacity increased/decreased with the keys E F.
AUTO means that the compressor runs in local
automatic operation according to the form of regulation chosen (suction pressure, brine, etc). It is
possible to change to MANUAL with the key C.
REMOTE means that the compressor runs in remote regulation. It is chosen when a number of
compressors are working together in a common
MULTISAB regulating system.
Regulators
In UNISAB II it is possible to regulate the compressor according to different pressures and

252/288

Set point Sp is the pressure or the temperature


desired in the plant.
Neutral zone Nz indicates how much the pressure or the temperature is allowed to fluctuate in
relation to the Sp without the compressor changing its capacity. The set value of Nz positioned
symmetrically around the set point (Sp+/- Nz).
Proportional band Pb indicates how powerful
the regulating signal to the compressor capacity
regulation is going to be, depending on the difference between the desired value (Sp) and the actual value.
In case the measured value is just outside the Nz,
the regulating impulses will be very brief, whereas
the regulating impulses will be very long if the
measured value is outside the P-band. The Pband is positioned symmetrically around Sp outside the Nz.

0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

10. Operating Instructions

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

Tel.: +45 8736 7000


Fax: +45 8736 7705

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

SELECT THE "CONFIGURATION" MENU


Main picture - I suction - K setup - I control - K config. - - - - - - - - - - - - - - - - - - i
Check whether UNISAB II is set correctly for the compressor.
Press H until the Main picture appears.

AUTO START YES

XXX
XX
XX

AUTO STOP
COLD STORE

10 operating instructions.fm

SELECT THE "TIMER SETUP" MENU


Main picture - I suction - K setup - I control
- Ktimers - I timers - K timer setup - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - i
Check the set times in Timer setup
Press H until the Main picture appears in the display.

START START

XXX
XXX

STOP START

START DELAY
STOP DELAY

XXX
XXX

READ SUCTION PRESSURE OR DISCHARGE PRESSURE IN BAR OR C/R.


Place cursor on suct. press or disch. pres and press "SET" (once).

SELECT THE MENU FOR SUCTION PRESSURE REGULATION


Main picture - I suction - I suct. press press "SET" for changing to C/R - - - - - - - - - - - - - - - - - - i
Press H until the Main picture appears.

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

CHANGING THE SET VALUES


In order to be able to change a set value, a password must be encoded as described:
Press "SET" for 2 seconds [Standard code number 1234].
Find the right password in the instruction manual
With H I and J K the correct password is encoded
Press "SET" and the password is kept open for 60 mins.

SETTING OF VALUES, f. inst. SUCTION PRESSURE (LOW ALARM)


Main picture - I suction - I suct. press - I high alarm -- K low alarm
Encode password (see pt. 6) - JK and HI changing of set values - SET for confirmation.

SELECT FUNCTION, f.inst. REGULATOR MODE


Main picture - I suction - K setup - I control - K config. - I type - K control on
Encode password (see pt. 6) - JK for selection of regulator - SET for confirmation.

SELECT COMPRESSOR CONTROL MODE


Main picture - I suction - K setup - I control - I compressor control mode - "SET" (the cursor is now in line 2)
- JK for selection of control type (manual / auto / remote / stopped) - "SET" for confirmation.

10

CHANGING BETWEEN MANUAL- AND AUTOMATIC / REMOTE CONTROL MODE


Press -g to switch between manual - auto/remote
The light diode above g lights up at manual control mode.
It is always possible to change between manual and auto/remote - also during operation.

0178-931 - ENG
Rev. 27.10.03

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10. Operating Instructions

11

MANUAL START (THE I-KEY):


By READY in the main picture or in any other monitoring picture: Press "I" to start the compressor.
The ready-line changes to Prelubrication or Starting or Operating. (Text depending on compressor type)
During the Starting period the green light diode flashes above the I-key.
After feedback from the motor starter, the light diode changes to a steady light.

12

MANUAL STOP (THE 0-KEY)


By pressing the "0"-key during operation, the compressor is stopped immediately.

13

MANUAL LOADING/UNLOADING OF CAPACITY (the E F keys)


E regulates the compressor capacity upwards - F regulates the compressor capacity downwards.
The immediate compressor capacity can be seen in the main picture or in any of the other monitoring pictures.

14

CONFIRMATION OF ALARMS (THE R-KEY)


Slow flashes from the red light diode = The warning limit has been exceeded.
Quick flashes from the red light diode = Alarm and compressor will stop.
The alarm may be confirmed by means of the R-key, and the quick flashes will stop once the situation is back to normal.

254/288

0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

10. Operating Instructions

Fig. 10.7
I

UNISAB II - Menu Tree


One-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

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

SMC /TSMC 100 Mk4 - Engineering Manual

10. Operating Instructions

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

Tel.: +45 8736 7000


Fax: +45 8736 7705

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

SELECT THE "CONFIGURATION" MENU


Main picture - I suction - K setup - I control - K config. - - - - - - - - - - - - - - - - - - i
Check whether UNISAB II is set correctly for the compressor.
Press H until the Main picture appears.

REFRIGERANT

XXX
XX
XX

CONTROL ON
VOLUME RATIO

k
3

SELECT THE "TIMER SETUP" MENU


Main picture - I suction - K setup - I control
- Ktimers - I timers - K timer setup - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - i
Check the set times in Timer setup
Press H until the Main picture appears in the display.

START START

XXX
XXX

STOP START

XXX

START DELAY
STOP DELAY

XXX
k

READ SUCTION PRESSURE OR DISCHARGE PRESSURE IN BAR OR C/R.


Place cursor on suct. press or disch. pres and press "SET" (once).

SELECT THE MENU FOR SUCTION PRESSURE REGULATION


Main picture - I suction - I suct. press press "SET" for changing to C/R - - - - - - - - - - - - - - - - - - i
Press H until the Main picture appears.

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

CHANGING THE SET VALUES


In order to be able to change a set value, a password must be encoded as described:
Press "SET" for 2 seconds [Standard code number 1234].
Find the right password in the instruction manual
With H I and J K the correct password is encoded
Press "SET" and the password is kept open for 60 mins.

SETTING OF VALUES, f. inst. SUCTION PRESSURE (LOW ALARM)


Main picture - I suction - I suct. press - I high alarm -- K low alarm
Encode password (see pt. 6) - JK and HI changing of set values - SET for confirmation.

SELECT FUNCTION, f.inst. REGULATOR MODE


Main picture - I suction side- K setup - I control - K config. - I type - K control on
Encode password (see pt. 6) - JK for selection of regulator - SET for confirmation.

SELECT COMPRESSOR CONTROL MODE


Main picture - I suction - K setup - I control - I compressor control mode - "SET" (the cursor is now in line 2)
- JK for selection of control type (manual / auto / remote / stopped) - "SET" for confirmation.

10

CHANGING BETWEEN MANUAL- AND AUTOMATIC / REMOTE CONTROL MODE


Press - g to switch between manual - auto/remote
The light diode above g lights up at manual control mode.
It is always possible to change between manual and auto/remote - also during operation.

256/288

0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

10. Operating Instructions

11

MANUAL START (THE I-KEY):


By READY in the main picture or in any other monitoring picture: Press "I" to start the compressor.
The ready-line changes to Starting or Operating. )
During the Starting period the green light diode flashes above the I-key.
After feedback from the motor starter, the light diode changes to a steady light.

12

MANUAL STOP (THE 0-KEY)


By pressing the "0"-key during operation, the compressor is stopped immediately.

13

MANUAL LOADING/UNLOADING OF CAPACITY (the E F keys)


E regulates the compressor capacity upwards - F regulates the compressor capacity downwards.
The immediate compressor capacity can be seen in the main picture or in any of the other monitoring pictures.

14

CONFIRMATION OF ALARMS (THE R-KEY)

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

SMC /TSMC 100 Mk4 - Engineering Manual

10. Operating Instructions

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

SMC /TSMC 100 Mk4 - Engineering Manual

10. Operating Instructions

Checks during Operation


for vibrations due to natural frequency. Rpm resulting in vibrations must be locked out in the VSD
controller. Check that oil pressure, suction and
condensing pressure is within the permissible
working range for the compressor.

10 operating instructions.fm

When the plant has been set for normal operating


conditions, an inspection of the plant must be carried out. Check for leaks and vibrations in the system, noise from valves, etc. Particularly variable
speed drive (VSD) compressors must be checked

0178-931 - ENG
Rev. 27.10.03

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10. Operating Instructions

260/288

0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

14. Transport Instructions

14. Transport Instructions


The purpose of this document is to describe:

The dangers which may occur when the


transport instructions and safety precautions are not observed.

How to assemble and transport this


equipment in a safe way.

This document is primarily intended for transport


supervisors, authorities and personnel who are involved in loading, unloading and transporting the
equipment.

14 transport instructions.fm

This document was produced by:


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

0178-931 - ENG
Rev. 27.10.03

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 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

SMC /TSMC 100 Mk4 - Engineering Manual

14. Transport Instructions

Transport Data

Table 14.1

Weight and Dimensions


When dispatched, the unit is placed on a wooden
frame and covered by plastic film. The wooden
frame, which is adjusted to the size of the unit, is
made so that the unit can be lifted with a forklift
truck.

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

The weight is exclusive electric motor

Table 14.2
Compressor
type

Weight of Compressor Units


Direct driven

Belt driven

Remarks

Kg

lb

Kg

lb

SMC 104

830

1830

880

1940

SMC 106

925

2039

970

2138

SMC 108

990

2183

1030

2271

SMC 112

1660

3660

1820

4012

SMC 116

1400

3086

1920

4233

TSMC 108

1060

2337

1130

2491

Excl. intermediate cooler

TSMC 108

1400

3086

1410

3109

Incl. intermediate cooler

TSMC 116

1900

4189

2080

4586

Excl. intermediate cooler

TSMC 116

2350

5181

2530

5578

Incl. intermediate cooler

262/288

0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

14. Transport Instructions

Table 14.3

Weight of Electric Motors


Motor Type
Schorch

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

The personnel who are to handle the unit during


loading, transport and unloading must have taken
the necessary courses in the operation of cranes
and forklift trucks.

Loading 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

As a minimum the lifting capacity of the crane and


the loading capacity of the chains, straps, lifting
eyes and shackles must correspond to the weight
of the unit + the weight of the electric motor + an
extra 100 kg for packing.

263/288

SMC /TSMC 100 Mk4 - Engineering Manual

14. Transport Instructions

Preparations before Lifting

Unloading Instructions

Before lifting the unit, make sure that


straps/chains are properly secured to lifting
eyes/shackles and that the lifting equipment is in
good condition.

The same rules apply as when loading the unit.


See therefore Loading Instructions.

Loading

Moving the Equipment to Mounting Site after


Unloading
See Section 7, Installation Instructions.

Take great care when loading the unit so that it is


not damaged. Note in particular that the instrumentation of the unit is very vulnerable to impacts.

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

Unpacking and Inspecting the Unit


See Section 7, Installation Instructions.

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

SMC /TSMC 100 Mk4 - Engineering Manual

15. Commissioning Instructions

15. Commissioning Instructions


The purpose of this document is to describe:

The dangers which may occur when the


commissioning instructions and safety precautions are not observed.

How to start-up this equipment in a safe


way.

How to prepare a safe and effective


start-up.

This document is primarily intended for inspectors


and supervisors.

15 commissioning instructions.fm

This document was produced by:


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

0178-931 - ENG
Rev. 27.10.03

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 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

SMC /TSMC 100 Mk4 - Engineering Manual

15. Commissioning Instructions

Preparations for Commissioning

Preparations on the Mounting Site

Final Check of Installation

Final Check of the Plant

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.

The check includes an examination of all parts


of the plant and all the connections to the
compressor.

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

Check in particular that

the piping connections are made as indicated in the installation drawings.

all electrical connections have been


checked.

the unit and the plant have been pressure


tested.

the coupling between motor and compressor are set up as indicated in Section 7, Installation Instructions.

the insulation has been carried out correctly.

the paint is in order, the screens have been


mounted correctly, etc.

Commissioning Instructions

It must be made sure that all personnel have been


trained so that the requirements listed under Personnel Requirements above are complied with.

Preparations before the First Start-up

Documentation

Besides this manual the personnel should be in


possession of the following documentation material before putting the plant into operation:

Section 10, Operating Instructions Preparations for Starting.

UNISAB II's Starting-up Manual - Before


Connecting the Voltage.

Operating Manual

Go through the following point by point:

Starting-up Manual and Instruction


Manual for UNISAB II

Press the Emergency Stop button and connect


voltage.

Certificates regarding the reciprocating


compressor unit

Installation drawings and functional descriptions for the plant

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

Before start-up, go through the following points:

0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

15. Commissioning Instructions

the plant. However, the values must not exceed


the limits in the table of set/alarm values, see
Section 9, Settings.
Carry out calibration of pressure transducers as
described in Calibration in the Starting-up Manual
for UNISAB II. Pressure transducers must be calibrated at atmospheric pressure. The easiest way
to do this is to dismount the transducers.

WDanger!

15 commissioning instructions.fm

Inadequate or erroneous setting of pressure


transducers may result in compressor breakdown
or personal injury.

Evacuation and Charging of


Refrigerant
Check that the plant is evacuated to a pressure
lower than 5 mm Hg. Pressure testing and evacuation of the plant is described in detail in Section
7, Installation Instructions.

0178-931 - ENG
Rev. 27.10.03

Check that the prescribed refrigerant corresponds


to the specification on the compressor name
plate. Charge the prescribed refrigerant. After
charging the refrigerant, check all connections
and valves for leaks by means of a leak detector.
Start-up
The plant can now be put into operation, See
Section 10, Operating Instructions - Starting.
After five hours of operation the alignment between motor and compressor must be checked
again while the compressor is still warm.
If the compressor is belt driven, check the belt tension. Before letting the plant start to work, activate
the emergency stop and dismount the main fuses
to ensure that the motor does not start unintentionally.
Important! Note the procedures for reducing the
evaporating pressure.

267/288

SMC /TSMC 100 Mk4 - Engineering Manual

15. Commissioning Instructions

Checks to be Performed after Start-up


Check List

Are settings and configuration correct?


Have alarm and warning limits been set correctly?
Have pressure transducers been calibrated?
Is the direction of rotation of the motor correct?
Has the coupling been aligned correctly?
Have the safety valves been adjusted correctly?
Has the plant been evacuated and dried before charging of refrigerant?
Does the plant contain enough oil?
Have valves been set correctly?
Is the capacity regulation correct?
Free passage for cooling water/refrigerant to e.g. oil cooler?
Is the plant leak-proof?

268/288

0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

16. Compliance Instructions

16. Compliance Instructions


The purpose of this document is to describe:

The norms and standards which this equipment complies with.

How this equipment complies with the


norms and standards.

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

contents hereof must not be imparted to a third


party nor be used for any unauthorised purpose.
Contravention will be prosecuted.

Conformity with EU Regulations


According to current EU regulations, the manufacturer is under an obligation to document that the
product complies with the EU Directive for Machines. This is done by completing a Declaration
of Manufacturer, which contains the principal information about the product in question.
The Directive for Machines does not apply to
countries outside the EU.
Example of a Declaration of Manufacturer, see
Fig. 16.1.

269/288

SMC /TSMC 100 Mk4 - Engineering Manual

16. Compliance Instructions

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

hereby declare that the below-mentioned product:


Type:_____________________________ Compressor No:____________________
YORK Serial No:____________________ Year:_____________________________
Customer No:______________________
is constructed and manufactured in conformity with the above-mentioned EEC Directive.
The product, which is covered by this declaration, may only be used when assembled with
or incorporated into another machine/unit and thus in conformity with all relevant provisions.
The following harmonised standards have been applied:
DS/EN 292
DS/EN 294

Machine safety - Fundamental concepts


Machine safety - Dangerous areas and safety distances

DS/EN 418

Machine safety - Emergency functions

Besides in case of machines with electric equipment:


Low-voltage switch gear and control gear assemblies EN 60 439-1
Type-tested and partially type-tested assemblies.
Electrical equipment of industrial machines.
EN 60 204-1
Operational instruction will be supplied.
Complete technical documentation has been prepared
Place and Date:

____________________________

Name and signature

____________________________

Agent/dealer stamp

270/288

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SMC /TSMC 100 Mk4 - Engineering Manual

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.

This document is mainly intended for inspecting


bodies and authorities.

Approvals

This document was produced by:


YORK Refrigeration
Chr. Xs Vej 201
DK-8270 Hoejbjerg
Denmark

17 certificate.fm

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.
The compressors are made according to the basic
specifications for the individual compressor type.
The products comply with current legislation with
regard to pressure and material testing.
If the product is to be delivered with certificate, the
certificate must be ordered when placing the or-

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

SMC /TSMC 100 Mk4 - Engineering Manual

17. Certificates

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SMC /TSMC 100 Mk4 - Engineering Manual

20. Final Disposal

20. Final Disposal


The purpose of this document is to describe how
to safely dispose of this equipment or part of it.
This document is primarily intended for the
de-commissioning engineers and authorities.
This document was produced by:
YORK Refrigeration
Chr. Xs Vej 201
DK-8270 Hoejbjerg
Denmark

20 final disposal.fm

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.

Before dismantling the plant, refrigerant and oil


must be drained into containers intended for the
purpose. Disconnect all electrical connections to
the unit. Remove fuses in the main switchboard.
During the dismantling process, the individual machine parts and components must be sorted so
that disposal can take place in an efficient way.

WDanger!
Take great care if using cutting tools, e.g. angle
grinder or flame cutter, during the dismantling
process as pipes or the like will contain oil residue
which may ignite. Refrigerant residue does also
involve a great risk as HFC and HCFC refrigerants
will develop toxic gasses when heated. Make sure
that there are no air traps as heating will result in
a pressure rise.

General
Disposal of Machine Parts
Safety Precautions

Before dismantling the plant, read Section 3,


Safety Precautions carefully. Failure to do so may
result in personal injury or even death.

When dismantling the plant, it is important to sort


the parts to be disposed of. Compressor, frame,
containers, etc. belonging to the category of iron
and metal scrap must be delivered to an approved
scrap dealer complying with the prevailing rules
and regulations of the individual country.

Dismantling of a cooling unit which is to be


scrapped must be carried out in a safe way.

Disposal of Oil and Refrigerant

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
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SMC /TSMC 100 Mk4 - Engineering Manual

20. Final Disposal

Disposal of Electrical Components

Disposal of Batteries

Electrical and electronic products, e.g. wiring,


panels, hardware, etc., must be delivered to a receiving station approved to handle electronic
waste. The receiving station must comply with the
prevailing rules and regulations of the individual
country.

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.

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Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

Appendix - SMC/TSMC 100


This section includes data sheets and instructions concerning the components and the tables of torque
moments.
1.

List of torque moments, 4 pages.

2.

Danfoss pressure transducer type AKS, 9 pages.

3.

Tempress temperature sensor P2208, 3 pages.

4.

Valves
Danvalve installation instructions SCV 40-200, 2 pages.
PM valves, 10 pages
Pilot valve, 3 pages

5.

Solenoid valve for oil return


Instruction EVRB-NC, 1 page

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
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SMC /TSMC 100 Mk4 - Engineering Manual

Fig. 21.1

1
Z

D
a

Table 21.1
Compressor

AMR
type of
coupling

Nominal
Distance
C

Torque moment

Max. variation measured with a


feeler gauge at a 180 turning of
the coupling
D

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

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SMC /TSMC 100 Mk4 - Engineering Manual

Torque Moments for Screws and Bolts

Metric thread (ISO 8.8)


M

10

12

14

16

18

20

22

24

27

Kpm

0.28

0.53

0.94

2.2

4.1

7.0

11

15

23

30

38

52

68

ft.lbf.

2.1

3.9

6.8

16

30

50

80

110

170

220

270

370

490

Nm

2.7

5.2

9.2

22

40

69

108

147

225

295

375

510

670

Metric thread (ISO 12.9)

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

Connecting rods with UNF thread

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

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SMC /TSMC 100 Mk4 - Engineering Manual

Sundry Clearances and Check Dimensions


Bearing clearance
CMO 1
CMP 1
TCMO 1
CMO 4

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

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

Crankshaft end-play
min.

0.30

0.30

0.40

0.40

0.75

0.95

max.

0.55

0.55

0.55

0.64

1.00

1.20

The end-play can be adjusted by means of the gasket under the bearing cover.
The gasket is available in the following thicknesses: 0.3, 0.5, 0.75, 1.0, 1.3, 1.5, 1.75 and 2.0 mm.

Piston ring gap


min.

0.25

0.25

0.25

0.33

0.33

0.66

max.

1.00

1.00

1.00

1.30

1.30

1.50

The piston ring gap must be measured with the ring placed in the cylinder liner.

New

Dimensions of crankshaft bearing journal


Main bearing journals

55

-0.06
-0.09

60

-0.06
-0.09

55

-0.06
-0.09

80

-0.07
-0.09

80

-0.07
-0.09

135

-0.11
-0.14

Connecting 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

Main bearing journals

54.5

-0.06
-0.09

59.5

-0.06
-0.09

54.5

-0.06
-0.09

79.5

-0.07
-0.09

79.5

-0.07
-0.09

134

-0.11
-0.14

Connecting rod
bearing journals

49.5

-0.025
-0.040

54.5

-0.025
-0.040

54.5

0
-0.02

79.5

0
-0.02

79.5

0
-0.02

134

-0.015
-0.040

79.5

-0.010
-0.029

Intermediate journals

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

278/288

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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

Boring of Hub ....................................................................................................... 149


Brine ...................................................................................................................... 28
By-pass system ..................................................................................................... 45
By-pass Valve
SMC ................................................................................................................. 35

Capacity Regulation .............................................................................................. 58


Capacity Regulation of Thermo Pump ................................................................... 92
Capacity Stages .................................................................................................... 63
Caution
Texts Marked with Caution .............................................................................. 17
Charging of oil ..................................................................................................... 230
Charging the Compressor with Oil ....................................................................... 176
Check of the Installation ...................................................................................... 231
Checks during Operation ..................................................................................... 259
Checks to be Performed after Start-up ................................................................ 268
Choice of Electric Motor ...................................................................................... 141
Coils for Solenoid Valves ..................................................................................... 113
Commissioning
Checks to be Performed after Start-up .......................................................... 268
Preparations ................................................................................................... 266
Preparations before the First Start-Up ........................................................... 266
Commissioning Instructions ................................................................................. 265
Compliance Instructions ...................................................................................... 269
Components ........................................................................................................ 233
Compressor Accessories ....................................................................................... 97

0178-931 - ENG

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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

SMC /TSMC 100 Mk4 - Engineering Manual

0178_931IX.fm

Discharge Pipe Thermostat KP98 .................................................................... 73


DVEA ............................................................................................................... 77
High Pressure Cut-out KP15 ............................................................................ 73
Intermediate Cooling
TEAT .......................................................................................................... 78
TEA-TEX .................................................................................................... 78
Intermediate Gas ............................................................................................. 77
Intermediate Pressure Cut-out KP5 ................................................................. 73
Low Pressure Cut-out KP15 ............................................................................ 73
Oil Differential Cut-out MP55 ........................................................................... 73
Oil Thermostat KP98 ........................................................................................ 73
Regulation of Intermediate Pressure IP ........................................................... 79
SMC
By-pass Valve ............................................................................................ 35
Connecting Rod .......................................................................................... 34
Cooling of Compressor and Oil .................................................................. 41
Crankshaft .................................................................................................. 36
Cylinder liners ............................................................................................. 33
Discharge Valve ......................................................................................... 34
Draining valve ............................................................................................. 40
Evacuating Valve ........................................................................................ 40
Filter bag .................................................................................................... 34
Heating Rod ............................................................................................... 40
Instrumentation ........................................................................................... 41
Oil Filter ...................................................................................................... 37
Oil Level Glass ........................................................................................... 40
Oil Pressure Regulating Valve ................................................................... 37
Oil Pump ..................................................................................................... 37
Pistons ........................................................................................................ 33
Safety spring .............................................................................................. 34
Shaft Seal ................................................................................................... 38
Stop Valves ................................................................................................ 41
Suction Filter .............................................................................................. 34
Suction Valve ............................................................................................. 34
Special unloading 104 ...................................................................................... 65
Standard unloading .......................................................................................... 62
Start Unloading ................................................................................................ 60
Suction Filters .................................................................................................. 45
TEA .................................................................................................................. 78
TEAT ................................................................................................................ 78
Total Unloading ................................................................................................ 63
TSMC
Compressor Block ...................................................................................... 43
Intermediate pressure ................................................................................ 44
Needle bearing ........................................................................................... 44
Piston Pin Bearing ...................................................................................... 44
Water Quality ................................................................................................... 88
Description of Compressor Types ......................................................................... 31
Description of Pumping Cycle ............................................................................... 92

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SMC /TSMC 100 Mk4 - Engineering Manual

Determining the Intermediate Pressure IP ............................................................79


Dimension Sketches ....................................................................................100, 120
Direction of Rotation ............................................................................................140
Electric Motor .................................................................................................147
Direction of Rotation of Electric Motor .................................................................147
Discharge GasTemperatures ..............................................................................242
Discharge Pipe Thermostat KP98 .........................................................................73
Discharge Pressure,PT2 .....................................................................................111
Discharge Valve ....................................................................................................34
Display .................................................................................................................247
Unisab II .........................................................................................................247
DVEA .....................................................................................................................77

282/288

Electric Motor .......................................................................................................141


Direction of Rotation ......................................................................................147
Electrical Connections .........................................................................................110
Electricity Supply .................................................................................................226
Emergency Stop ....................................................................................................16
Ensuring Liquid to the Thermo Pump ....................................................................94
Evacuating Valve
SMC .................................................................................................................40
Explosion-proof ......................................................................................................97
Explosion-proof heating .........................................................................................97
Explosion-proof solenoid valves ............................................................................97
Extended set of tools .............................................................................................97

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

Handling of Compressor and Unit .......................................................................148


Heating Element ..................................................................................................113
Heating Rod
SMC .................................................................................................................40
High voltage ...........................................................................................................22
Hot and Cold Surfaces ........................................................................................244

0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

Hub
Boring of Hub ................................................................................................. 149

Installation and Relocation Safety ......................................................................... 21


Installation Instructions
....................................................................................................................... 213
Instrumentation ...................................................................................................... 72
SMC ................................................................................................................. 41
Intermediate Cooler Type DVEA ........................................................................... 77
Intermediate Cooling
Liquid Injection ................................................................................................. 78
TEAT ................................................................................................................ 78
TEA-TEX .......................................................................................................... 78
Intermediate Gas .............................................................................................45, 77
Intermediate pressure
TSMC ............................................................................................................... 44
Intermediate Pressure Cut-out KP5 ....................................................................... 73

KP 15 ................................................................................................................... 245
KP 5 ..................................................................................................................... 245
KP 98 ................................................................................................................... 245
KP15 ...................................................................................................................... 73
KP5 ........................................................................................................................ 73
KP98 ...................................................................................................................... 73

Laying the Foundation ......................................................................................... 159


Lifting and Carrying Safety .................................................................................... 20
Lifting the compressor Block ............................................................................... 148
Lifting the compressor Unit .................................................................................. 148
Liquid Injection ....................................................................................................... 78
Loading Instructions ............................................................................................ 263
Long block ............................................................................................................. 31

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

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Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

Moment of Inertia .................................................................................................146


Motor Dimension .................................................................................................141
Motor weight ........................................................................................................118
Mounting Directly on Foundation .........................................................................160
Mounting Directly on the Foundation ...................................................................218
Mounting of Vibration Dampers ...........................................................................161
Mounting on Vibration Dampers ..........................................................................217
MP 55 ..................................................................................................................245
MP55 .....................................................................................................................73

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

Oil Charging .................................................................................................176, 230


Oil Consumption ..................................................................................................177
Oil Cooling
Settings ..........................................................................................................241
Oil Differential Cut-out MP55 .................................................................................73
Oil Draining Valve
SMC .................................................................................................................40
Oil Filter
SMC .................................................................................................................37
Oil Level Glass
SMC .................................................................................................................40
Oil Pressure .........................................................................................................112
Oil Pressure Regulating Valve
SMC .................................................................................................................37
Oil Pump
SMC .................................................................................................................37
Oil Return ..............................................................................................................48
Coil for the solenoid valve ................................................................................49
Float Valve Controlled ......................................................................................51
Parallel Operation ............................................................................................51
Different Et ..................................................................................................55
Float valve ..................................................................................................53
Same Ct ......................................................................................................57
Same Et ......................................................................................................52
Oil return
Nozzle size .......................................................................................................49
Solenoid Valve Controlled ................................................................................48
Oil Separators ......................................................................................................178

0178-931 - ENG
Rev. 27.10.03

SMC /TSMC 100 Mk4 - Engineering Manual

Oil Thermostat KP98 ............................................................................................. 73


One-stage .............................................................................................................. 32
Opening the Cabinet ............................................................................................ 246
Operating Instructions ......................................................................................... 243
Operating Limits Diagrams .................................................................................. 125

Parallel Operation .................................................................................................. 51


Parallel Shafts ..................................................................................................... 223
Personal Safety ..................................................................................................... 19
Physical and Connection Data .............................................................................. 99
Piping Connections .............................................................................................. 225
Piston Pin Bearing
TSMC ............................................................................................................... 44
Pistons
SMC ................................................................................................................. 33
Planning the Machine Room ............................................................................... 124
Power Transmission ............................................................................................ 155
Preliminary Installation ........................................................................................ 223
Preparations for Starting ...................................................................................... 250
Pressure .............................................................................................................. 243
Pressure and Temperature Setting ..................................................................... 238
Pressure levels .................................................................................................... 175
Pressure Loss ........................................................................................................ 88
Pressure Testing ................................................................................................. 228
Pressure transmiters
Discharge Pressure,PT2 ................................................................................ 111
Oil Pressure ................................................................................................... 112
Suctiaton Pressure,PT1 ................................................................................. 111
Pressure Transmitters
AKS32-AKS2050 ........................................................................................... 111
PT1 ...................................................................................................................... 111
PT2 ...................................................................................................................... 111
PT3-PT1 .............................................................................................................. 112
Purging a Refrigeration Plant ................................................................................ 27

Quick Reference
One Stage ...................................................................................................... 253
SMC ............................................................................................................... 253
TSMC ............................................................................................................. 256

Refrigerants .....................................................................................................27, 28
Regulation of Intermediate Pressure IP ................................................................. 79

Safety at Servicing ................................................................................................. 16


Safety Instructions

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SMC /TSMC 100 Mk4 - Engineering Manual

High voltage .....................................................................................................22


Installation and Relocation ...............................................................................21
Lifting and Carrying Safety ...............................................................................20
Maintenance Safety .........................................................................................21
Personal Safety ................................................................................................19
Set-Up and Operation ......................................................................................21
Tool Safety .......................................................................................................20
Work Area Safety .............................................................................................20
Safety Precautions ................................................................................................19
Settings ................................................................................................................237
Oil Cooling .....................................................................................................241
Unisab II .........................................................................................................239
Set-Up and Operation Safety ................................................................................21
Shaft Seal
SMC .................................................................................................................38
Short blocks ...........................................................................................................31
Sign
CAUTION .........................................................................................................14
Cold surfaces ...................................................................................................15
Dangerous noise level .....................................................................................15
Hazardous substance ......................................................................................15
High Voltage ....................................................................................................14
Internal overpressure .......................................................................................15
Internal Protection ............................................................................................15
Temperature of Tangible Surfaces ..................................................................15
Signs and Warnings ................................................................................................9
Signs in Instructions ..............................................................................................14
SMC
Cylinder liners ..................................................................................................33
Designation ......................................................................................................31
Safety spring ....................................................................................................34
Type E ..............................................................................................................31
Type L ..............................................................................................................31
Type S ..............................................................................................................31
SMC/HPC 104 Special Unloading .........................................................................65
Sound Data
How to check .................................................................................................170
Spare parts set ......................................................................................................97
Special unloading 104 ...........................................................................................65
Specification of Materials .....................................................................................174
Start Unloading ......................................................................................................60
Start up
SMC/HPC 100 - HFC/HCFC - 25% load ........................................................145
Start up torque SMC/HPC 100 R717 25% load ...................................................144
Starting ........................................................................................................250, 251
Starting Torque ....................................................................................................143
Stop Valves
SMC .................................................................................................................41
Structure of the Thermo Pump ..............................................................................90

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SMC /TSMC 100 Mk4 - Engineering Manual

Suctiaton Pressure,PT1 ....................................................................................... 111


Suction Filter
SMC ................................................................................................................. 34
Suction Filters ........................................................................................................ 45
Round holes ..................................................................................................... 45
Square holes .................................................................................................... 45
Suction Valve
SMC ................................................................................................................. 34

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

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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

Valve Position during Operation ..........................................................................250


V-Belt Drive .........................................................................................................153
Construction ...................................................................................................157
Motor pulley ...................................................................................................158
V-Belts and Pulleys .............................................................................................154
Ventilation ............................................................................................................243
Vessel Name Plate ................................................................................................12
Vibration Dampers
Mounting ........................................................................................................161
Vibration dampers .................................................................................................97
Vibration Data ......................................................................................................173

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

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